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Hustler® Diesel Z General Service Manual

1. ORG RED 16 x LL zb 5 EE I sike ORG 18 Site mot 8 3 ORG 18 een 8 59 i a lt lt _ A SS o mine A 3 m ir ik se A z 23 SG A ee a p E E sr gt gt ipu S an zao o I 21 2 Se vu o 2 z sl E S z is S 3 san Us O E m rr E NNN BE As A Se z ES P 2 S EE 3 SC s us 9 z e E z d 2 o oi a g x core ds x 2 ez HS zra v ZE Er er SEN ES S al a Z o pa 25 s 3 e e 3 RED 14 gt 9 Si al RED 10 2 e o 3 z V PUR 6 o S S x A a z T RED 14 m 3 2 L BLK CD E e El z ORG 18 a 8 cS ge 4 ze E E s 9 SJ 2 n z a A a 4 ox E E 3 9 2 2 g i Z o S ert S a 2n 5 E EN 7 x5 s ot d BE d 85 BONO ec r E a lt ZS EC Z SS gess RER kij a se Ei Deus BEE 7 28 d zi af pe uw a x E ER 2 s 9 a 2 El E ea GRN BLK 10 i 4 z oe x E E PPRS 2 o a Ed E s a m 4 x A x R 3 ES 5 E N YEL WHT 18 5 H YEL 18 z EM YEL BLK 18 a
2. E E 8 RED BLK 18 pi Gre FUEL na ar GAUGE prre e PINOT s je jg PIN 8 S la s IZ S 2 e 53 ORG 20 SE Z CLUTCH SWITCH T lesen m HE x m gt 9a emi S ERO ER 61 BLK 20 LH FUEL 13 ORG 18 h 25 ORG RED 18 P TANK SENSOR LI ORG 18 ca 12 ORG 18 on m Ve mo 14 ORG 18 uu 29 TAN 18 3 SEAT SWITCH S E S gt 15 ORG 18 v V 30 RED i 31 TAN RED 18 2 18 pee Ei NEUTRAL SWITCHx NEUTRAL SWITCH ETI CHEN 3 4 JI MY JI JY JI FY JI EY JI DY JI JI C gt TANK 21 ORG 18 Ch 36 GRN BLK 18 SENSORS E 3 z DIESEL CONTROLLER E CLUTCHx GLOWPLUGSx 8 16 ORG 18 P N 601368 17 ORG 18 Gan 47 BLK 16 Ji BA JI HA JI KA JI GA JI RA JI AA JI N zl N 35 GRN BLK 18 25 37 ORG GRN 18 Te 9 RED BLK 18 RM 4 RED 14 p NND 5 RED 14 42 YEL WHT 28 PNK 18 21 PNK 16 4 o 48 BLK 16 18 ENGINE 8 ig ERE 15A 25A MD H20 TEMP liz ALARMx EE e KS 2 ES M Bs ALT CHARGE 50A E RED 10 x1x24 PUR 6 ui 33 YEL REDIN 32 YEL RED 18 18 2VDCx BATTERY BLK 2 45 BLK 8 GROUND SPLICE Figure 7 5 115164 7 5 REV C REV C 7 6 115164 Maintenance Schedule H
3. Figure 6 19 Center spindle to right spindle belt 60 72 Rear Discharge Deck Idler pulley 5 8 cap screw Belt Pulley sled 3 4 jam nuts 1 80 45 7mm Figure 6 20 60 72 Rear Discharge Decks Two Belt System Later Style There are two deck drive belts on these decks The belt tension remains constant by means of a tension idler and spring on each belt 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 belts stretch 115164 and wears in adjustment may become necessary Figure 6 21 amp Figure 6 22 Tension adjustment for either belt is the same To increase belt tension move the spring chain one or more link s at the anchor point on the deck frame Figure 6 21 amp Figure 6 22 IMPORTANT Do not over tension the spring to compensate for a badly worn belt or pulley 60 Rear Discharge Deck el Spring chain anchor point Spring Spring chain anchor point
4. Figure 6 22 115164 6 7 REVC Deck Belt Routing 8 Tensioning XR7 54 66 72 Side Discharge Deck NOTE The following notes are the same for the three different decks shown 1 Spring length after tensioning new belt Measured from outside of hook to outside of hook with deck set at 3 50 88 9mm cut height 2 Route belt as shown 9 3 10 3 236 262mm Figure 6 23 REV C 6 8 115164 XR7 60 Side Discharge Deck 1 Spring length after tensioning new belt Measured from outside of hook to outside of hook with deck set at 3 50 88 9mm cut height 2 Route belt as shown 9 3 10 3 236 262mm Figure 6 24 115164 6 9 REV C VX4 54 60 66 72 Side Discharge Deck NOTE The following notes are the same for the four different decks shown 1 Spring length after tensioning new belt Measured from outside of hook to outside of hook with deck set at 3 76 2mm cut height 2 Route belt as shown 9 3 10 3 236 262mm Figure 6 25 REV C 6 10 115164 60 72 Rear Discharge Deck Single Belt
5. Figure 8 2 Figure 8 4 REV C 8 2 115164 Side Discharge Deck Maintenance Locator Chart 8 Belt Routing Deck Pusher Arm Zerks 2 Deck Belt Spindle Housing Zerks 3 Blades BN Figure 8 5 Rear Discharge Deck Rear Discharge Deck Maintenance Locator Chart amp Belt Routing Maintenance Locator Chart amp Belt Routing Figure 8 6 Figure 8 7 115164 8 3 REV C REV C 8 4 115164 TROUBLESHOOTING The majority of operating problems that occur with a system can be traced to improper adjustments or delayed service A consistently applied preventative maintenance program as outlined in the Maintenance Schedule section of this manual will prevent many problems The following chart is designed to help you locate a problem by suggesting probable causes and the recommended solutions SYMPTOMS PROBABLE CAUSES SUGGESTED REMEDIES Starting motor does not crank Steering control levers not in park brake position or switch not a
6. SUGGESTED REMEDIES Uneven cutting height The blade s are not sharp Sharpen the blades A cutting blade s is are bent Install new cutting blade s The deck is not level Level the deck per the Deck leveling and height adjustment section of the General Service Manual An anti scalp wheel is not set correctly Adjust the height of the anti scalp wheel The underside of the deck is dirty Clean the underside of the deck Tires improperly inflated Adjust air pressure to 8 12 psi 55 83 KPa A blade spindle is bent Contact your dealer REV C 115164 PAGE BELU I de armer 4 6 6 4 Blades i25 tesa O ea 6 3 Control lever stops 4 2 Deck Belt adjustment sssssssssssss 6 5 Deck leveling 6 1 Engine air filter 5 1 Engine Controller 5 2 Engine oil and filter 5 1 Engine RPM Settings 5 8 General engine maintenance 5 1 General maintenance precautions 2 2 Hydraulic pump belt adjustment 4 6 Hydraulic system sss 4 6 Maintenance introduction 1 1 Maintenance Locator Chart 8 2 Maintenance precautions 2 2 115164 i 1 PAGE Maintena
7. 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 8 28 When completed all chains will be tight and deck cutting height will be set to the deck height indicator Nut M L Deck lift threaded rod ml en ee Chains Figure 6 11 Blades Mower blade maintenance Check the mower blades daily they are the key to power efficiency and well groomed turf Keep them sharp a dull blade will tear rather than cut the grass leaving a brown ragged top on the grass within a few hours A dull blade also requires more power from the engine REVC Replace any blade which is bent cracked or broken A WARNING Never attempt to straighten a bent blade by heating or weld a cracked or broken blade as the blade may break and cause serious injury 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 rock branch or other foreign object during mow WARNING WARNING ing Always wear adequate eye protection when grinding mower blades A Mower blade removal Use a 15 16 wr
8. TO STIKI ege eege ss ad E o mm eneen Drs ge Soent cine ond aa o e SE ez xoc EE Diagnostics 4 tet EH ClarAlFaus 8 9 o 23833 P 414 mer Count mar PONER brennen GOOG o nnnnnnnn re 9900 AAA Fault logged 3 eneen 99909 nnnnnnmnm OVER TEMPERATURE 9000 nnnmmmmm sr oe ee 5522255 One time count POSITION CAL HI KC BRA AAR AA D zer GAL Lo 9990 Active Poemon SENSOR MI 99909 annannnan Poemon senson Lo eooo PROTECTON FAULT vooo gt 5mnmmmmmm Active currently ser SPEED POL 9990 nnnnnnnn SET SPEED POTLO sooo i if It TORQUE LMT AcHEVeD 999 nmmmmmnm occurring autt Connected on COM Des Hep egenen omes 32 mme j Tete Dore Ke Ed Droog Desires Ses Erare Load eo00000 E ees 23 4M Diagnostics 4 ET veo Lana EC PR nun 29909 hl mar poner super s m nmmmmmmm OPS VIRE BREAK eooo i gt gt 555555mn t OvERSPEED o mmnmmmnmm I OVER TEMPERATURE eeea m nmmommnmn SE oo assansas Fault cleared POSITION CAL HI EK 55555555 Poemon oa to oooga o POSITION SENSOR HI ooog gt mmmmmmnmnm osmon sensoro 9000 PROTECTION FAULT CECR nmmmmnnmn ser FEED Por ni 9900 nnnnnnmnnmn SET_SPEED POLO 9900 TOROLE LIMIT ACHEVED Figure 5 16 115164 5 7 REV C Engine RPM Settings The engine rpm s are set at the factory for maximum mowing efficiency Occasionally it may be ne
9. or container opening at all times until fueling is com plete 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 A 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 con tainer opening Keep fuel away from eyes and skin If fuel 1s spilled on clothing change clothing immedi ately Understand Machine Operation A Only qualified and trained personnel should operate the equipment A Carefully read the operator s manual and all manuals fur nished with the attachments Learn the location and pur pose of all controls instruments indicators and labels Wear Protective Clothing 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 A Always wear adequate eye protection when servicing the hydraulic system and battery or when grinding mower blades and removing accumulated debris A Prolonged exposure to loud noise can cause impairment or loss of hearing Always wear adequate ear protection such as ea
10. 14 I E e 985 RED 10 ol x x A PUR 6 8 Si ge z Si Oo ro sa a a i 8 RED 14 pri 3 z BLK 14 y ORG 18 3 co c E 3 3 Y se 2 E 2 Nu b 4 2 M ai zi al 27 3 2 2 E ech s S VA M 37 al us Ir gt 3 2 as 3 d Z BEE al a z 2 SL as SS a5 E y o 3 z 2 e E Bei s ES 5 3 E E a 22 GRN BLK 10 a E s oa s Bs A g z s 5 t x o 3 LI 2 3 3 o S 8 YEL WHT 18 2 YEL 18 ax YEL BLK 18 E 2 2 9 2 a 2 Je oo i ER Li ZS tja CS LI zg x an al 2 WHT RED 20 WHT RED 20 WHT GRN 20 WHT PUR 20 WHT BRN 20 s i atr ug 2 Figure 7 2 REV C 7 2 115164 Electrical Schematic Shibaura Diesel Domestic mowers built between serial number 1110 first four digits and serial number 13110000 Export amp CE mowers built after serial number 1110 first four digits ch 48 BLK 16 eh FAN CLUTCH amp H20 TEMP KE pi OIL PRESS ALARM 27 PNK 16 26 ORG RED 16 28 fw um ua K e Hm gt ech z a i x E B z Ka a M 2 w KX 2 3 2 e Eel 5 ES z o i u
11. 3 Block 60 72 Rear Discharge Decks Figure 6 3 60 72 Rear Discharge Deck 3 Block 2 U 3 Block 3 Block 3 Block Figure 6 4 should be able to move with only a slight drag Figure 6 8 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 to move up and down freely Figure 6 9 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 REV C 6 2 3 75 Block EN 3 75 Block 3 Block J A 60 Rear Discharge Deck shown d Figure 6 5 Clamp here Br Stop gt mp handle Deck adjustment stop AAA O O Figure 6 6 Nuts O _____ Foot pedal Figure 6 7 115164 Figure 6 9 17 Tighten the adjuster bolt jam nut to prevent the adjuster bolt from moving Figure 6 9 18 Tighten the hardware holding the chain and adjuster onto the de
12. Dn EN E Wi pela dite St rg 3 1 Standard TOQUES akse un os be pie 3 gale NA GERD pen PX 3 1 Special Torques x Dae REA ae ad koda 3 1 A PN ed aati tee de eu 3 1 Power Unit Maintenance 2 2 5 505 550 eee ee n bees 4 1 Steering Adjustments 4 1 Park brake adjustment i 4 4 Park brake spring adjustment 4 5 Bels Lio ais N Quis at eds od asp c do at ae ahh 4 6 Hydraulic Pump Belt Adjustment 4 6 Hydraulic System sui e ntu 2 De aan 4 6 Warner Clutch Re gap Adjustment Procedures 4 9 TIPS Rabe dic le e ETE BUS E gn E v eae 4 11 Engine Maintenance d most Eur pa a aa Spike 5 1 General Engine Maintenance 5 1 engine Oil and Filler sor eee ete tient Psu REESE 5 1 Engine AIC FIIO iot a tof os Eoo aces ve ee 5 1 Engine Controller Tier 4 Engines Only 5 2 Engine RPM Setlngs 22 22 06 3546466 ada 5 8 Deck Adj stMeENtS 2 54 0343 cata a a ne AE 6 1 Deck Leveling cari rear Ran 6 1 Blades E tao it a des 6 3 BOS spe Ebel ca rai elas 6 4 Deck Belt Adjustment 6 5 Deck Belt Routing amp Tensioning 6 8 Electrical aoo sd s a des 7 1 Maintenance Schedule 8 1 Hustler Diesel Z Maintenance Locator Chart 8 2 TROUDIESMOOUNG ceo se tin Series tube reger 9 1 toc 1 REV C REV C toc 2 115164 G
13. Replace with new parts function Disconnection of actuator posi Goes into power cutback mode Limp home mode immediately 33 ond Ensure connection tion sensor connector after power distribution Disconnection of actuator posi Continuity test tion sensor harness Actuator drive malfunction Replace with new parts Disconnection of actuator drive Indicates warning light code 4 and shut down engine immedi Ensure connection 04 connector ately after detection Disconnection of actuator drive Indicates warning light code 13 and 4 after engine shut down harness Continuity test 115164 5 3 REV C WARNING LIGHT CODE PROBLEM SYMPTOMS SUGGESTED REMEDIES Speed sensor malfunction Replace with new parts Disconnection ors BREG SOR Goes into power cutback mode Limp home mode immediately Ensure connection 15 connector after detection Disconnection of speed sensor harness Continuity test Error Code Breakdown The warning light code indicates the light flashing pattern First digit flashing Second digit light on one second Number times of patterns Light action continues to flash the code until the problem is corrected Case 1 One error detected Code 31 Light up 3 times Flashing 1 time 1 sec 1 sec 1 sec FLS 0 5 0 5 0 5 sec sec sec 1 CYCLE 1 CYCLE REPEAT Case 2 Combinat
14. System NOTE The following notes are the same for the two different decks shown 1 Spring length after tensioning new belt Measured from outside of hook to outside of hook with deck set at 3 82 6mm cut height 2 Route belt as shown 9 3 10 3 236 262mm B al Figure 6 26 115164 6 11 REV C 60 72 Rear Discharge Deck Two Belt System Early Style NOTE The following notes are the same for the two different decks shown 1 Spring length after tensioning new belt Measured from outside of hook to outside of hook with deck set at 3 82 6mm cut height 2 Route belt as shown 9 3 10 3 236 262mm 1 80 45 7mm Figure 6 27 REV C 6 12 115164 60 Rear Discharge Deck Two Belt System Later Style 1 Spring length a
15. 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 REV C 115164 115164 Table of Contents General Information 2 2b eee ee 1 1 Service Program aa eso eel e hee eS re 1 1 Maintenance Introduction 1 1 Waranty ege Ce eege 1 1 e ERA S TT 2 1 Sale Servicing Practices sei or os cee Eee era 2 1 Pre Operation Precautions 2 1 Operation Precautions 424240014606 ea 2 2 Operate Machine Safely 2 2 General Maintenance Precautions 2 2 Maintenance Precautions i i i ii i i 2 2 POJ
16. 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 rotat ing 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 2 Open the restriction valve all the way 3 For the pump being tested move the steering control levers in full forward motion It will be necessary to lock the steering control levers into full forward position to prevent false readings 4 Operate without any load for approximately 30 seconds to 1 minute This allows the system oil temperature to rise NOTE Raising the system oil temperature will make a difference in the readings you receive It has been determined that to complete this test accurately the oil temperature must be near system operating temperatures Suggested temperature range 160 210 F 71 1 98 9 C 5 Increase the throttle until the flow meter reads 12 gpm 15 gpm 45 43 l min 56 78 l min Leave the throttle set in this position CAUTION Damage to the flow meter and or re calibration may result from testing at input speeds that exceed 15 gpm 56 78 l min 6 With the engine running at the rpm setting established in step 5 tighten the flow meter restriction valve until the gauge reads 300 psi
17. first 50 hours of machine operation then replace filter and oil in reser voir every 500 hours thereafter Figure 4 19 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 add ing system oil The Hustler Diesel Z system filter is located inside the hydraulic reservoir on the rear underneath side of the tank Use a 5 8 socket to change the filter threads are right handed Use a Hustler Turf Eguipment approved filter element only REAL Figure 4 18 dai deer A Hydraulic filter Figure 4 19 Hydraulic oil heat exchanger The Hustler Diesel Z 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 20 Hydraulic Pump Flow Test The design purpose of the Bi Directional Flow Test Kit 1s to allow the technician to isolate the pump from the wheel motor and determine if the pump is acceptable The following 115164 47 La 23 Heat exchanger Figure 4 20 information can be used to install and test the pump by simulating a wheel motor load WARNING Certain procedures require the vehicle engine to be operated and the vehicle to be raised off of the ground To prevent possib
18. gap and allow the clutch to continue to function Figure 4 21 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 ft lbs 115164 4 9 REV C Procedure WARNING WARNING 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 proper brake torque Figure 4 21 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 22 Figure 4 24 2 Using needle nose pliers or by hand take hold of the tab and remove shim do not discard shim until proper clutch function has been confirmed Figure 4 25 Figure 4 22 Check the air gap between rotor amp armature with feeler gage If the gap is less than 070 then follow the troubleshooting pro cedure outlined in Warner Electric P1177 installation trouble shooting guide available on Warner Electric s web site www Warnerelectric com If the air gap is over 070 follow the procedure outlined below Figure 4 23 Figure 4 25 3 Using a pneumatic line blow out any debris from under the brake pole and around the a
19. lt gt lt px gt lt gt lt gt lt gt lt Check pump and deck belt tension and condition 6 Check fuel system 7 Check hydraulic lines Check fuel valve and grommet 7 Tighten lug nuts on wheels 2 x X lt gt x lt Xx Xx Change fuel filter 7 Clean or replace hydraulic fill cap Change hydraulic oil filter 8 oil 3 Drain 8 replace engine coolant Clean radiator core 8 Check ROPS mounting hardware 9 X lt lt gt lt gt lt gt lt gt lt NOTES 1 Initial oil change is after 50 hours of operation Thereafter change oil after every 100 hours operation Change more often under dusty or dirty condi tions and during hot weather periods Torque initially and after first 2 hours of operation Perform initial hydraulic oil filter change after 50 hours one week of oper ation Change engine oil filter per the engine manufacturer s recommendations Refer to Engine Owner s Manual for recommendations and other mainte nance items Service more often under dusty or dirty conditions Use caution when ser vicing to prevent dust contamination in the engine Do not clean filter ele ment Replace with a new one REFERENCES Refer to Engine Owner s Manual NOTE After completing maintenance cycle 500 hours repeat cycle 115164 Pump drive belt only Inspect every 100 hours and replace if worn
20. minimize oil spillage on the exhaust system The oil filter and oil drain plug are located on the underneath side of the engine Figure 5 2 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 eguipment on these 115164 5 1 Figure 5 2 mowers and supplies clean combustion air to the engine Figure 5 3 These mowers are eguipped with a safety filter The filter element slides over the safety filter Figure 5 4 The safety filter does not reguire servicing unless it becomes contaminated with dirt or moisture 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 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 3 4 Check all fittings and clamps periodically for tightness and inspect hoses for holes or cracks REV C Safety filter Figure 5 4 5 Periodically check the intake hose for signs of ingested dust Locate and repair the source of ingested dirt 6 Never operate the machine withou
21. or cracking is noticed Otherwise replace every 400 hours or 2 years which ever comes first Check fuel system for any cracks or leaks including but not limited to fuel line hoses fuel valve vent line hoses vent valve vapor valve carbon canis ter and grommets Repair as needed More often under dusty or dirty conditions and during hot weather Inspect ROPS after the first 20 hours of operation and then after every 500 hours of operation or yearly whichever comes first REV C Hustler Diesel Z Maintenance Locator Chart Figure 8 1 Engine Oil Dipstick Fuel Filter Engine Air Cleaner Engine Oil Drain Plug Battery Fuel Tanks Hydraulic Oil Reservoir Hydraulic Oil Filter Gauge Wheel Bearing Zerks 2 10 Engine Oil Filter 11 Deck Height Pivot Zerks 4 12 Park Brake Switch 13 Drive Tire 14 Pump Idler Zerk 1 15 Pump Belt 16 Deck Drive Belt 17 Engine Coolant Fill 18 Engine Oil Fill 19 Hydraulic Oil Heat Exchanger SNIE MR oM
22. sources of ignition Do not remove fuel cap or fill tank with engine run ning 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 115164 2 1 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 dis penser nozzle If a fuel dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank
23. the problem Spring Figure 4 17 Hydraulic system IMPORTANT Never use hydraulic or automatic transmis sion fluid in this system use only motor oil as specified Remember dirt is the primary enemy of any hydraulic system WARNING Hydraulic fluid escaping under pressure may have suffi cient force to penetrate skin and cause serious injury For eign 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 work ing 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 Fluid level should be 1 25 4mm from top of reservoir Use only SAE 20W50 SL SM service motor oil Figure 4 18 NOTE The reservoir will require approximately 7 U S quarts 6 6 liter of SAE 20W50 SL SM service motor oil when replacing the oil after an oil and filter change Do not overfill the reservoir 115164 Change hydraulic system filter element and oil after
24. to create a 3 76 2mm high support at the four corners of the deck marked with the locator triangle as shown Figure 6 2 NOTE Back of deck will automatically be set 1 4 6 35mm higher Rear Discharge Decks Figure 6 3 amp Figure 6 4 Place four 3 76 2mm high deck support blocks two stacked 2 x 4 blocks can be used to create a 3 76 2mm high support at the corners of the deck as shown Rear Discharge Decks Figure 6 5 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 76 2mm high support at the sides of the deck as shown 4 XR7 Side Discharge Decks Set cutting height at 3 50 88 9mm in the height indicator by placing the height adjusting stop in the 3 50 88 9mm hole and turning the height stop so that the pin side is against the stop handle V X4 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 5 Clamp the height adjusting stop against the stop handle This will assure that the height will not move d
25. 115164 Hustler Diesel Z General Service Manual HUSTUER TURF EQUIPMENT 200 South Ridge Road Hesston Kansas 67062 REV C 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 information regarding the
26. 21 bar Record the flow reading on the Bi Directional Flow Meter 7 Increase the pressure to 1100 psi 76 bar Record the flow reading on the Bi Directional Flow Meter 8 The acceptable gpm flow droop or difference is TC 21 2 5 gpm 9 4 l min If the difference exceeds these values the pump would not be operating efficiently and should be replaced or repaired See the following example REV C 4 8 115164 Test Example TC 21 Pump RESTRICTION VALVE A POME 300 psi 21 bar reading 9 gpm 34 l min 1st reading CONNECTIONS TO THE FWD RVS LINES DISCONNECTED FROM WHEEL MOTOR RESTRICTION VALVE 1100 psi 76 bar reading 5 gpm 19 l min 2nd reading Bi DIRECTIONAL FLOW METER PK 12 300 psi 21 bar reading 9 gpm 34 l min 1st reading 1100 psi 76 bar reading 5 gpm 19 l min 2nd reading 4 gpm 15 l min the difference CONNECTIONS TO THE FWD RVS LINES DISCONNECTED Subtract the 1st reading from the 2nd FROM WHEEL MOTOR In this example 4 gpm difference would indicate further pump examination Warner Clutch Re gap Adjustment Procedures The air gap is only adjustable on clutches that have a removable shim see Figure 4 25 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 engaging when hot the brake shim can be removed to reduce air
27. 23 BLU 14 zum AUX M 58 ORG 16 4 53 ORG 20 60 ORG 16 13 ORG 18 11 ORG 18 PNGA NENE Mole 12 ORG 18 41 YEL BLU 18 8 ORG 18 uU 14 ORG 18 amp ls TEMP x s A c S 19 ORG 18 15 ORG 18 ro gt Aet m m Zoe TEMP GAUGE mom 44 WHT YEL ua o ORG 18 21 ORG 18 2 50 BLK 18 E A ss 1 ORG 18 16 ORG 18 Sn d Um 18 35 GRN BLK 18 37 ORG GRN 18 6 P RELAY 30 9 RED BLK 18 3 REDJ 10 eye Se FUEL RELAY 40 BLK Lis eV 85 SES i aye im E cs oO 0 Es z 39 RED 6 WATER TEMP SENS 50A TEMP 51 YEL BLK 18 OIL Press m GLOW 14 BLK 16 Deere O 66 GRN RED 16 38 GRN RED 16 SEU EL 67 GRN WHT 16 lol RACK 72 YEL CANBUS Vui LC HREF 71 GRN CANBUS ol SENSOR zi S 73 CANBUS SHIELD GND 63 PNK 18 RED 2 64 GRN YEL 18 EE x ole POSITION i 65 GRN BLK 18 ol SENSOR se a 77 PNK YEL 18 ei 78 PNK WHT 18 5 79 BLK PNK 18 BAR PRESS x BLK 2 v v Y Y V V d D ES 000 YYYYYY ee ae AYT eY Y RN MERC E m Ja Ali So ei 2 8 GE EEN Ia Le cf E DIESEL ECM P N 604774 JI D2 JI EL JI F2 2 F2 s 2 J3 JI D 1 03 ig 8d JI F3 gd bey Sl Ai Ss MTM ND Idi In ki 70 YEL GRA 18 68 GRA 18 x 69 GRA RED 18 See REV C Figure 7 4 115164 Electrical Schematic Shibaura Diesel Domestic mowers built after serial number 1311000
28. E E BR 2 EET o a 25 HHHH E Al 3 z WHT RED 20 WHT GRN 20 Qs ORG 20 WHT PUR 20 a WHT BLU 20 WHT BRN 20 ze o 2 2 as 5 I WHT RED 20 ORG 20 WHT GRN 20 2 WHT PUR 20 2 WHT BLU 20 WHT BRN 20 Ars a 36 mnra Ne 2x29 HHH HI r i Lj Figure 7 1 115164 7 1 REV C Electrical Schematic Shibaura Diesel Mowers built between serial number 0902000 and serial number 1110 first four digits 2d a z z E o E 3 3 o 5 y ot E S 7 ZE S OO tE EIS ORG RED 16 c o z PNK 18 gt gt 1 I lt gt kx m Ke ORG 18 w e pO 08 A e ORG 18 we S LEE lt lt S 5 a e 3 pS ER Ed s ow e 5 Toa c a S x a E aia m 2 e Bea L 5 g ba oj s a Sisy i ES a Z a s 2 z als 2 z SI E jeu SE pa E E gt S HERE NAHE 5 ki 5 z z 5 a a 3 T ss 2 ok 5 3 RE l s s E ER aj m m LES E 3 2 2 E E sou o s ER Na 5 e RED
29. ENERAL INFORMATION Service Program This manual is part of a service package for the Hustler Diesel Z mowers Use of this manual in conjunction with other Hustler mower and component manuals will provide the information necessary to service and maintain Hustler Diesel Z mowers This General Service Manual is a service guide for use by Service Technicians It provides the necessary information needed to perform normal maintenance reguirements 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 products Maintenance Introduction Regular maintenance is the best prevention for costly downtime or expensive premature repair The following pages contain suggested maintenance information and schedules which the operator 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 guickly as possible is the best insurance Clear away heavy build up of grease oil and dirt especially in the engine
30. ORG 18 o E z gt gt Se K __ na nome E 5 u 5 2 12 ors 18 a L g qe E de Re m E si a z 3 3 s gt zi 3 s S Qc a 5 3 aw e 2 a m xk gt F de E z ae E 5 z lt 4 El z Z 2 s n E PA 8 z 3 RED 10 g z s PE o o z s a I o 8 8 z Doo bej We a 2 er 8 o oe HE EH asd 2 A a 3 s Li o e 3 R et za lo 354 MEE o s s pU Zi d g jc 3 E o a R Hd S mm cn s 2 E za gt al a El E o E Bd E o 42 ve wat Gal 38 rt 018 40 vEL BLK ul e PEZYCTEIDEZEETWUTED ES N z a piko aes E OS n uxo n z BZ zz o rau ej Be E eco E IFoo S x z I 8 o 2 54 WHT RED 20 s 55 WHT RED 20 56 WHT GRN 201 57 GRN WHT 20 59 BLK 20 52 BLK 20 S Figure 7 3 115164 7 3 REV C Electrical Schematic Shibaura Diesel Domestic mowers built after serial number 13110000 IGNITION SWITCH 8 RED BLK EE y 6 RED aal 4 L 52 BLK
31. The software products support the engineer throughout the control system lifetime from creation to simulation to run time operation to viewing and troubleshooting Search and Download Software Products Enter a search term for example a product or software name and click on the Search button to view and download software software descriptions or senice packs for your system Use the optional Software Type and Product Category fields and click on the Search button to narrow your search results ed 1 Search Seeds Scare pe APECS 4800 Selecta Product Category Search Clear Software Search Results orem 2 Download APECS APECS 4800 Service Tool Download More Info 4800 Service Tool DRONE Figure 5 7 115164 REVC Assembly 1 2 Park the mower on a solid level surface set the park brakes and shut off the engine Begin with the computer on and located near the mower Locate the two cables included in this kit Connect the converter cable to a USB port on the computer Connect the converter cable to the ECU cable Connect the ECU cable to the wire harness on the engine near the ECU Figure 5 8 Start the APECS 4800 Service Tool program on the computer Turn the mower key to the RUN position but do not start the engine NOTE You can access the ECU to receive live data from the sensors while the engine is running but it is not nec essary to start the engine to access an
32. 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 Ibs N M Wheel lug nuts 70 95 Blade spindle bolt top 70 95 Blade spindle bolt bottom 118 160 Electric clutch mounting bolt 45 48 61 65 Front wheel axle bolt 100 136 Wheel motor hub nut s n 1110 first four digits and later 230 312 Wheel motor hub nut prior to s n 1110 first four digits 325 440 Hydraulic pump pulley screw 14 19 Engine torques N A N A Engine mount bolts 64 87 Notes Particular attention must be given to tightening the drive wheel lug nuts and blade spindle bolts Failure to cor WARNING 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 rectly torque these items may result in the loss of a wheel 3 If clutch mounting bolt
33. ace with new parts Disconnection of actuator drive Ensui connection 04 connector No Warning light action only Disconnection of actuator drive m Continuity test harness Speed sensor malfunction Replace with new parts Disconnection of speed sensor deeg K E Ensure connection connector No warning light action at the time of power distribu Without warn z No tion ing light action Pisconnection of speed sensor Indicate warning light code 13 two seconds after start Continuity test harness crankin g Air gap failure between speed Adjust air gap sensor and ring gear Error Codes When Engine is Running WARNING LIGHT CODE PROBLEM SYMPTOMS SUGGESTED REMEDIES Oil pressure decline No error detection until after 180 seconds from engine starting even in case of weak signal Add engine oil Goes into power cutback mode Limp home mode in case more Ensure harness and connector than 5 seconds of error detection after above 180 seconds and connection then shut down the engine after 180 seconds Weak signal from oil pressure 31 switch Short circuiting shunting due to harness disconnection Pressure sensor malfunction Replace with new parts Disconnection of pressure sen Goes into power cutback mode Limp home mode immediately Check connection 22 sor connector after power distribution Disconnection of pressure sen Continuity test sor harness Actuator position sensor mal
34. alve open Close tow valve The traction drive belt is worn loose or broken Install a new traction drive belt Air in system Check filter and fittings For additional causes See engine manual Liquid cooled or Diesel engines overheating Temperature light glows Frequent refilling of radia tor required Coolant appears rusty Audible alarm 115164 Leaks in system Coolant level low Replace tighten hoses and connections Add coolant Radiator screen clogged Clean screen Thermostat stickling or inoperative See engine manual Heat light malfunction Contact your dealer SYMPTOMS PROBABLE CAUSES SUGGESTED REMEDIES Low engine oil pressure Low oil level Add oil Oil diluted or too light Change oil and check for source of contamination Failed oil pump Contact your dealer High oil consumption Numerous Contact your dealer Mower jerky when starting or operates in one direc tion only Steering control linkage needs adjustment Adjust linkage Pump or wheel motors faulty Contact your dealer Tow valves not closed com pletely Close tow valves Hydraulic system oper ates hot oil in reservoir smells rancid Low hydraulic oil level Fill reservoir Hydraulic pump faulty Contact your dealer Hydraulic oil heat exchanger clogged Clean oil heat exchanger core Mower creeps whe
35. and under the seat platform areas minute dust 115164 1 1 particle are abrasive to close tolerance engine and hydraulic assemblies Daily inspect mower for grass clippings and wire and string tangles The underside of the mower deck will collect a build up of grass clippings and dirt especially when grass is wet or has high moisture content This build up will harden restricting blade and air movement and will probably show a poorer quality of cutting Therefore it should be removed routinely To do this it will be necessary to raise and block the deck 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 Turf Equipment for additional information Warranty Warranty repair must be performed by a Hustler Turf Equipment Authorized Dealer before warranty credit can be allowed Work perform
36. andling A Charge batteries in an open well ventilated area away from sparks and flames Unplug charger before connect ing or disconnecting from battery Wear protective cloth ing and use insulated tools A 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 con tact occurs flush area with clean water and call physi cian 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 posi tive 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 bat tery Clean the battery terminals with a solution of four 115164 2 3 parts water and one part baking soda when they become corroded A 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 per sonal injury Prevent the battery terminals from touchin
37. ay 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 sup plied with the vehicle stands Keep hands hair clothing etc clear of the cooling fans on top of the transmissions Exercise extreme caution A A WARNING A WARNING A WARNING 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 115164 44 3 gt 6 a 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 Figure 4 1 Figure 4 1 Start the engine Position the steering control lever in the neutral position and observe which way the wheels are rotating Figure 4 2 Control lever Za Figure 4 2 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 3 amp Figure 4 4 Re
38. cessary to check and adjust the settings The high idle speeds with no load should be set as follows Shibaura Model 773 ENGINE SPEED MODEL NO ENDING WITH HIGH IDLE MODEL NO WITHOUT EXTENSION 3000 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 REV C 5 8 115164 DECK ADJUSTMENTS 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 recommended pressures are as follows Drive wheels 8 12 psi 55 83 KPa Gauge wheels 8 12 psi 55 83 KPa A A Stop engine Make sure deck clutch switch is in the down OFF position Place control levers in the brake position before leaving machine WARNING 2 Park the unit on a flat surface 3 XR7 Side Discharge Deck Place 4 101 6mm high deck support blocks at the front corners of the deck This will set the cutting height at 3 50 88 9mm Place 3 25 82 6mm high deck support blocks at the rear corners of the deck Figure 6 1 NOTE Back of deck will automatically be set 1 4 6 35mm higher VX4 Side Discharge Decks Place 3 76 2mm high deck support blocks two stacked 2 x 4 blocks can be used
39. chain one or more link s at the anchor point on the deck frame Figure 6 17 IMPORTANT Do not over tension the spring to compensate for a badly worn belt or pulley Spring chain anchor point 54 60 66 72 VX4 Decks Figure 6 17 60 72 Rear Discharge Decks Single Belt System 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 REV C 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 18 IMPORTANT Do not over tension the spring to compensate for a badly worn belt or pulley Spring chain anchor point 60 72 Rear Discharge Decks Figure 6 18 60 72 Rear Discharge Decks Two Belt System Early Style There are two deck drive belts on these decks The belt tension remains constant by means of a tension idler and spring on each belt The spring tension should be such that the belt does
40. ck lift arm Figure 6 9 O Lift block 1 IA C N 1 4 BASE lift rod O Figure 6 8 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 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 10 22 Tighten the other nut on the opposite side of the block and jam them tightly together against the block as SS Figure 6 9 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 11 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 115164 6 3 Eam d lo BEN Nez sam y ro O O O 5 Figure 6 10 Figure 6 11 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
41. de Figure 5 13 Figure 5 14 Figure 5 15 amp Figure 5 16 115164 1 In Diagnostics 1 or 2 or 3 Clear All Faults becomes available ECKE Ciar AlFauhs lang Cado SSe mm Also fault information im am suchas ES n 55 5 code description ACTUATOR OVEROJRRENI n i I fos 4 Lolo o 88H B58 2 I I I I Leg co orcum AP FFEO OUT OF PANCE POSPONER SLR Amen n GAL Sommer s nanmanna s sm mue sennanea lamp code number ojo 2555555 5 sim 5 5 active vs logged fault count etc DE 00000905 Figure 5 13 Fle View Dee Setinge Took Hep PENE ZE Bi comer Zenner Y Ca Fore zeg eege Vins Shi es ELS pa Speed Sep Mode Drooo Desired Seed nare Load eee0e000 ka SAJE ez Lx CARA Diagnostics 4 DEA PSP EECH E APPO MP power ppm 99000 5 eo AAA DAA AH OPS VIRE BREAK eooo gt mammanmam Fault logged E zapen e eeg llsls 0 55555555 OVER TEMPERATURE se o v gt mananman O ti G t PosmoN_cov e 5 7 AR AAA AAR ne time coun L eme a m 9000 gt anannmanm pase OOOO Inactive Posmon SENSOR Mi 9000 gt BRS SHAH Poemon SENSOR LO e 5 PROTECTION FAULT ve gt gt BREBABRAH SET SPEED Por HI 99000 gt BRARARAR ser SPEED POT LO 9000 D TOROJE MAMO RE gt pnmnnmmmmm Conneced on COMB ji Deas e Setinge Tools Hep BB Be O o eegen Tp Comer Okcomect Y
42. djusted Place steering control levers in park brake posi tion or re adjust switch Deck clutch switch engaged Disengage clutch switch Weak or dead battery Recharge or replace Electrical connections are corroded or loose Check the electrical con nections For additional causes See engine manual The engine will not start starts hard or fails to keep running No fuel or line plugged Fill tank or replace line See Fuel System section for more details Fuel valve is turned off Open the fuel valve There is incorrect fuel in the fuel system There is dirt in the fuel filter Drain the tank and replace the fuel with the proper type Replace the fuel filter Dirt water or stale fuel in the fuel system Contact your dealer The choke is not on Move the choke lever to ON Numerous See engine manual Engine Runs with continuous mis firing 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 Hydraulic line blockage See your dealer Internal interference or leakage in wheel motor See your dealer Insufficient hydraulic oil supply Check level in reservoir Have dealer check hydrau lic pump Poor compression See your dealer Steering linkage needs adjustment Adjust linkage Tow v
43. ds Lower the mower Reconnect the negative battery cable Lower and secure the seat platform 4 5 1 8 8 3 175mm Figure 4 15 Park brake spring adjustment NOTE This adjustment is only on mowers with serial numbers prior to 1110 first four digits 1 2 Occasionally check the park brake spring adjustment using the following method Shut engine off place control levers in the park brake position disengage deck clutch remove ignition switch key and disconnect negative battery cable before doing any adjustments Measure the park brake spring It should be compressed to 1 625 If it is not adjust the nylock nut until the proper spring compression is achieved Figure 4 16 Repeat for the other side REV C 1 625 compressed spring length Figure 4 16 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 rav eling 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 bot tom of the groove Replace the pulley when this is the case oth erwise 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 belt
44. ed by anyone other than an Authorized Dealer will invalidate the warranty claim and warranty credit will not be approved REV C REV C 1 2 115164 SAFETY 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 eguipment 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 A DANGER WARNING 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 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 running 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 in handling fuel Fuel is extremely flamma ble and the vapors are explosive A Observe usual fuel handling precautions Do not smoke while refueling Extinguish all ciga rettes cigars pipes and other
45. ench 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 dealer for more information Sharpen the blades on a grinder following pattern as shown Figure 6 12 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 13 amp Figure 6 14 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 Nm 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 cut ting IMPORTANT When mounting blades rotate them after installation to ensure blade tips do not touch each other
46. fter tensioning new belt Measured from outside of hook to outside of hook with deck set at 3 82 6mm cut height 2 Route belt as shown 9 3 10 3 236 262mm 9 3 10 3 236 262mm Figure 6 28 115164 6 13 REV C 72 Rear Discharge Deck Two Belt System Later Style 1 Spring length after tensioning new belt Measured from outside of hook to outside of hook with deck set at 3 82 6mm cut height 2 Route belt as shown 9 3 10 3 236 262mm 9 3 10 3 236 262mm Figure 6 29 REV C 6 14 115164 ELECTRICAL Electrical Schematic Shibaura Diesel Mowers built prior to serial number 0902000 ch BLK 16 ch BLK 16 FAN CLUTCH PNK 16
47. g 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 per sonal injury Always disconnect the negative black bat tery 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 A 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 vegetable oil Get medical attention immediately REV C REV C 2 4 115164 TOROUE Standard Torgues The following chart lists the standard torque values for the threaded fasteners found in this manual
48. he pump linkage rods and rotate the rod to shorten the steering control linkage until the wheel s come to a stop Figure 4 3 amp 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 A i 12 IMPORTANT With the engine off disconnect the two 5 place when the adjustment is correct by re tightening female spade connectors from each other from step 3 the jam nut Do this for each side and reconnect them to the seat switch This must be To adjust the stops for driving straight when steering completed so that the safety circuit is functioning 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 1 To make the first adjustment the tractor 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 t
49. he 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 REV C 4 2 115164 Stop screw Figure 4 5 panel see Figure 4 6 2 Then stop the tractor and loosen the lock nut on the side which is rotating too fast and turn the stop set screw inward to stop the 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 Steering control lever 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 115164 4 3 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 doi
50. ion of 2 errors if 2 occur at the same time Code 31 Light up 3 times Flashing 1 time Code 04 Flashing 4 times 1 sec 1 sec 1 sec FLS FLS FLS FLS FLS 0 5 0 5 0 5 0 5 0 5 0 5 sec sec sec sec sec sec 1 CYCLE REV C 5 4 115164 Tier 4 Communication Kit Part Number 119801 This kit is needed to perform ECU diagnostics on the Hustler Diesel Z eguipped with Tier 4 engines Listed below are the parts included in this kit ECU Cable Instructional CD USB to RS 232 Converter Computer Software A computer with APECS 4800 software loaded on it is reguired to connect to the diesel engine in order to perform ECU diagnostics using the Hustler Diesel Z Tier 4 Communication Kit Be sure to close all programs on your computer prior to installing the software To download the software visit www woodward com software aspx Download and install the APECS 4800 Service Tool Once the software is installed proceed through the steps below to run the diagnostics Figure 5 7 weder ess Di Z woodward com sof c B 213 amp Dr is B Most Visited Getting Started 2 Latest Headlines B Most Visited Bb Getting Started Latest Headlines Z nosa ict noas ewk PTO PBSNet Compass NW woopwaRD Contact Search um Woodward has incorporated decades of experience controlling engines and turbines into its suite of software products and tools
51. is loosened or removed do not or blade which can cause serious damage or personal re use Replace with a new bolt Use only hand tools to injury install this fastener 115164 3 1 REV C REV C 3 2 115164 POWER UNIT MAINTENANCE 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 posi tion 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 trans mission 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 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 St
52. le injury to the servicing technician and or bystanders insure the vehicle is properly WARNING secured Do not attempt any adjustments with the engine run ning Use extreme caution while working in or around all vehicle linkage High temperatures can be gener ated Follow all safety procedures outlined in the vehi cle owner s manual Installation amp Testing Procedures Disconnect the system hoses at the wheel motor or system hoses from the pump and connect the Bi Directional Flow Test Kit Special care should be taken to prevent contamination debris from entering pump or wheel motor system ports NOTE Using the Bi Directional Flow Test Kit determina tion of directional flow is not necessary The flow meter may be connected in either direction into the forward and reverse high pressure system lines NOTE The following adapter fittings will be required when connecting the Bi Directional Test Kit Excel P N 783886 or Hydro Gear P N 70661 TC 21 Series Pumps require two 771311 adapter fittings CAUTION Ensure all fittings and hoses are attached securely This test is being completed on the vehicle s high pressure system lines Failure to perform this properly could result in bodily injury Testing Procedures 1 Use approved jack stands to raise the drive wheels off the REV C floor A WARNING A Never work under the machine or attachment unless it is safely supported with jack stands Make
53. luminum spacers Figure 4 22 4 Re torque each bolt M6 X 1 to 120 in Ibs Bo certain that the gap between the 5 Using a 015 thick feeler gage verify that a gap is rotor and armature face is greater present between the rotor and armature face on both ends than nika prior to shim removal of the brake pole as shown Figure 4 26 and Figure 4 27 Figure 4 23 a nee is less than 015 the clutch must be 1 Loosen both brake mounting bolts 1 2 to 1 full turn as b If sufficient gap is present then proceed to safety shown in Figure 4 24 check outlined below REV C 4 10 115164 Figure 4 27 Perform safety check WARNING 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 P1177 installation troubleshooting guide available on Warner 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 5 orbe 8 12 psi 55 83 KPa 115164 4 11 If you wish to use non pneumatic tires on your Hustler mower the tires must be an a
54. n steering control levers are in neutral Steering linkage needs adjustment Adjust linkage Mower circles or veers in one direction Steering linkage needs adjustment Adjust linkage Wheel motors faulty Contact your dealer Tires improperly inflated Adjust air pressure to 8 12 psi 55 83 KPa Hydraulic pump faulty Contact your dealer Mower creeps when park ing brake engaged Steering linkage out of adjustment Adjust steering linkage Brakes need adjustment Adjust parking brakes There is abnormal vibra tion The engine mounting bolts are loose Tighten the engine mount ing bolts The engine pulley idler pul ley or blade pulley is loose Tighten the appropriate pul ley The engine pulley is dam aged Contact your dealer The cutting blade s is are bent or unbalanced Install new cutting blade s A blade mounting bolt is loose Tighten the blade mounting bolt Spindle bearing is worn or loose Replace or tighten spindle bearing A blade spindle is bent 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 engag ing Check and or replace 10 amp fuse Contact your dealer REV C SYMPTOMS PROBABLE CAUSES
55. nce Schedule 8 1 Mower blade maintenance 6 3 Mower blade removal sssssesseesrrsssesrrrssererrsseeees 6 4 Operate machine safely 2 2 Pre operation precautions 2 1 Safe servicing practices 2 1 Service Program 1 1 Special torgues 3 1 Standard torques 3 1 Steering adjustments 4 1 Steering control lever adjustment 4 3 Steering control lever neutral adjustment 4 1 Steering damper esee 4 3 MIOS Linee 4 11 Warner Clutch Re gap Adjustment Procedures 4 9 Wai Yui tinis ae eid Pc n ER Lao fd 1 1 REV C
56. ng 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 amp Figure 4 9 4 Pull the damper spring housing past the point that the internal spring is engaged Figure 4 8 amp Figure 4 9 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 Tin ech Steering control lever shown in park brake position Mowers prior to serial number 1110 first four digits Steering damper spring id Figure 4 8 Steering control lever adjustment The steering control levers can be adjusted for operator com fort 1 By loosening the cap screws that attach the upper control lever to the lower lever the upper control lever can be REV C Align steering control lever 4 125 3 175mm Figure 4 11 Park brake adjustment Figure 4 9 A s pivoted to fit the operator s personal preference see NOTE This procedure is only used on mowers produced Figure 4 10 A bo
57. not slip under normal operating load conditions assuming the belt is not excessively worn or damaged As the belts stretch and wears in adjustment may become necessary Clutch to deck drive belt To increase belt tension move the spring chain one or more link s at the anchor point on the deck frame Figure 6 19 IMPORTANT Do not over tension the spring to compensate for a badly worn belt or pulley Center deck spindle pulley to right spindle pulley belt To adjust the tension of this belt use the following procedure Figure 6 20 1 Loosen and back off the two 3 4 nuts 2 Loosen the 5 8 cap screw in the front idler pulley 3 Slide the pulley sled back until you can route the belt onto the pulley as indicated 4 Slide the pulley sled forward 5 Using a 15 16 wrench turn the 3 4 nut until the spring compresses to a measured length of 1 80 45 7mm 6 Re tighten the 5 8 cap screw in the front idler pulley 7 Run the belt in by starting the mower and engaging the deck Run in at full throttle for a minimum of 10 minutes 8 Repeat steps 1 7 9 Jam the two 3 4 nuts together REV C 6 6 IMPORTANT Do not over tension the spring to compensate for a badly worn belt or pulley Clutch to deck drive belt Spring chain Spring chain anchor point
58. 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 inside 1 8 3 175mm the park brake slot Figure 4 14 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 REV C 4 4 115164 10 11 12 13 14 115164 Brake link Do not adjust Figure 4 13 will still rotate but friction will start to become noticeable here However if no brake resistance is noticed the brake needs adjusted as follows a Loosen the brake linkage jam nuts Figure 4 15 b 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 c 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 14 d Place the control lever in the neutral position The tire should rotate freely Close the hydraulic pump s bypass valve Figure 4 13 Repeat steps 4 through 9 for the other side Check to make sure all tools or obstructions are removed from under the mower Raise the rear of the mower and remove the jack stan
59. or sides of the mower REV C 6 4 A Failure to correctly torque the bolt may result in the loss of the blade which can cause serious injury A Mower blades are sharp and can cut Wrap the blade s or wear gloves and use extra caution when servicing them WARNING WARNING 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 Figure 6 12 Warped Blade Replace Cutting plane Straight Blade Comparison of Warped and Straight Blades Figure 6 13 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 115164 Cutting edge Twisted Blade Edge replace Cutting Plane Cutting edge E Straight Blade Edge End view of blades comparing twisted and straightened blades Figure 6 14 belt or one in good condition should never run against the bottom of the groove Replace the pulley when this is the case otherwise belt will lose power and slip excessively Never pry a belt to get it on a pulley as this will cut or damage the fibers of the belt cove
60. peat for the opposite side if necessary If wheel s are rotating in reverse then loosen the jam REV C properly Figure 4 1 AA WARNING A 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 A WARNING A Mowers prior to serial number 1110 first four digits Aa be Never operate the mower with a non functioning seat switch Always reconnect the seat switch to the mower harness Mowers with serial number 13 Check to make sure all tools or obstructions are removed 1110 first four digits and later 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 steering control lever stops see Figure 4 5 are designed to do two things First and most important they must keep the pumps from bottoming out internally Secondly the stops may be adjusted to help drive straight when the 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 WARNING A Pump damage will occur if these stops are set incor rectly Figure 4 4 nuts on t
61. pproved tire purchased from Hus tler Turf Equipment Warranty claims will be denied on any mower equipped with unapproved non pneumatic tires REV C REV C 4 12 115164 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 recommendations bolt torques etc The engine warranty is backed by the manufacturer Special attention should be paid to applicable data which will not be duplicated here Engine Oil and Filter A A If the engine has been running and is up to operating tem perature 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 WARNING 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 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 freguently IMPORTANT When removing the oil filter take precautions to
62. r to the ECU 2 If no errors are detected when the engine is started the Engine Warning Light flashes once and then turns off 3 Ifan error is detected when the engine is started or after the engine is running the Engine Warning Light will flash one of the codes listed in the table 4 Determine what the problem is and resolve it before 115164 continuing mower operation Error Codes When Starting Engine WARNING ENGINE LIGHT CODE PROBLEM START SYMPTOMS SUGGESTED REMEDIES Oil pressure switch malfunction Replace with new parts Disconnection ofoilpressure Shift to engine stop mode immediately after power dis Check connection 13 switch Yes SEO tribution and then stop after 180 seconds Disconnection of oil pressure iud Continuity test harness Pressure sensor malfunction Replace with new parts Disconnection r pressure seit Goes into power cutback mode Limp home mode Check connection 22 sor connector Yes E te immediately after power distribution Disconnection of pressure sen e Continuity test Sor harness Actuator position sensor mal k Replace with new parts function Disconnection of actuator posi Goes into power cutback mode Limp home mode e 33 Yes E MES Ensure connection tion sensor connector immediately after power distribution Disconnection of actuator posi Continuity test tion sensor harness Actuator drive malfunction Repl
63. ring 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 54 60 66 72 XR7 Decks 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 15 amp Figure 6 16 IMPORTANT Do not over tension the spring to compensate for a badly worn belt or pulley Spring chain anchor point 54 66 72 XR7 Deck Figure 6 15 115164 6 5 60 XR7 Deck Spring chain Spring chain Eg anchor point Idler spring Ur Figure 6 16 54 60 66 72 VX4 Decks 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
64. rplugs when operating this equipment as prolonged exposure to uncomfortable or loud noises can cause impairment or loss of hearing REV C Do not wear radios or music headphones while operat ing 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 Avoid possible injury or death from machine runaway A Do not start engine by shorting across starter terminals A Before you start the engine Sit on the operator s seat Move control levers to the neutral brake position Operate Machine Safely A Refer to the unit s operator s manual for complete safety information on safe machine operation A Always maintain a safe distance from people and pets when mowing A Always be aware of what is behind the machine before backing up A Never leave machine unattended with ignition key in switch especially with children present A Follow daily and weekly checklists making sure hoses are tightly secured and bolts are tightened A Always keep engine and machine clean removing accu mulated dirt trash and other material from machine A Never put hands or feet under any part of
65. s and never use belt dress ings 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 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 9 50 13 241 3 3 3mm when measured from the inside of the hook to the inside of the other hook Figure 4 17 To increase belt tension loosen the jam nut on the eye bolt Then tighten the nut on the eyebolt until the 9 50 13 241 3 3 3mm dimension is attained Lock the eyebolt in place by tightening the jam nut Figure 4 17 IMPORTANT Do not over tension the spring to compensate for a badly worn belt or pulley Figure 4 17 IMPORTANT Inspect the belt every 100 hours and replace as needed Replace the belt every 400 hours or every two 2 years whichever comes first REV C 4 6 WARNING 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
66. ss 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 freguency of air filter element changing Air restriction indicator These units have an air restriction indicator installed in the air cleaner Figure 5 5 REV C 5 2 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 5 Engine Controller Tier 4 Engines Only An engine controller is used on all Tier 4 engines It monitors and controls the engine s fuel system and subsequent exhaust emissions When a problem is detected a code is sent to the Engine Warning Light located on the mower s control panel Controller Figure 5 6 The following provides the necessary troubleshooting information needed to interpret the error codes Before starting the engine 1 Ensure that all wires are connected correctly before turning on the powe
67. t 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 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 pa
68. the mower making sure that no part of the body especially arms and hands are under mower A 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 A Always wear adequate eye protection when servicing the hydraulic system and battery or when grinding mower blades and removing accumulated debris A 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 A Exercise caution when releasing spring tension from any of the belt idlers or when working with any of the deck lift components A 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 appro priate 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 A Keep nuts and bolts tight especially the blade attachment bolts Keep equipment in good working condition A Never tamper with safety devices Check their proper operation regularly A Exercise ca
69. the machine while it is running A Never attempt to start engine when there is a strong odor of gasoline fumes present Locate and correct cause A Keep all safety shields and covers in place except for servicing A Do not touch hot parts of machine General Maintenance Precautions A Repairs or maintenance requiring engine power should be performed by trained maintenance person nel only A 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 A 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 sure proper ventilation is available when engine must be operated in an enclosed area REV C 2 2 A Before working on or under the deck make certain engine cannot be accidentally started Shut engine off remove ignition switch key and disconnect negative bat tery cable for maximum safety A Except when changing or checking belt always keep belt covers on mower deck for safety as well as cleanliness A Use a stick or similar instrument to clean under
70. uring the 115164 6 1 10 11 12 XR7 Decks 4 Block 4 Block n kal 3 25 Block 3 25 Block Locator triangle 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 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 7 Figure 6 8 amp Figure 6 11 Loosen the two nuts on the front of height indicator so that the foot pedal is free Figure 6 7 Start the leveling process on the left front of the mower Set the amount of threads protruding on the deck lift rod from the lift block at approximately 1 25 4mm left amp right side Figure 6 8 Jam both nuts against the block 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 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 REV C 3 Block juda 3 Block 3 Block
71. ustler Diesel Z Maintenance Schedule Refer to Figure 8 1 Figure 8 2 Figure 8 3 Figure 8 4 Figure 8 5 Figure 8 6 8 Figure 8 7 SERVICE AT INTERVALS INDICATED WEEKLY MONTHLY ANNUALLY OR 50 OR 100 OR 500 HOURS HOURS HOURS erify safety start interlock system Prior to each use Check coolant level Prior to each use isually inspect unit for loose hardware and or damaged parts Prior to each use isually inspect tires Prior to each use Check oil level engine 1 Prior to each use or every 4 hours Clean air intake screen 8 Prior to each use or every 4 hours Clean oil heat exchanger 8 Prior to each use or every 4 hours Check radiator screen 8 Prior to each use or every 4 hours Check fuel level Prior to each use Blades sharpen 8 securely fastened Prior to each use Discharge chute securely in place in lowest position Prior to each use Clean engine and pump compartment Daily Check air cleaner service indicator 5 Daily isually inspect radiator core Grease deck pusher arms Grease pump idler Grease deck height pivots Grease gauge wheel bearings Change engine oil and filter 1 4 Clean cylinder and head fins a Check battery connections Check tire pressure with a gauge Check hydraulic oil level Clean engine exterior a x gt lt gt lt gt
72. ution 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 A Use only genuine Hustler replacement parts to ensure that original standards are maintained Maintenance Precautions Avoid Fire Hazards A 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 A Provide adequate ventilation when charging batteries A Do not smoke near battery A Never check fuel level with an open flame A Never use an open flame to look for leaks anywhere on the equipment A Never use an open flame as light anywhere on or around the equipment A When preparing engine for storage remember that fuel stabilizer is volatile and therefore dangerous Seal and tape openings after adding the inhibitor Keep container tightly closed when not in use 115164 A Inspect electrical wiring for worn or frayed insulation Install new wiring if wires are damaged Prepare For Emergencies A Be prepared if a fire starts A Keep a first aid kit and fire extinguishers available A Keep emergency numbers for doctor ambulance service hospital and fire department near the telephone Prevent Battery Explosions A 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 h
73. with serial numbers 1110 first four digits and later 2 The steering control levers should be adjusted so that leno they align vertically with each other when in the neutral position Figure 4 11 WARNING 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 sup plied 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 12 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 13 6 Try and rotate the tire by hand The tire should rotate Figure 4 10 Remember hydraulic
74. y stored codes or sensor faults Click Connect at the top of the APECS tool and confirm the selection of the USB cable not the TCP IP Click Connect at the bottom of the window Figure 5 9 v Figure 5 8 Programming and Configuraton Tool Desired Sod ed Eine Seed Eran Loss 1 Select Confirm APECS 480 USB Cable Not TCP IP 2 Click Connect 1 Confirm Level 1 cc NUR E Device 18524177 is a secure device Please log in Password 2 Click Log In Figure 5 10 M5 wooDwA It APECS 4800 KE Info Gay ECU serial number Engine type Engine RPM Software status Figure 5 11 1 Pull down menu scroll to Diagnostics 1 ARENT av n 3m n AUI b amam c N Lb weour o I e e r CONFIGURATION eo a CPU FALURE e o fu CPU POWER sun c 5 s 10 11 REV C Figure 5 9 Confirm Level 1 and Log in Figure 5 10 You should now be connected to the ECU This screen shows some detailed information Figure 5 11 Click on the pull down menu and scroll to Diagnostics 1 Figure 5 12 5 6 Figure 5 12 12 Contained in the Diagnostics 1 2 3 4 is a button to use for clearing faults Pressing this button will clear the faults in the memory so that you can recheck to see if the fault reappears after the repair has been ma

Hustler® Diesel Z General Service Manual

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Hustler&reg; Diesel Z General Service Manual

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Hustler® Diesel Z General Service Manual