Hustler® TrimStar General Service Manual
Contents
1. Figure 6 18 36 Rear Discharge Deck 36 Rear discharge deck available as a CE mower only Figure 6 19 REV 6 10 114674 0512 48 Rear Discharge Deck 48 Rear discharge deck available as a CE mower only Figure 6 20 114674 0512 6 11 REVB REVB 6 12 114674 0512 ELECTRICAL Electrical Schematic Recoil Start 33N343434 553 34IM 040 REVB SC O TIN INIONI 0 Aldans DIAZ Esa 3 19 3 SE 5 ers lt gt 81 NYL 8 5 E HOLIMS gt 2 4907 IVYLNIN N CO 2 S 25 e 5 81 8 S 25 2 lt A 81 4718 l A 81 NYG 9 81 1AM 8Nd 81 418 ZI e di a 4313 von CO E HOLIMS a 2 27 81 034 940 6 HOLN 19 114674 0512 Electrical Schematic Electric Start ka 7 1 81 NUS2. 1 1 Maintenance Locator Chart een 8 2 114674_0512 1 1 Maintenance Precautions 2 2 Maintenance Schedule 8 1 Mower blade maintenance 6 6 Mower blade removal 6 7 Operate Machine Safely 2 2 Operation Precautions 2 2 Park Brake Spring Adjustment 4 2 Pre Operation Precautions 2 1 Pump Clutch Belt Adjustment 4 3 Safe servicing practices 2 1 Service Program 1 1 Special torques 3 1 Standard 3 1 Steering adjustments 4 1 Steering neutral adjustment 4 1 E fent 4 5 Warranty Staaten 1 1 REV
3. 23 so that the bar has play Figure 6 2 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 2 54cm left amp right side Figure 6 2 Jam both nuts against the block Push or pull on the deck lift bell crank until the chain on the left front just becomes tight making sure that the deck stays tight against the block Figure 6 2 While keeping the chain tight tighten the nuts against the deck lift block on the height indicator rod just enough to carry most of the deck weight on that side the block should be able to move with only a slight drag Figure 6 2 Jam nuts tightly together against the deck lift block Figure 6 2 Go to the right front of the mower 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 2 Tighten the adjuster bolt until the chain just becomes tight Then tighten just enough to carry the weight of the front of the deck on that side to check move the blocks back and forth they should move with a slight drag Figure 6 2 Tighten the adjuster bolt jam nut to prevent the adjuster bolt from moving Figure 6 2 Tighten the hardware holding the chain and adjuster onto the deck lift arm Go to the right rear of the mower Make sure that there is still slack in the chain If not loosen the two nuts on the block holding
4. Stop engine Make sure deck clutch switch is in the down OFF position Place neutral lock park brake lever in the brake engaged position 2 Park the unit on a flat surface 3 Place 3 high deck support blocks two stacked 2 x 4 blocks can be used to create a 3 7 62cm high support at the four corners of the deck as shown NOTE Back of deck will automatically be set 1 4 6 35mm higher Figure 6 7 4 Place the height stop in the 3 7 62cm hole with the flat on all four blocks Figure 6 8 NIIN side of the height adjusting stop against the deck stop 6 Loosen the two nuts on the front of height indicator bar bracket Clamp the height adjusting stop against the deck so that the bar has some play Figure 6 8 stop bracket This will assure that the height will not 7 Start the leveling process on the right rear of the mower move during the setting process Figure 6 8 8 Set the amount of threads protruding on the deck lift rod 5 Loosen all nuts on the deck lift threaded rods and the from the lift block at approximately 1 50 left amp right side Figure 6 8 9 Jam both nuts against the block Figure 6 8 Figure 6 7 hardware on the adjuster on the left rear until all the deck lift chains are loose and the deck is sitting tightly 5 16 bolt Adjuster N Deck lift R SS lt SIN E Or rod Deck adjustment W l
5. The engine pulley is damaged Contact your Dealer The cutting blade s is are bent or Install new cutting blade s unbalanced A blade mounting bolt Tighten the blade is loose mounting bolt Spindle bearing is worn or loose Replace or tighten spindle bearing A blade spindle is bent Contact your Dealer Steering linkage needs adjustment Adjust linkage Tow valve open Close tow valve The traction drive belt is worn loose or broken Install a new traction drive belt The traction drive belt is off the pulley Install the traction drive belt and check for a reason For additional causes See engine manual Overheating Air intake screen or cleaning fins clogged Clean screen and fins For additional causes See engine manual 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 parts 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 A blade spindle is bent Contact your Dealer Low engine oil pressure Low oil level Add oil Oil dilu
6. Z Y 81 NY9 94O 61 NE97S80 81 1 2 930 6 940 8 E NEED 940 11 81 419 734 22 A SS3UA SSINYVH 3YIM 240 81 N49 940 02 67531 81 418 0 81 940 0 o YILIN SS 81 NYG t2 81 62 8N0 21 ZE w avaan O 11101 9N3 81 NY9 940 L 10 13041 9 19 19 6 gt SS34 1101 0 CHE 81 418 0384 71 gt Co a HOLIMS IVYLNIN 2 gt 2 5 7 034 81 1 o ES 9 _ G1ON310S T 2 lt lt gt e UILUVIS e 81 TE 82 81 038 940 91 AN 81 940 9 nta 5 gt 81 92 91 25005 91 134 940 SI 2 JIN HOLIMS 9 p W H3107 ET HOLNI gt ALLY 91 940 190421 T lt 81 R 7 dau x 21790 BN A 21 aa 3503 VS HOLIMS NOI LIND 81 418 038 21 114674_0512 7 2 REVB MAINTENANCE SCHEDULE Hustler TrimStar Maintenance Schedule Refer to Figure 8 1 Figure 8 2 Figure 8 3 Figure 8 4 Figure 8 5 Figure 8 6 amp Figure 8 7 SERVICE ar E INTERVALS INDICATED HOU
7. TrimStar Service Program This manual is part of a service package for the Hustler TrimStar mowers Use of this manual in conjunction with other Hustler TrimStar mower and component manuals will provide the information necessary to service and maintain Hustler TrimStar mowers This maintenance manual is a service guide for use by Service Technicians It provides the necessary information needed to perform normal maintenance requirements on these units The Parts Manual provides a complete parts listing for the unit Use this manual when ordering parts The Operator s Manual provides fundamental operational information and operational safety that is needed when operat ing the mower The component manuals are furnished by the various manu facturers to be used for the troubleshooting and servicing of their products Maintenance Introduction Regular maintenance is the best prevention for costly down time or expensive premature repair The following pages con tain 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 per forming scheduled maintenance service Correcting the problem as quickly as possible is the best insurance Clear away heavy build up of grease oil and dirt especially 114674_05
8. 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 caution when working under the deck as the mower blades are extremely sharp Wrap the blade s or wear gloves and use extra caution when servicing them A Use only genuine Hustler Turf Equipment 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 114674_0512 A Never use an open flame as light anywhere on around the eguipment 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 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 s
9. feet under any part of 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 reguiring 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 odorless and deadly poison A Unless specifically reguired DO NOT have engine run ning when servicing or making adjustments to mower Park the machine on level ground Always disengage deck clutch place H Bar steering in neutral place neutral lock park brake lever in park brake position stop engine and remove ignition key when leaving the unit Remove the spark plug wires from the spark plugs or if applica ble disconnect the negative battery cable Wait for engine and all moving parts to come to a complete stop before doing any maintenance adjusting cleaning or repairing Repairs or maintenance reguiring engine REV 2 2 power should be performed by trained maintenance per sonnel only To prevent carbon monoxide poisoning be sure proper ventilation is available when engine must be operated in an enclosed area Read and observe safety warnings in front of manual A Before working o
10. nut on the opposite side of the block and jam them tightly together against the block When completed all chains will be tight and deck will be resting on the blocks Figure 6 4 Deck Leveling 48 Rear Discharge Deck NOTE 48 Rear discharge deck is available as a CE mower only Leveling the deck must be done in the following manner and order 1 114674_0512 Check tire pressures to make certain they are properly inflated before starting to level deck The recommended pressures are as follows Drive wheels tire pressure 8 12 psi 6 3 blocks can be used to create a 3 7 62cm high support at the four corners of the deck as shown NOTE Back of deck will automatically be set 1 4 6 35mm higher Figure 6 5 Figure 6 5 REVB 10 11 12 13 14 15 16 17 18 19 20 REVB Place the height stop in the 3 7 62cm hole with the flat side of the height adjusting stop against the deck stop bracket Clamp the height adjusting stop against the deck stop bracket This will assure that the height will not move during the setting process Figure 6 6 Loosen all nuts on the deck lift threaded rods and the hardware on the adjuster on the right front until all the deck lift chains are loose and the deck is sitting tightly Deck stop bracket on all four blocks Figure 6 6 Loosen the two nuts on the front of height ind
11. performed by anyone other than an Authorized Dealer will invalidate the warranty claim and warranty credit will not be approved REVB REVB 1 2 114674_0512 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 WARNING Denotes a hazard or unsafe practice which COULD result in severe personal injury or death Safe Servicing Practices This product is capable of amputating hands and feet and throwing objects Always follow all safety instructions to avoid serious injury or death Understand Correct Service 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 e Do not smoke while refueling Extinguish all ciga rettes cigars
12. pipes and other sources of ignition Do not remove the fuel tank cap or fill fuel tank with engine running or while the engine is hot Never refuel near an open flame or near devices which can create a spark Refuel outdoors Never refuel or drain the fuel from the machine indoors 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 114674 0512 2 1 Use extreme care when handling gasoline and other fuels They are extremely flammable and vapors are explosive A fire or explosion from fuel can burn you and others and can damage property Refuel outdoors Never refuel or drain the fuel from the machine indoors e 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 eguipment from the truck or trailer and refuel the eguipment with its wheels on the ground If this is not possible then refuel such eguipment on the truck or trai
13. the down OFF position Place neutral lock park brake lever in the brake engaged position 2 Park the unit on a flat surface 3 Place 3 high deck support blocks two stacked 2 x 4 blocks can be used to create a 3 7 62cm high support at the four corners of the deck as shown NOTE Back of deck will automatically be set 1 4 6 35mm higher Figure 6 3 4 Place the height stop in the 3 7 62cm hole with the flat side of the height adjusting stop against the stop handle Clamp the height adjusting stop against the deck stop bracket This will assure that the height will not move during the setting process Figure 6 4 5 Loosen all nuts on the deck lift threaded rods and the hardware on the adjuster on the left rear until all the deck lift chains are loose and the deck is sitting tightly on all four blocks Figure 6 4 REVB 6 2 11 12 A 75 16 bolt Ir AN A ar mandy Jam nut Figure 6 3 Loosen the two nuts on the front of height indicator bar so that the bar has some play Figure 6 4 Start the leveling process on the right rear of the mower Set the amount of threads protruding on the deck lift rod from the lift block at approximately 1 50 left amp right side Figure 6 4 Jam both nuts against the block Figure 6 4 Push or pull on the deck lift bell crank until the chain on the right rear just becomes tight making sure that the deck stays tight again
14. the threaded rod until there is slack in the deck lift chain Figure 6 2 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 2 Tighten the other nut on the opposite side of the block and jam them tightly together against the block Go to the left rear of the mower Figure 6 2 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 2 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 2 Tighten the other nut on the opposite side of the block and jam them tightly together against the block Figure 6 2 When completed all chains will be tight and deck cutting height will be set to the deck height indicator REVB Deck stop bracket Se S 59 Nuts lt Deck lift lt G N Figure 6 2 Deck Leveling 36 Side Discharge Deck Leveling the deck must be done in the following manner and order 1 Check tire pressures to make certain they are properly inflated before starting to level deck The recommended pressures are as follows Drive wheels tire pressure Gauge wheels tire pressure WARNING Stop engine Make sure deck clutch switch is in
15. 12 1 1 in the engine and hydraulic reservoir areas minute dust particles are abrasive to close tolerance engine and hydraulic assemblies Daily inspect mower for grass clippings and wire and string tangles The underside of the mower deck will collect a build up of grass clippings and dirt especially when grass is wet or has high moisture content This build up will harden restricting blade and air movement and will probably show a poorer guality 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 reguire the assistance of a trained service mechanic and should not be attempted by unskilled personnel Consult your Hustler Turf Eguipment service center when assistance is needed Information included in this manual was current at the time of printing but subseguent 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 con tact the Customer Service Department at Hustler Turf Equip ment for additional information Warranty Warranty repair must be performed by a Hustler Turf Equip ment Authorized Dealer before warranty credit can be allowed Work
16. 3 Figure 6 14 amp Figure 6 15 IMPORTANT Do not over tension the spring to compensate REVB for a badly worn belt Spring chain Spring chain Spring chain anchor point EN N So Spring chain anchor point spring 36 Side Discharge Deck 36 Rear discharge Figure 6 12 deck available as a 36 Rear Discharge Deck CE mower only Spring chain Spring chain Figure 6 14 anchor point 48 Rear Discharge Deck Spring chain Spring chain _ 48 54 Side Discharge Deck Figure 6 13 11 48 Rear discharge deck available as a CE mower only Figure 6 15 REV 6 8 114674 0512 Deck Belt Routing amp Tensioning NOTE The following notes are the same for all the different decks shown 1 Spring length after tensioning new belt Measured from outside of hook to outside of hook with deck set at 314 cut height 2 Routebelt as shown 36 Side Discharge Deck Figure 6 16 48 Side Discharge Deck Figure 6 17 114674 0512 6 9 REVB 54 Side Discharge Deck
17. 6 Side Discharge Deck Figure 8 5 48 54 Side Discharge Deck Eh BIN DIE Engine oil fill amp dipstick Fuel filter Engine air cleaner Engine oil drain Fuel tank Engine oil filter Drive tire Gauge wheel bearings Blades Discharge chute Deck drive belt Pump belt Transaxle oil filter Evaporative emission system filter Battery REVB 114674_0512 Figure 8 6 48 Rear Discharge Deck N L Engine oil fill amp dipstick Fuel filter Engine air cleaner Engine oil drain Fuel tank Engine oil filter Drive tire Gauge wheel bearings Blades Discharge chute Deck drive belt Pump belt Transaxle oil filter Evaporative emission system filter E SEA A DA Figure 8 7 36 Rear Discharge Deck joi Ps err 114674 0512 8 3 REVB REV 8 4 114674_0512 TROUBLESHOOTING SYMPTOMS PROBABLE CAUSES SUGGESTED REMEDI
18. ES SYMPTOMS PROBABLE CAUSES SUGGESTED REMEDIES The engine will not start starts hard or fails to keep running Deck clutch engaged Disengage deck clutch Mower creeps when H Bar steering lever is in neutral Steering linkage needs adjustment Adjust linkage No fuel or line plugged Fill tank or replace line Fuel valve is turned off Open the fuel valve There is incorrect fuel in the fuel system Drain the tank and replace the fuel with the proper type Mower circles or veers in one direction Steering linkage needs adjustment Adjust linkage Tires improperly inflated Adjust air pressure to 8 12 psi 55 83 KPa Transxle component faulty Contact your Dealer There is dirt in the fuel filter 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 misfiring or engine Numerous See engine manual runs unevenly or erratically Loss of power or system will not operate in either direction Restrictions in air cleaner Service air cleaner Poor compression Contact your Dealer There is abnormal vibration The engine mounting bolts are loose Tighten the engine mounting bolts The engine pulley idler pulley or blade pulley is loose Tighten the appropriate pulley
19. Hustler TrimStar General Service Manual HUSTLER TURF EQUIPMENT P O Box 7000 Hesston Kansas 67062 2097 114674_0512 REVB 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 t
20. RS HOURS HOURS Verify safety start interlock system Prior to each use Visually inspect unit for loose hardware and or damaged parts Prior to each use Visually inspect tires Prior to each use Check oil level engine 1 Prior to each use or every 4 hours Clean air intake screen 4 Prior to each use or every 4 hours Check fuel level Prior to each use Blades sharpen amp securely fastened Prior to each use Discharge chute securely in place amp in lowest position Prior to each use Replace air cleaner paper element As needed Clean engine amp transaxle compartment Daily Change transaxle oil amp filter 7 Every 200 hours or 2 years Grease deck height pivots X Grease front wheel bearings X Change engine oil amp filter 1 3 X Clean cylinder amp head fins a X Check battery connections x Check tire pressure with a gauge X Check hydraulic oil level X Clean engine exterior a X Clean amp regap spark plugs a X Check pump amp deck belt tension and condition 5 X Check fuel system 6 X Check fuel tank grommet 6 X Check hydraulic lines X Tighten lug nuts on wheels 2 X Change fuel filter Replace spark plugs Replace fuel evaporation system filter 8 X NOTES 1 Initial oil change is after 5 hours of operation Thereafter change oil after every 50 hours operation Change more often under dusty or dirty conditions and during hot weather periods 2 Torque initially and after first 2 hours of operation 3 Change engine oil filte
21. ade Edge End view of blades comparing twisted and straightened blades Figure 6 11 WARNING Failure to correctly torque the bolt may result in the loss of the blade which can cause serious injury Belts Inspect belts freguently 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 belt to get it on a pulley as this will cut or damage the fibers of the belt covering Keep oil and grease away from belts and never use belt dress ings Any of these will destroy the belt composition in a very short time Deck Belt Adjustment The spindle belt tension remains constant by means of a ten sion idler and spring The spring tension should be such that the belt does not slip under normal operating load conditions assuming the belt is not excessively worn or damaged As the belt stretches and wears in adjustment may become necessary To increase belt tension move the spring chain one or more link s at the anchor point on the deck frame Figure 6 12 Fig ure 6 1
22. ckwise and pull out to open the valve Allow 10 minutes for engine oil to adequately drain 6 After oil is drained close the valve by pushing in on the valve body and twisting it clockwise 7 Once the valve is closed carefully remove the oil drain hose and clean up any spilled oil IMPORTANT All oil drips or spills must be cleaned off of the exhaust system before operating the machine Re install the dust cap on the oil drain valve nipple 9 Clean the oil drain hose and store it appropriately Figure 5 1 Ga Engine Air Filter Perform engine air filter maintenance per the engine s 114674 0512 5 1 Figure 5 2 Carbon canister Some Hustler TrimStar mowers will have a carbon canister incorporated into the fuel system Figure 5 3 These canisters should be replaced every 5 years or if they become damaged Fuel evaporation system filter All domestic Hustler TrimStar mowers manufactured after January 1 2011 have a fuel evaporation system filter Non domestic Hustler TrimStar mowers units with a CE or EX extension after the model number manufactured between serial number 11010000 and 12010641 have a fuel evaporation sys tem filter Non domestic TrimStar mowers units with a CE or EX extension after the model number manufactured after serial number 12010641 do not have a fuel evaporation system filter REVB Fuel evaporation system filter Carbon canister Figure 5 4 Fuel evaporation system fil
23. er and order 1 Check tire pressures to make certain they are properly inflated before starting to level deck The recommended pressures are as follows Drive wheels tire pressure 8 12 psi Gauge wheels tire pressure 8 12 psi WARNING Stop engine Make sure deck clutch switch is in the down OFF position Place neutral lock park brake lever in the brake engaged position 2 Park the unit on a flat surface 3 Place 3 high deck support blocks two stacked 2 x 4 blocks can be used to create a 3 7 62cm high support at the four corners of the deck as shown NOTE Back of deck will automatically be set 1 4 6 35mm higher Figure 6 1 Figure 6 1 4 Place the height stop in the 3 7 62cm hole with the flat side of the height adjusting stop against the stop handle Clamp the height adjusting stop against the deck stop bracket This will assure that the height will not move during the setting process Figure 6 2 5 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 2 6 Loosen the two nuts on the front of height indicator bar 114674 0512 6 1 A 10 11 12 13 14 15 16 17 18 19 20 21 22
24. gnition key when leaving the unit Remove the spark plug wires from the spark plugs or if applicable disconnect the negative battery cable Block up mower when you must work under it Wear gloves when handling blades Always check for blade damage if mower strikes a rock branch or other foreign objects dur REV 6 6 ing mowing Always wear adequate eye protection when grinding mower blades A WARNING WARNING Mower blades are sharp and can cut Wear gloves and use extra caution when servicing them Always place deck clutch switch in the disengaged position place neutral lock park brake lever in the brake engaged posi tion turn engine off and remove ignition key when leaving the unit Remove the spark plug wires from the spark plugs or if applicable disconnect the negative battery cable Block up mower when you must work under it Wear gloves when han dling blades Always check for blade damage if mower strikes 114674 0512 rock branch or other foreign objects during mowing 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 9 Mower blade removal Use 15 16 wrench to remove the 5 8 cap screw holding the blade to the spindle shaft from underneath NOTE A blade holding tool part number 381442 is available fro
25. grinding mower blades and removing accumulated debris A Prolonged exposure to loud noise can cause impairment or loss of hearing REVB Always wear adeguate ear protection such as earplugs when operating this eguipment as prolonged exposure to uncomfortable or loud noises can cause impairment or loss of hearing Do not wear radios or music headphones while operat ing the machinery Safe operation reguires your full attention Operation Precautions Avoid Fire Hazards A Clean flammable material from machine Prevent fires by keeping engine compartment exhaust area battery if applicable fuel line and fuel tank 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 Operate Machine Safely A Refer to the unit s operators 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
26. he 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 114674 0512 114674_0512 Table of Contents General Information 1 1 DOS ta ad e Re AN SE eA dS 2 1 TOUS Er and 3 1 Power Unit 4 1 Engine Maintenance 5 1 Deck Adjustments ers en bear 6 1 Electrical AS 7 1 Maintenance Schedule 8 1 THOUDISSHOOUNG KEE 9 1 1 REV REVB c 2 114674_0512 GENERAL INFORMATION Hustler
27. he ports Figure 4 10 12 Continue to fill the transaxles through the expansion tank until the Full Cold line is reached on the expansion tank 13 Re install the expansion tank cap by hand Be careful not to overtighten 14 Proceed to the purge procedure Filter Top port plug Figure 4 8 wires from the spark plugs or if applicable disconnect the negative battery cable 2 Remove the three 1 4 filter guard screws and filter guard Clean any loose debris from around the filter Figure 4 9 3 Place an oil drain pan beneath the oil filter and remove the oil filter from the transaxle 4 Afterthe oil has been drained wipe the filter base surface off and apply a film of new oil to the gasket of the new replacement filter 5 Install the new filter by hand turn 3 4 to one full turn after the filter gasket contacts the filter base surface Figure 4 10 6 Re install the filter guard with three 1 4 screws Torgue the screws to 65 in Ibs each Figure 4 9 7 Repeat steps 2 6 for the opposite side transaxle 8 Drain oil filters of all free flowing oil prior to disposal Place used oil in appropriate containers 9 IMPORTANT Remove the top port plug from both transaxles prior to filling with oil This will allow the transaxles to vent during oil fill Figure 4 10 10 Remove the cap from the transaxle s expansion tank Purging procedure Due to the affects air has on efficiency in hydrostatic drive ap
28. icator bar so that the bar has some play Figure 6 6 Start the leveling process on the right rear of the mower Set the amount of threads protruding on the deck lift rod from the lift block at approximately 1 50 left amp right side Figure 6 6 Jam both nuts against the block Figure 6 6 Deck Iift Deck lift Figure 6 6 Push or pull on the deck lift until the chain on the right rear just becomes tight making sure that the deck stays tight against the deck support block Figure 6 6 While keeping the chain tight tighten the nuts against the deck lift block on the height indicator Figure 6 6 Jam nuts tightly together against the deck lift block Figure 6 6 Go to the left front of the mower 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 6 Tighten the appropriate nut until the chain just becomes tight making sure that the deck stays tight against the deck support blocks Figure 6 6 Tighten the other nut on the opposite side of the block and jam them tightly together against the block Figure 6 6 Go to the right front of the mower Loosen the 5 16 jam nut on the deck leveler yoke and back the 5 16 adjuster bolt out to allow the deck leveler yoke to move up and down freely Figure 6 6 Be sure that the deck adjuster is free to move up and down Figure 6 6 Tighten the adjuster bolt until the cha
29. in just becomes tight making sure that the deck stays tight against the 6 4 21 22 23 24 25 26 27 bell crank Deck lift J gt Jam nut 2 N lt Q Wi S IN amp 19 deck support blocks Figure 6 6 Tighten the adjuster bolt jam nut to prevent the deck adjuster from moving Figure 6 6 Tighten the hardware holding the chain and deck adjuster onto the deck lift arm Figure 6 6 Go to the left rear of the deck 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 6 Tighten the appropriate nut until the chain just becomes tight making sure that the deck stays tight against the deck support blocks Figure 6 6 Tighten the other nut on the opposite side of the block and jam them tightly together against the block Figure 6 6 When completed all chains should be tight and the deck should still be resting on the blocks Deck Leveling 36 Rear Discharge Deck NOTE 36 Rear discharge deck is available as a CE mower only Leveling the deck must be done in the following manner and order 1 Check tire pressures to make certain they are properly 114674 0512 inflated before starting to level deck The recommended pressures are as follows Drive wheels tire pressure 8 12 psi Gauge wheels tire pressure 8 12 psi A WARNING
30. inkage may be adjusted as follows This procedure will reguire that the unit to be raised and blocked up off of the ground It is necessary for the wheels to rotate without coming in contact 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 Keep hands hair clothing etc clear of the cooling fans on top of the transmissions Exercise extreme caution 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 WARNING WARNING A WARNING 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 114674_0512 4 1 3 Remove brake link from lower brake bell crank Figure 4 1 a a Brake link E Turnbuckle Figure 4 2 4 Place the neutral lock park brake lever in the park brake position with the engine running Figure 4 3 5 If rear wheels rotate forward or rearward loosen the locking hardware on the turnbuckle as
31. l not to get soap and water into the bat tery Clean the battery terminals with a solution of four 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 e Prevent the battery terminals from touching any metal mower parts when removing or installing the battery Do not allow metal tools to short between the battery terminals and metal mower parts A Incorrect battery cable routing could cause damage to the mower and battery cables This can cause sparks which can cause a battery gas explosion which will result in 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 e Filling batteries in a well ventilated area e Wearing eye protection and rubber gloves Avoiding breathing fumes when electrolyte is added Avoiding spilling or dripped electrolyte If you spill acid on yourself e Flush your skin with water e Apply baking soda or lime to help neutralize the acid e Flush your e
32. ld line on the expansion tank Use only SAE 20W50 SL service motor oil Initial system oil and filter change must be after the first 75 hours of use or 1 year whichever comes first Thereafter replace 114674 0512 4 3 Figure 4 5 Spring 9 gt Hydraulic pump belt Tension idler Bottom View Figure 4 6 filter and oil in each transaxle every 2 years or 200 hours whichever comes first NOTE The filter guard must be removed to access filter Each transaxle s filter is located per Figure 4 8 A standard oil filter wrench is used to change filter threads are right handed Use a Hustler approved filter element only When washing the mower direct the spray away espe cially if using a power washer from the transaxle s seals to prevent water intrusion and to ensure component per formance WARNING Fluid changing procedure 1 Park the machine on level ground Disengage deck clutch place the H Bar steering lever in neutral place neutral lock park brake lever in park brake position stop engine and remove ignition key Remove the spark plug REVB Hydraulic expansion Screw ter guard Figure 4 9 11 Fill with 20W50 motor oil until oil just appears at the bottom of each transaxles top port approximately 2 gts per transaxle Install the top port plug into each transaxle as the oil level reaches this port Torgue plugs to 180 in Ibs Clean up any oil that leaked from t
33. ler 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 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 e 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 is spilled on clothing change clothing immedi ately Understand Machine Operation A Only gualified and trained personnel should operate the eguipment 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 eguipment 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 adeguate eye protection when servicing the hydraulic system and battery if applicable or when
34. m Hustler Turf Equipment It is designed to prevent the blades from rotat ing when they are being removed or installed on the spindle Contact your Hustler Turf Equipment dealer for more informa tion Sharpen the blades on a grinder following pattern as shown in Figure 6 9 Touch up sharpening can be done with a file Check the blades for balance following grinding A commer cial balancing tool is available through most hardware supply stores or balancing can be done by placing the blade on an inverted line punch or 5 8 bolt Blade should not lean or tilt Spin the blade slowly blade should not wobble If blade is out of balance true it up before reinstalling Lay the blade on a flat surface and check for distortion Fig ure 6 10 and Figure 6 11 Replace any distorted blade Do not re use spindle bolts which have stripped worn or undercut threads Torque bolts on spindles to 118 foot pounds 160 013 when reinstalling blades 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 or sides of the mower 114674_0512 6 7 Warped Blade Replace Cutting plane n Straight Blade Comparison of Warped and Straight Blades Figure 6 10 Cutting edge Twisted Blade Edge replace Cutting Plane Cutting edge dee Straight Bl
35. n or under the deck make certain engine cannot be accidentally started Shut engine off and disconnect spark plug wires from the spark plugs for maximum safety If machine has a battery disconnect negative battery cable Repairs or maintenance reguiring engine power should be performed by trained personnel only 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 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 adeguate eye protection when servicing the hydraulic system and battery if applicable 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 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
36. nd grease away from belts and never use belt dress 114674_0512 W Brake rod Figure 4 4 ings Any of these will destroy the belt composition in a very short time Pump Clutch Belt Adjustment The TrimStar mower is eguipped with a pump clutch that disengages the pump clutch belt When the belt is disengaged the engine will start easier in colder temperatures To disengage the pump clutch pull the chain Figure 4 5 until the tension is released from the pump drive belt and latch in the slot Figure 4 5 To engage the pump clutch with the H Bar steering lever locked in neutral release the chain from the latching slot NOTE When engaged the spring should be extended to a dimension of 5 4 6 4 13 7cm 16 3cm Figure 4 6 NOTE Never operate the unit with the pump clutch par tially engaged Make sure the clutch is completely released and the chain has slack Hydraulic system The TrimStar mower is eguipped with two transaxles 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 The hydraulic expansion tank is located behind the left rear corner of the engine Figure 4 7 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 at the Full Co
37. on the right hand steering rod assembly If the unit pulls to the left loosen the lock nuts on the left hand steering rod assembly Figure 4 3 2 Start the engine 3 While driving adjust the steering rod assembly by rotating the center adjustment rod until the tractor tracks straight Figure 4 3 4 Stop the machine and shutoff the engine 5 Tighten the lock nuts on the steering rod assembly Figure 4 3 6 Repeat steps 2 5 for the other side if necessary Park Brake Spring Adjustment Occasionally check the park brake spring adjustment using the following method 1 Park the machine on level ground Disengage deck clutch place the H Bar steering lever in neutral place neutral lock park brake lever in park brake engaged position stop engine and remove ignition key Remove the spark plug wires from the spark plugs or if applicable disconnect the negative battery cable REVB 4 2 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 Place the H Bar steering lever in the neutral position and the neutral lock park brake lever in the park brake engaged position 5 Measure the park brake spring It should be compressed to the 2 00 If it is not adjust the nylock nut until the proper spring compression is achieved Figure 4 4 6 Check engagement of internal park brake pawl by manually rotating t
38. plications it is critical that it is purged from the system Air creates inefficiency because its compression and expan sion rate is higher than that of the oil approved for use in hydro static drive systems These purge procedures should be implemented any time a hydrostatic system has been opened to facilitate maintenance or the oil has been changed REV 4 4 114674 0512 The resulting symptoms in hydrostatic systems may be 1 Noisy operation 2 Lackof power or drive after short term operation 3 High operation temperature and excessive expansion of oil Before starting make sure the transaxle is at the proper oil level If it is not fill to the specifications outlined in this manual The following procedures are performed with the vehicle drive wheels off the ground 1 Raise and block the mower up so the drive wheels are off of the floor Never work under the machine or attachment unless it is safely supported with jack stands Make certain machine is secure when it is raised and placed on the jack stands The jack stands should not allow the machine to move when the engine is running and the drive wheels are rotating Use only certified jack stands Use only appropriate jack stands with a mini mum weight rating of 2000 pounds to block the unit up Use in pairs only Follow the instructions supplied with the vehicle stands WARNING 2 Chock the front tires 3 With the bypass valve open and
39. r 21 Loosen the 5 16 jam nut on the deck adjuster and back the 5 16 adjuster bolt out to allow the deck adjuster to move up and down freely and there is slack in the deck lift chain 22 Tighten the adjuster bolt until the chain just becomes tight making sure that the deck stays tight against the deck support blocks 23 Tighten the adjuster bolt jam nut to prevent the deck leveler yoke from moving 24 Tighten the hardware holding the chain and deck adjuster onto the deck lift arm 25 When completed all chains should be tight and deck should still be resting on the deck support blocks Blades Mower blade maintenance Check the mower blades daily they are the key to power effi ciency 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 Figure 6 9 Replace any blade which is bent cracked or broken Figure 6 10 amp Figure 6 11 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 A WARNING WARNING A A 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 neutral lock park brake lever in the brake engaged position turn engine off and remove i
40. r per the engine manufacturer s recommendations Refer to Engine Owner s Manual for recommendations and other maintenance items 4 Service more often under dusty or dirty conditions 5 Pump drive belt only Inspect every 6 months or 100 hours and replace if worn or cracking is noticed Otherwise replace every 200 hours or 2 years whichever comes first Refer to Cold weather pump clutch section for tensioning information 6 Check fuel system for any crack or leaks including but not limited to fuel line hoses fuel valve vent line hoses vent valve vapor valve carbon canister and grommets 7 Initial system oil and filter change must be after the first 75 hours of use or 1 year whichever comes first Thereafter replace filter and oil in each transaxle every 2 years or 200 hours whichever comes first 8 More often under dusty or dirty conditions and during hot weather 9 REFERENCES a Refer to Engine Owner s Manual NOTE After completing maintenance cycle 300 hours repeat cycle 114674 0512 8 1 REVB Maintenance Locator Chart Figure 8 1 Figure 8 3 3
41. ransmission axle in both directions If pawl is engaged the axle should not rotate 7 Place the H Bar steering lever in the run position and the neutral lock park brake lever in the disengaged position 8 The washer under the double jam nuts should still be free to rotate and have approximately 06 clearance If not re adjust jam nuts to this dimension 9 With brakes still in the disengage run position verify that wheels rotate freely without brakes grabbing If brakes are grabbing adjust jam nuts closer to end of brake rod assembly until wheels rotate freely Re engage brake lever to ensure that brakes are set Repeat engagement and disengagement as required to ensure that brakes are set in the engaged position and are released in the operate disengaged position Brakes are now set 10 11 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 belt to get it on a pulley as this will cut or damage the fibers of the belt covering Keep oil a
42. respective engine owner s manual If clutch mounting bolt is loosened or removed do not re use Replace with a new bolt Use only hand tools to install this fastener 114674 0512 3 1 WARNING Particular attention must be given to tightening the drive wheel lug nuts and blade spindle bolts Failure to cor rectly torgue these items may result in the loss of a wheel or blade which can cause serious damage or personal injury REV REVB 3 2 114674_0512 POWER UNIT MAINTENANCE Steering Adjustments Steering neutral adjustment The mower s steering has been factory adjusted to eliminate creeping when the H Bar steering lever is in the neutral position However should the mower begin to creep the steering control linkage can be adjusted Before considering any adjustment check the tire air pressure Unegual 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 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 H Bar steering lever is in the neutral position and the mower does not creep or the transmissions do not whine If this occurs the steering control l
43. s backed by the manufacturer Engine Oil and Filter WARNING 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 Check engine oil daily and after every 4 hours of operation Mower must be on a level surface when checking oil Refer to engine manual and maintenance schedule for oil recommenda tion and capacities Change the engine oil and filter after the first 5 hours of oper ation and then per the engine manufacturer s recommendations after that If mower is being operated in extremely dirty condi tions then it is recommended oil be changed more frequently IMPORTANT All oil drips or spills must be cleaned off of the exhaust system before operating the machine Draining the engine oil 1 Locate the oil drain valve on the engine Figure 5 1 2 Locate the oil drain hose that was supplied with the machine Be sure to clean and clear it of debris that might block the flow of the engine oil 3 Attach one end of the hose onto the oil drain valve nipple Make sure the hose is pushed all the way onto the valve 4 Position the loose end of the hose out to the side of the mower so that it can drain into a suitable oil drain container 5 With the hose in position twist the valve counterclo
44. sembly Figure 4 2 6 Tighten or loosen the turnbuckle until rear wheel comes to a stop Figure 4 2 7 Retighten locking hardware 8 Neutral should now be set 9 Re attach the brake link to the lower brake bell crank Figure 4 1 10 Place the neutral lock park brake lever in the unlocked position 11 With engine running rotate the H Bar steering lever forward and then into reverse REVB Disengage Engage Locking hardware La i a Neutral lock lever Steering rod assembly Tat Esto Figure 4 3 12 Wheels should both return to neutral when the H Bar steering lever is pulled forward out of reverse If not repeat step 4 6 until they do Return neutral lock park brake lever to the park brake position and check to make sure wheels are not rotating If wheels rotate repeat steps 3 11 Once both sides are properly adjusted check them together to make sure everything is working properly Check to make sure all tools or obstructions are removed from under the mower Raise the rear of the mower and remove the jack stands Lower the mower 13 14 15 16 Drive straight linkage adjustment It may be necessary to adjust the drive linkage on the mower If the mower tracks to the right or left when operating use the following method to adjust the drive linkage 1 If the unit pulls to the right loosen the lock nuts
45. st the deck support block Figure 6 4 While keeping the chain tight tighten the nuts against the deck lift block on the height indicator Figure 6 4 Go to the left rear of the deck 114674_0512 Adjuster 5 16 bolt Jam nut Deck adjustment stop Figure 6 4 13 Loosen the jam nut on the adjuster and back the 5 16 Gauge wheels tire pressure 8 12 psi bolt out to allow the adjuster to move up and down freely The deck lift chain should be slack Figure 6 4 14 Tighten the 5 16 bolt until the chain just becomes tight making sure that the deck stays tight against the deck support block Figure 6 4 15 Tighten the jam nut to prevent the adjuster from moving Figure 6 4 16 Tighten the hardware holding the chain and adjuster onto the deck lift arm Figure 6 4 17 Go to the right front of the deck WARNING Stop engine Make sure deck clutch switch is in the down OFF position Place neutral lock park brake lever in the brake engaged position 2 Park the unit on a flat surface 3 Place 3 high deck support blocks two stacked 2 x 4 18 19 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 Figure 6 4 Tighten the appropriate nut until the chain just becomes tight making sure that the deck stays tight against the deck support block Figure 6 4 Tighten the other
46. t E S Nuts stop S N a N Deck stop Deck lift IA YA bracket NS du N rank A Jam nut gt J Deck height LL I indicator bar N Deck gt Figure 6 8 10 Push or pull on the deck lift bell crank until the chain on 12 Go to the right front of the mower the right rear just becomes tight making sure that the 13 Make sure that there is still slack in the chain If not deck stays tight against the deck support block Figure 6 loosen the two nuts on the block holding the threaded rod 8 until there is slack in the deck lift chain 11 While keeping the chain tight tighten the nuts against the 14 Tighten the appropriate nut until the chain just becomes deck lift block on the height indicator Figure 6 8 tight making sure that the deck stays tight against the 114674 0512 6 5 REVB deck support blocks 15 Tighten the other nut on the opposite side of the block and jam them tightly together against the block 16 Go to the left front of the mower 17 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 18 Tighten the appropriate nut until the chain just becomes tight making sure that the deck stays tight against the deck support blocks 19 Tighten the other nut on the opposite side of the block and jam them tightly together against the block 20 Go to the left rear of the mowe
47. tarts 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 handling 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 114674 0512 2 3 e Electrolyte may overflow and damage paint wiring or structure When cleaning the battery use soap and water Be carefu
48. ted or too light Change oil and check for source of contamination High oil consumption Mower jerky when starting or operates in one direction only 114674 0512 Numerous Steering control linkage needs adjustment Transaxle component faulty Contact your Dealer Adjust linkage Contact your Dealer 9 1 Blades do not rotate The deck drive belt is worn loose or broken Install a new deck drive belt The deck drive belt is off the pulley Install the deck drive belt and check for a reason Electric clutch is not engaging Check and or replace 10 amp fuse Contact your dealer REVB REVB 9 2 114674_0512 4 2 6 7 Blads ii e to dd dera aN Eaa 6 6 Carbon canister 5 1 Deck Belt adjustment 6 7 Deck Belt Routing amp Tensioning 6 9 Deck leveling oes ERS 6 1 Electrical Schematic 7 1 Engine alr titer 5 1 Engine oil and filter 5 1 Engine RPM settings 5 3 Fuel evaporative system line routings 5 2 Fuel evaporation system filter en 5 1 General engine maintenance 5 1 General Maintenance Precautions 2 2 Hydraulic system 4 3 Maintenance introduction
49. ter Figure 5 4 REV 5 2 Fuel amp evaporative system line routings There are two rubber hoses that are connected to the fuel tank One is the fuel hose that is part of the fuel system The other is the vapor line that is part of the fuel evaporative system The fuel hose is connected to the port on the side wall of the fuel tank It connects the fuel tank to the fuel shutoff valve Fig ure 5 5 The vapor line is connected to the port in the top of the fuel tank It connects the fuel tank to the engine s vapor port Figure 5 5 Vapor line Fuel evaporation Fuel line system filter Figure 5 5 114674 0512 Engine RPM Settings The engine rpm s are set at the factory for maximum mowing efficiency Occasionally it may be necessary to check and adjust the settings The engine speeds should be set as follows Kawasaki FS481 FS541 FS600 ENGINE SPEED MODEL NO ENDING WITH HIGH IDLE MODEL NO WITHOUT EXTENSION 3600 50 RPM MODEL NO WITH EX EXTENSION MODEL NO WITH US EXTENSION MODEL NO WITH CE EXTENSION NOTE Model numbers may or may not end with an extension after the number There are several different extensions that may be shown 1 EX or CE Example 922222 no extension 922222 EX 922222 CE 922222 US 114674 0512 5 3 REVB REVB 5 4 114674_0512 DECK ADJUSTMENTS Deck Leveling 48 54 Side Discharge Deck Leveling the deck must be done in the following mann
50. the engine running slowly move the H Bar steering lever in both forward and reverse directions 5 or 6 times Figure 4 11 4 With the bypass valve closed and the engine running slowly move the H Bar steering lever in both forward and reverse directions 5 or 6 times Check the oil level and add oil as required after stopping the engine 114674 0512 4 5 5 It may be necessary to repeat Steps 3 and 4 until all the air is completely purged from the system When the transaxle operates at normal noise levels and moves smoothly forward and reverse at normal speeds then the transaxle is considered purged Bypass valve rod shown in operating position Right transaxle shown gt Figure 4 11 Tires It is important for level mowing that the tires have the same amount of air pressure The recommended pressure are Drive wheels 8 12 psi 55 83 KPa Gauge wheels 8 12 psi 55 83 KPa Solid fill tires are not recommended for Hustler TrimStar mowers On any machine with solid filled tires the warranty claim will be denied REVB REV 4 6 114674_0512 ENGINE MAINTENANCE General Engine Maintenance Detailed instructions and recommendations for break in and regular maintenance are specified in the Engine Owner s man ual Please refer to this manual for engine servicing lubricating oil levels with quality and viscosity recommendations bolt torques etc The engine warranty i
51. yes with water for 10 15 minutes Get medical attention immediately If acid is swallowed e Drink large amounts of water or milk Then drink milk of magnesia beaten eggs or vegetable oil e Get medical attention immediately REVB REV 2 4 114674_0512 TORQUE Standard Torques The following chart lists the standard torque values for the threaded fasteners found in this manual Torque all cap screws nuts and set screws to these values unless a different torque is shown in the Special Torques section Size Ft Ibs NM Size Ft Ibs NM 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 8 222 IN LBS 25 500 73 99 M10 37 50 562 105 143 12 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 NM Wheel lug nuts 65 75 88 14 101 7 Blade spindle bolt top 118 160 01 Blade spindle bolt bottom 118 160 01 Electric Clutch mounting bolt 3 45 48 61 65 250 339 Transaxle pump pulley nut 45 55 61 74 6 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 Engine torgue values Refer to the
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