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Hustler Turf 927558 Lawn Mower User Manual

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 Engine Oil Filter Deck Height Pivot Zerks 4 Park Brake Switch Drive Tire Pump Idler Zerk 1 Pump Belt Deck Drive Belt Engine Coolant Fill Engine Oil Fill Hydraulic Oil Heat Exchanger 1 2 3 4 5 6 7 8 9 Viewed from left Viewed from right side of tractor side of tractor Viewed from bottom of tractor Figure 4 17 601656_1108 35 Hustler Z Super Z ATZ Rear Discharge Deck Maintenance Locator Chart Rear discharge deck 1 Deck Pusher Arm Zerks 2 2 Deck Belt 3 Spindle Housing Zerk 3 4 Blades Hustler Z Super Z ATZ Hustler Z Shibaura Diesel Rear Discharge Deck Maintenance Locator Chart 1 Deck Pusher Arm Zerks 2 2 Deck Belt 3 Spindle Housing Zerk
2. Neutral Right control lever Left control lever Figure 3 15 601656_1108 discharge chute Figure 3 16 Use the control levers to control ground speed rather than engine rpm Keep blades sharp Many professional mowing companies have additional sets of blades and change blades twice a day once in the morning and again atnoon Many problems with incorrect cutting patterns are due to dull blades or blades which have been sharpened incorrectly Information on sharpening blades is listed in this manual s maintenance section In addition most communities have individuals or companies which specialize in sharpening mower blades Blade sharpness should be checked daily DANGER 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 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 mowing Use high blade speed Your mower is designed to operate at full throttle The throttle setting directly controls blade speed The highest blade speed generally gives best cut Direct grass discharge to right away from unmown area Select a mowing pattern that directs grass discharge towards th
3. Owner s Manual Shibaura Diesel GENERAL INFORMATION This manual applies to the following Hustler equipment lines Hustler Z Super Z Hustler Z Shibaura Diesel Hustler ATZ To the new owner The purpose of this manual is to assist owners and operators in maintaining and operating the Hustler Z tractor and deck Please read it carefully information and instructions furnished can help you achieve years of dependable performance A separate Engine Manual is included with your owner s packet which contains additional engine information that will not be repeated in this manual You are urged to read it before attempting any operation or repair ofthe engine The Quick Reference Decals are designed to give the operator brief information needed in the daily operation ofthe machine These decals are not intended to be used in place of this manual but instead are to be used as an extension of this manual These decals should not be removed or obliterated Replace these decals ifthey become unreadable It is the owner s responsibility to make certain that the operators and mechanics read and understand this manual and the Quick Reference Decals before operating this machine It is also the owner s responsibility to make certain that the operators and mechanics are qualified and physically able individuals properly trained in the operation of this equipment All operators and mechanics must become familiar with the safe operati
4. Super Z XR7 927467 927624 927673 927848 927855 927871 927897 927913 927921 927947 927970 927988 928002 928010 928028 928044 928051 928069 927681 927889 927939 927996 928036 106575 22 50 Super Z XR7 927467 927624 927673 927848 A B 927855 A B 927889 A B 927897 A B 927921 A B 927939 A B 927970 A B 927988 A B 928028 A B 928036 A B 928044 A B 928051 A B 928069 A B 928879 A B 928887 A B HTB 928895 A B 928911 A B 928929 928937 927681 927871 A B 927913 A B 927947 A B 928010 A B 108603 22 50 Hustler Z Diesel 928606 A B 928614 A B 928622 A B Shibaura engine 928648 928655 109706 22 50 ATZ XR7 928226 928234 107906 22 50 42 601656_1108 INDEX Anti scalp wheels u uuessnsnenensnssnsnennnnensensensensennennenn 22 ATZ tilt seat Control lever adjustment uenseneesnenenesneneenennennne nenne nenne 30 Control panels O A en I R AE Cooling Systema senienas e i i iaa Deck cutting height adjustment eeeeneenenenennn 22 Driving the tractor icenen eeta a a a a i 20 Electrical system cesensesnsensensennennennensnnnesnnnnnnnennennenn 26 Engine air filter 22 aaa dic Engine oil and filter neeneeseesensensnssesnesnnnnnensensennennen Engine diesel starting Engine gasoline starting uneneeeneeeseneneneene nennen Fuel syst ocro
5. 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 IMPORTANT When mounting blades rotate them after installation to ensure blade tips do not touch each other or sides of the mower WARNING Failure to correctly torque the bolt may result in the loss of the blade which can cause serious injury WARNING Mower blades are sharp and can cut Wrap the A blade s or wear gloves and use extra caution when servicing them Control lever adjustment The steering control levers can be adjusted for operator comfort By loosening the cap screws that attaches the upper control lever to the lower lever Fig 4 15 the upper control lever can be pivoted to fit the operator s personal preference The steering control levers should be adjusted so that they align with each other when in the neutral position Warped Blade Replace Cutting Plane Tl n Straight Blade Comparison of Warped and Straight Blades Figure 4 13 Cutting Edge I Twisted Blade Edge Cutting Plane Replace Cutting Edge Straight Blade Edge End view of blades comparing twisted and straighten blades Figure 4 14 601656_1108 Cap screw 601656_1108 Figure 4 15 Upper control lever 31 32 601656_1108 Hustler Z Super Z Hustler ATZ Maintenance Schedule Refer to Fig 4 16 4 18 4 19 4 20 amp 4 21 WEEKLY MONTHLY AN
6. ROPS not shown for clarity Engine Oil Fill amp Dipstick Kawasaki amp Honda Engine Oil Fill amp Dipstick Kohler Fuel Filter Fuel Filter 927053 amp 927061 Fuel Filter Kawasaki liquid cooled Engine Air Cleaner Engine Oil Drain Plug Battery Fuel Tanks Hydraulic Oil Reservoir Hydraulic Oil Filter Gauge Wheel Bearing Zerks 2 Engine Oil Filter Deck Height Pivot Zerks 4 Park Brake Switch Drive Tire en Pump Idler Zerk 1 o Hustler Z 26hp K ki ee 25hp 29hp K ki ai ustler p Kawasaki Hydraulic Oil Heat Exchanger p p Kawasaki air liquid cooled engines Engine Coolant Fill cooled engines Kawasaki liquid cooled 31hp Kawasaki air cooled engines Figure 4 16 34 601656_1108 Hustler Z Shibaura Diesel Maintenance Locator Chart
7. fuel tank and operator s station clean of accumulated trash grass clippings and other debris Always clean up spilled fuel and oil Always buckle seat belt if provided with one and only if a ROPS is installed properly before starting tractor Using a ramp A A A A Use extreme caution when loading and unloading a unit onto a truck or trailer with a ramp Use only a single full width ramp do not use individual ramps for each side of the unit Having a full width ramp provides a surface for the tractor frame to contact if the unit starts to tip backwards It also reduces the risk of a wheel going off and the machine tipping over Do not exceed a 15 degree angle between the ramp and the ground or between the ramp and the trailer or truck When on a ramp avoid sudden acceleration Slope Operation Slopes are a major factor in loss of control and tip over accidents which can result in severe injury or death All slopes require extra caution If you cannot back up the slope or if you feel uneasy on it do not mow it REMINDER Only operate on slopes of 15 degrees or less A gt gt Use extreme caution when operating on slopes Be extremely careful changing directions on a slope Slow down Do not operate where the machine could slip or tip Turn slowly Turn on the most level part of the slope To maximize traction it is better to turn the front of the machine uphill rather than downhill If driv
8. is not opening or closing and if the cause can not be determined replace the seat switch If the problem can not be located contact your Hustler Dealer WARNING The safety interlock system should always function per steps 4 and 5 If it does not function properly it should be corrected immediately Do not operate machine without properly functioning seat safety switch Engine gasoline starting The tractor s safety start interlock system is also designed to protect the operator and others from accidental injury due to unintentional engine starting The engine starting motor will not engage until A Control levers are in the park brake position B Deck clutch switch is in the down OFF position WARNING The safety interlock system must not be disconnected or bypassed Doing so could cause the machine to operate unexpectedly resulting in personal injury NOTE The operator s seat is equipped with a separate safety switch If for any reason the operator should become unseated when the control levers are not in the park brake position park brake switches are disengaged or the deck clutch switch is engaged the engine will stop The following steps are the correct procedures for starting the engine If difficulty is encountered contact the Hustler Dealer in your area 1 Before starting tractor each day perform daily pre operation checking See Safety start interlock system section 2 Make sure the control levers are in the
9. 3 4 Blades Figure 4 19 36 601656_1108 XR7 Deck Maintenance Locator Chart 54 66 72 XR7 deck 1 Deck Pusher Arm Zerks 2 2 Deck Belt 3 Spindle Housing Zerk 3 4 Blades 60 XR7 deck Figure 4 20 601656_1108 37 Hustler ATZ Maintenance Locator Chart ROPS not shown for clarity 4 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Viewed from bottom of tractor Figure 4 21 38 Engine Oil Fill amp Dipstick Fuel Filter Engine Air Cleaner Engine Oil Drain Plug Battery Fuel Tanks Hydraulic Oil Reservoir Hydraulic Oil Filter Gauge Wheel Bearing Zerks 2 Engine Oil Filter Deck Height Pivot Zerks 4 Park Brake Switch Drive Tire
10. filter element with clean oil before installing to prevent drawing air into the system pump Fuel system DANGER Observe usual fuel handling precautions Do not smoke while refueling Extinguish all cigarettes cigars pipes and other sources of ignition Do not remove fuel cap or fill tank with engine running or while engine is hot Clean up any fuel spills Allow engine to cool before storing machine inside a building Keep fuel away from open flame or spark and store machine away from open flame or spark or pilot light such as on a water heater or appliances Use extreme care when handling gasoline and other fuels They are extremely flammable and vapors are explosive A fire or explosion from fuel can burn you and others and can damage property Refuel outdoors Never refuel or drain the fuel from the machine indoors Never attempt to start engine when there is a strong odor of gasoline or diesel fuel fumes present Locate and correct cause Store fuel in an approved container and keep it out of the reach of children Never buy more than a 30 day supply of fuel Always place fuel containers on the ground away from your vehicle before filling 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 powered equipment from the truck or trailer and ref
11. fuel Bleed fuel system as outlined in Maintenance section Run machine at half speed for 5 minutes checking operation of steering control lever Stop engine and check for oil leaks loose fittings and so forth WARNING At start of new season always check that fresh oil and coolant have been added to machine If oil and coolant are drained at season s end and not replaced engine damage will result 4 Tighten any bolts that have loosened and make sure all hair pins cotter pins and clevis pins are in place 5 Install all safety shields and review safety precautions listed in this manual 6 Check and inflate tires to 8 12 psi 55 83 KPa 7 Install fully charged batteries and attach the battery cables PRODUCT LITERATURE This section contains sources of additional literature concerning your tractor Literature should be ordered from your Hustler dealer or direct from indicated source Parts Manuals If you would like to order a Parts Manual for a particular tractor the Hustler part number for that manual is listed in the following chart Please contact your Hustler dealer to order the manual 601656_1108 41 Parts Manual P N Model Number List Model Price Hustler Z XR7 927723 927731 927749 927756 927772 927798 927806 927814 106567 22 50 Hustler ZXR7 927723 A B 927749 A B 927756 A B 927772 A B 927798 A B 927806 A B 927814 A B 928432 928853 A B 928861 A B 108602 22 50
12. park brake position and deck clutch switch is disengaged Only start the engine from the operator s position 3 Use choke if unit is equipped with one when engine is cold or if warm engine fails to start within 5 seconds of cranking Avoid flooding and operate engine without choking as soon as possible 4 Set throttle at approximately 1 2 open position 5 Insert key in ignition switch and rotate full clockwise to engage starting motor Release key when engine starts IMPORTANT The engine starter should not be operated for periods longer than 30 seconds at a time An interval of at least two minutes should be allowed between such cranking periods to protect the starter from overheating and burn out 6 Perform test to make sure safety start interlock system is operating properly Refer to Safety start interlock system section 7 As soon as engine begins to run check to make certain the oil warning light check engine light and alternator warning light if applicable are off If not stop engine immediately and check for the cause 8 Allow the engine to idle a few minutes before advancing the throttle and or engaging the deck clutch 601656_1108 17 Ambient Preheating time temperature Ordinary heat type Approx 6 seconds 10 C 50 F to 5 C 23 F Below 5 C 23 F Approx 12 seconds Engine diesel starting The Hustler Z Shibaura Diesel safety start interlock system is designed to protect the operator a
13. party is authorized to make any warranty in addition to those made in this agreement ALLOCATION OF RISKS This agreement allocates the risks of product failure between Hustler Turf Equipment and the purchaser This allocation is recognized by both parties and is reflected in the price of the goods OWNER S RESPONSIBILITY You must maintain your Hustler Turf Equipment product following the maintenance procedures described in your owner s manual Such routine maintenance whether performed by a dealer or by you is at your expense This machine like any other powered equipment is potentially dangerous unless properly operated Any operator must be cautious and keep safety in mind at all times Any operator prior to using the Hustler Turf Equipment should thoroughly familiarize himself with the owner s manual regarding operation and safety of the machine as well as all safety warnings on the machine itself WARRANTY REGISTRATION 1 Register the unit on line at www Hustler dealer com or by filling out the Warranty registration form provided in the owner s packet If using the Warranty registration form it MUST be completed and signed by the authorized dealer and original purchaser 2 For validation the completed Warranty registration form MUST be forwarded to Hustler Turf Equipment within ten 10 days following date of purchase 3 The date of purchase constitutes delivery 601656_1108 SAFETY PRECAUTIONS This safety ale
14. should never be worn WARNING To minimize chance of injury or death from rollover keep ROPS in the raised and locked position and use the seat belt Never operate machine on a slope with the ROPS folded down lowered position There is no roll over protection when the ROPS is in the lowered position Lower the ROPS only when absolutely necessary Drive slowly and carefully Raise the ROPS as soon as clearance permits Read and follow slope operation instructions and warnings Do not wear seat belt when the ROPS is in the lowered position WARNING Always pull from the tractor hitch Do not A attach chains or ropes to the ROPS for pulling purposes as the machine can tip backwards Always fasten seat belt during operation of the machine mower equipped with ROPS in raised up position Inspect the area to be mowed for proper overhead clearance tree limbs guy wires doorways etc Do not contact any overhead object with the ROPS Inspect the seat belt system all seat seat belt parts seat pan and seat pan latch daily prior to mowing for signs of any damage These parts should be replaced if any parts indicate signs of 1 cuts fraying extreme or unusual wear significant discoloration due to UV exposure dirt or stiffness abrasion to the seat belt webbing damage to the buckle latch plate or hardware or any other problem SAIDM PWN If the seat belt is to be cleaned use soap and water Do not use car
15. skin contact with battery acid Do not overfill battery e Electrolyte may overflow and damage paint wiring or structure When cleaning the battery use soap and water into the battery Be careful not to get soap and water into the battery Use soda mixed in water to clean corrosion off the terminals e Always wear eye protection when checking the battery acid can cause serious injury to skin and eyes If contact occurs flush area with clean water and call physician immediately Acid will also damage clothing WARNING This structure s protective capability may be impaired by structural damage overturn or alteration If any of these conditions occur this structure must be replaced A Use seat belt ANWARNING TO MINIMIZE THE CHANCE OF INJURY OR DEATH FROM ROLLOVER KEEP THE ROPS IN THE RAISED AND LOCKED POSITION AND USE THE SEAT BELT THERE S NO ROLLOVER PROTECTION WHEN THE ROPS IS IN THE LOWERED POSITION LOWER THE ROPS ONLY WHEN ABSOLUTELY NECESSARY DRIVE SLOWLY AND CAREFULLY RAISE THE ROPS AS SOON AS CLEARANCE PERMITS READ AND FOLLOW THE SLOPE OPERATION INSTRUCTIONS AND WARNINGS DO NOT WEAR THE SEAT BELT WHEN THE ROPS IS IN THE LOWERED POSITION 601656_1108 e Do not allow open flame near the battery when charging e Hydrogen gas forms inside the battery This gas is both toxic and flammable and may cause an explosion if exposed to flame Al
16. so weight is off tires NOTE Do not deflate tires 7 Perform separate engine and battery preparation as listed below 8 Store tractor in a clean dry place Preparation of engine for storage When engine is to be unused for long periods proceed as follows Run engine for a minimum of 15 minutes Drain oil from crankcase while engine is still warm Refill with fresh oil of proper viscosity Drain fuel tanks Remove and replace fuel filter Clean exterior surface of engine Spread a light film of oil over any exposed metal surfaces of engine that are subject to corrosion 7 Check oil filler cap and fuel tank cap to make certain they are securely in place surupe Preparation of batteries for storage When the machine is to be unused for long periods it is best to disconnect the batteries and remove them from the unit At this time perform the following battery maintenance 1 Clean battery 2 Check the electrolyte level 3 Charge the battery if necessary 4 Store battery in a cool dry place do not expose to freezing temperatures 5 Always keep the battery fully charged Especially important to prevent battery damage when the temperature is below 32F New season preparation Before starting the tractor following post season storage the following servicing is required 1 Clean tractor removing trash and dirt accumulation 2 Check engine oil hydraulic oil and coolant levels 3 Fill fuel tanks with fresh
17. the area belts Part Number 601624 WARNING e Never operate the mower Thrown objects deck with side deflector damaged altered removed or in raised position except when the entire grass catcher attachment or mulching system is being used Part Number 779280 AA WARNING Hot surface e Avoid skin contact with hot surface 601656_1108 WARNING Fire Part Number Part Number 601968 601967 WARNING Fluid under pressure e Avoid hydraulic fluid escaping under pressure e Hydraulic fluid escaping under pressure can penetrate skin e Hydraulic fluid may also cause infection in a minor cut or opening in the skin if exposed to hydraulic fluid see a doctor at once Before applying pressure to hydraulic system make sure all connections are tight and all hoses and lines are in good condition e Relieve all pressure in the system before disconnecting or working on hydraulic lines e To find a leak under pressure use a piece of cardboard or wood never use your hands To relieve all pressure in system turn engine off and lower attachment 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 DANGER Battery Hazards Part Number 601815 e Avoid
18. them to stop before crossing gravel drives walks or roads Always keep clear of the mower blades and attachments during their operation Turn off blades when not mowing Slow down before turning Stop the engine before removing the grass catcher or unclogging the discharge chute Never clear the discharge chute with the engine running Turn off the engine and be sure the blades have stopped before cleaning Use a stick to clear a plugged discharge area Never use your hand Always keep clear of the mower blades and attachments during operation Do not operate the machine while under the influence of alcohol or drugs Exercise caution when loading or unloading the machine onto a trailer or truck Always wear safety goggles or safety glasses with side shields when operating the mower Data indicates that operators age 60 years and above are involved in a large percentage of riding mower related injuries These operators should evaluate their ability to operate the mower safely enough to protect themselves and others from serious injury Follow the manufacturer s recommendation for wheel weights or counterweights If any attachment or additional weight is mounted on the rear of the unit any rapid movement of the control levers in either direction could result in a reaction of the tractor that can cause serious injury Clean flammable material from machine Prevent fires by keeping engine compartment exhaust area battery fuel line
19. while operating the machine place the steering control levers in the park brake position immediately Inspect the machine and involve your Hustler dealer to resolve the problem before continuing to operate WARNING The unit s steering control levers are very responsive Easy does it For smooth operation move lever slowly avoid sudden movement Skill and ease of operation come with practice and experience The machine can spin very rapidly Use caution when making turns and slow down before making sharp turns Inexperienced operators may have a tendency to oversteer and lose control Slow moving practice maneuvers are recommended to become familiar with these characteristics before attempting normal speed operation WARNING Sharp depressions or raised obstacles such as gutters or curbs should not be directly approached at high speed in an attempt to jump them as the operator could be thrown from the equipment Approach at a slow speed and angle one drive wheel at the obstruction Continue at an angle until the wheel clears and then pivot the opposite wheel around When turning on soft wet turf keep both wheels rolling either forward or backward Pivoting on one stopped wheel can damage turf This is especially important when mowing Tractor performance is maximum when the throttle is set at full rpm This gives maximum power to the drive wheels and deck when needed 601656_1108 Three point turn
20. 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 Hustler dealer to resolve the problem before continuing to operate Inspect the belt pulley grooves and flanges for wear A new belt or one in good condition should never run against the bottom of the groove Replace the pulley when this is the case otherwise belt will lose power and slip excessively Never pry a belt to get it on a pulley as this will cut or damage the fibers of the belt covering Keep oil and grease away from belts and never use belt dressings Any of these will destroy the belt composition in a very short time Mower blade maintenance Check the mower blades daily they are the key to power efficiency and well groomed turf Keep them sharp a dull blade will tear rather than cut the grass leaving a brown ragged top on the grass within a few hours A dull blade also requires more power from the engine Replace any blade which is bent cracked or broken WARNING Never attempt to straighten a bent blade by heating or weld a cracked or broken blade as the blade may break and cause serious injury Replace worn or damaged blades DANGER 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 control levers in the park brake position and turn engine off and disco
21. 1656_1108 39 SYMPTOMS Liquid Cooled or Diesel Engines Overheating Temperature light glows Frequent refilling of radiator required Coolant appears rusty Audible alarm PROBABLE CAUSES Leaks in system Coolant level low SUGGESTED REMEDIES Replace tighten hoses and connections Add coolant Radiator screen clogged Clean screen Radiator core clogged Clean radiator core Thermostat sticking or inoperative See engine manual Heat light malfunction See your dealer For additional causes See engine manual Air Cooled Engine Overheating Air intake screen or cleaning fins clogged For additional causes Clean screen and fins See engine manual 40 601656_1108 STORAGE When storing the unit at the the end ofthe mowing season the following steps should be taken to ensure readiness for the next mowing season 1 Remove all grass dirt and trash from tractor and mower Clean tractor and mower and touch up all scrapes with Hustler spray paint 2 Replace air filter element 3 Check thoroughly for any worn or damaged parts that need replacing and order them from your dealer 4 Thoroughly lubricate machine according to lubrication instructions 5 Check hydraulic oil level Add oil if necessary or change oil and filter if not done in last 500 hours Refer to Maintenance section 6 Block tractor up
22. NUALLY OR SERVICE AT INTERVALS INDICATED Verify safety start interlock system Daily Check coolant level Daily Visually inspect unit for loose hardware and or damaged parts Daily Visually inspect tires Daily Check oil level engine 1 Daily or every 4 hrs Clean air intake screen 8 Daily or every 4 hrs Clean oil heat exchanger 8 Daily or every 4 hrs Check radiator screen 8 Daily or every 4 hrs Check fuel level Daily Blades sharpen 4 securely fastened Daily Discharge chute securely in place amp in lowest position Daily Clean engine and pump compartment Daily Replace air cleaner paper element 5 As needed Grease deck pusher arms Grease pump idler Grease deck height pivots Grease gauge wheel bearings Change engine oil amp filter 1 4 Clean cylinder and head fins a Check battery connections Check tire pressure with a gauge Check hydraulic oil level x x x x x x x x x x Clean engine exterior a Clean and regap spark plugs a Check pump and deck belt tension amp condition 6 Check fuel and hydraulic lines 7 Check fuel valve and grommets 7 Tighten lug nuts on wheels 2 Change fuel filter Clean or replace hydraulic fill cap Change hydraulic filter and oil 3 Grease deck spindle housings Replace spark plugs Drain amp replace en
23. Pump Idler Zerk 1 Pump Belt Hydraulic Oil Heat Exchanger 601656_1108 Hustler Z Super Z Hustler Z Shibaura Diesel Hustler ATZ TROUBLESHOOTING The majority of operating problems that occur with a system can be traced to improper adjustments or delayed service A consistently applied preventative maintenance program as outlined in the maintenance section of this manual will prevent many problems The following chart is designed to help you locate a problem by suggesting probable causes and the recommended solutions SYMPTOMS PROBABLE CAUSES SUGGESTED REMEDIES Starting motor does not crank Control handle not in park brake position or switch not adjusted Place control handle in park brake position or re adjust switch Mower clutch switch engaged Disengage clutch switch Weak or dead battery Recharge or replace For additional causes See engine manual Engine cranks but No fuel or line Fill tank or replace does not start plugged line See Fuel System section for more details Numerous See engine manual Engine Numerous See engine manual Runs with continuous misfiring or engine runs unevenly or erratically 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 hydra
24. ake sure that line A is horizontal Align line B with a vertical surface such as a pole tree or building Fold the paper along the slope guide lines C D or E Align the closest slope guide line with the ground slope This will give you a close estimation of the ground slope to be Sere mowed Figure 2 1 601656_1108 11 12 601656_1108 OPERATION Safe Operating Practices Some of the following safety instructions are from ANSI Standard B 71 4 2004 while others are specific to the Hustler Mid Mount Z line This product is capable of amputating hands and feet and throwing objects Always follow all safety instructions to avoid serious injury or death Operation A gt gt gt gt gt gt gt gt gt gt A A Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job Only use accessories and attachments approved by the manufacturer Never leave a running machine unattended Always stop on level ground disengage deck clutch place steering control levers in park brake position stop tractor engine and remove ignition key before leaving operator s seat for any reason including emptying the catcher or unclogging the chute Do not change the engine governor setting or overspeed the engine Always remain seated while operating machine Always keep safety shields and covers in place except for servicing Always maintain a safe distance from peo
25. all defects in the mowing deck which results in the front edge of the deck being bent into the the blades O Against hydraulic hose and fitting leaks If the original Purchaser discovers within this warranty period such a defect O He must promptly notify Hustler Turf Equipment or an authorized dealer in writing of the defect Such notification must be received by Hustler Turf Equipment or an authorized dealer during the period when the equipment is owned by the original purchaser O Hustler Turf Equipment will correct any defect in the frame resulting in frame breakage by repairing or replacing part s with new or used replacement parts O Hustler Turf Equipment will correct any defect in the deck resulting in the front edge of the deck being bent into the blades by repairing or replacing part s with either new or used replacement parts O Such repair including parts and labor shall be at the expense of Hustler Turf Equipment and f The gas engines are covered by a two 2 year limited warranty by the engine manufacturer to the original owner commercial or residential and The Shibaura diesel engines are covered by a three 3 year or 2000 hour whichever comes first limited warranty to the original owner commercial or residential and g The battery is covered by a one 1 year limited warranty to the original owner only WHO MUST PERFORM THE WARRANTY SERVICE All warranty service will be performed by dealers authori
26. ance of injury or death from rollover Seat belt must be fastened while operating a machine equipped with ROPS Failure to use seat belt will result in serious injury in the event of a roll over Children Tragic accidents can occur if the operator is not alert to the presence of children Children are often attracted to the machine and the mowing activity Never assume that children will remain where you last saw them A A gt gt gt gt gt gt gt Never leave machine unattended with ignition key in switch especially with children present Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended Always disengage deck clutch place control levers in park brake position stop tractor engine and remove ignition key when leaving operator s seat Keep children out of the mowing area and under the watchful care of a responsible adult other than the operator Be alert and turn the machine off if children enter the area Before and while backing look behind and down for small children Never carry children even with the blades off They may fall off and be seriously injured or interfere with safe machine operation Children who have been given rides in the past may suddenly appear in the mowing area for another ride and be run over or backed over by the machine Never allow children to operate the machine Never allow children or others in or on towed equipment Use care w
27. and parts WARNING Warranty registration The Delivery and Warranty Registration form must be completed and signed to validate your warranty protection As the new equipment owner you are expected to see that the form is completed and forwarded to Hustler Turf Equipment at time of delivery Be sure to register the tractor plus each attachment that displays a model and serial identification number plate with Hustler Turf Equipment IMPORTANT Any unauthorized modification alteration or use of non approved attachments voids the warranty and releases Hustler Turf Equipment from any liability arising from subsequent use of this equipment Model and serial number Tractor model and serial numbers are found on the serial identification plate located on the frame directly below and to the left of the operator s platform These numbers are required on the Warranty Registration form They will also assure you of the correct service parts when replacement becomes necessary Parts and service Use original Hustler replacement parts only These parts are available through your local Hustler dealer To obtain prompt efficient service always provide the following information when ordering parts 1 Correct part description 2 Correct model number 3 Correct serial number All warranty repair and service must be handled through an authorized Hustler dealer Arrangements should be made through your local service center dh The engine
28. aterial 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 Always wear adequate eye protection when servicing the hydraulic system and battery or when grinding mower blades and removing accumulated debris Use extra caution when handling gasoline and other fuels They are flammable and vapors are explosive Never attempt to start engine when there is a strong odor of gasoline fumes present Locate and correct cause Never remove the fuel cap or refuel tractor while engine is running 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 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 Never attempt to make any adjustments or repairs to the tractor drive system mower deck or any attachment while the tractor engine is running or deck clutch is engaged Repairs or maintenance requiring engine power should be performed by trained maintenance personnel only 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 no
29. bon tetrachloride naphtha etc as these will weaken the webbing For the same reason do not bleach or dye the webbing Replace seat belt if worn or damaged 601656_1108 Hustler Z Super Z shown A ROPS post a x ROPS post 625 11 x 2 00 bolt d Figure 3 13 Possible damage to the ROPS If the unit has rolled over or the ROPS has been in some other type of accident such as hitting an overhead object during transport the ROPS must be replaced to retain the best protection Following an accident check the ROPS the operator s seat and the seat belt and seat belt mountings for possible damage Before operating the machine replace all damaged parts IMPORTANT Do not attempt to weld or straighten the ROPS WARNING If the ROPS or cab is removed or replaced make sure that the proper hardware is used and the recommended torque values are applied to the attaching bolts FRONT OF TRACTOR FACES THIS DIRECTION FORWARD TRAVEL ZERO DEGREE TURN N Neutral Position Direction of arrows indicate direction of tractor movement FORWARD TRAVEL RIGHT TURN CJ REVERSE TRAVEL REVERSE TRAVEL RIGHT TURN Figure 3 14 WARNING The ROPS structure s protective capability may be impaired by structural damage overturn or alteration Do not remove or alter any of the ROPS parts Do not attempt to weld or straighten ROPS Failure to adhere to these instructions could result in severe injury or death Driving th
30. d fill tires are not recommended for Hustler turf equipment On any machine with solid filled tires the warranty claim will be denied Lubrication Use SAE multi purpose grease Electrical system The electrical system is a 12 volt negative ground Recommended battery size is a garden tractor BCI group UIR with 225 or better cranking AMP rating A maintenance free battery is recommended Otherwise follow battery manufacturer s maintenance safety storing and charging specifications Hustler Z Shibaura diesel units only These models require a recommended battery size BCI group 45 with 480 or better cranking AMP rat ng WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to cause cancer and reproductive harm Wash hands after handling WARNING Charge batteries in an open well ventilated area away from sparks and flames Unplug charger before connecting or disconnecting from battery Wear protective clothing and use insulated tools WARNING Avoid skin contact with battery acid Always wear eye protection when checking the battery acid can cause serious injury to skin and eyes If contact occurs flush area with clean water and call physician immediately Acid will also damage clothing Do not allow open flame near the battery when charging Hydrogen gas forms inside the battery This gas is both toxic and flammable and may cause an explosion if exposed to flame A
31. e clothing or jewelry may get tangled in moving parts Always wear long pants safety glasses ear protection and safety shoes when operating this machine Always be aware of what is behind the machine before backing up Do not mow in reverse unless absolutely necessary Always look down and behind before and while backing up Never push forward suddenly on your control levers while the machine is in rearward motion because machine may tip backwards Never pull back suddenly on your control levers while the machine is in forward motion When moving in reverse push forward slowly on control levers and avoid sudden movement Rapid movement of the control levers in either direction could result in a reaction of the tractor that can cause serious injury Never operate a poorly maintained machine Never attempt high speed maneuvering especially in crowded or congested areas Never allow persons to operate this machine without proper instruction or allow children to operate machine Allow only responsible adults who are familiar with these instructions to operate his machine Never put hands or feet under any part of the machine while it is running Never carry passengers 601656_1108 A gt gt gt gt gt gt gt gt gt gt Never direct discharged material toward anyone Avoid discharging material against a wall or obstruction Material may ricochet back towards the operator Always disengage the blades and wait for
32. e outside not towards center of mowing area Generally this means using a pattern utilizing left turns because side discharge is to right In any case avoid throwing grass discharge onto unmowed area because grass is then mowed twice Mowing twice puts an unnecessary load on the unit and reduces mowing efficiency When mowing a lawn for the first time cut grass slightly longer than normal to avoid scalping uneven terrain When possible it is best to use the cutting height that was used in the past When cutting grass taller than six inches you may want to mow the lawn twice to achieve a better quality of cut During normal mowing cut only about 1 3 of the grass blade Cutting more than that is not recommended unless grass is sparse or it is the end of the mowing season Alternate mowing direction to keep the grass growing straight and better dispersion of the clippings Remember grass grows at different rates at different time of the year Mow more often in the early spring to maintain the same cutting height As the growth rate slows in mid summer mow less frequently If you cannot mow at a regular interval mow at a high cutting height then mow again two days later at a lower cutting height Raise the cutting height of the mower if the cutting width of the mower is wider than the previous mower This ensures that uneven turf is not cut too short Raise the cutting height of the mower if the grass if slightly taller than normal o
33. e stop Fig 3 17 EXAMPLE When the height adjusting stop is placed in the 1 2 54 CM hole with the 1 4 64 CM plate facing to the front of the unit the cutting height is at 1 When the height adjusting stop is placed in the 1 2 54 cm hole with the 1 4 64 cm plate on the operator s side of the 22 all Figure 3 19 hole the cutting height is at 1 1 4 3 18 cm The notch located at the rear of the height adjusting bar is to be used when the deck is placed in the transport mode Anti scalp wheels Anti scalp wheel kits are standard on Hustler Mid Mount Z units These anti scalp wheels are designed to minimize scalping when mowing on rough uneven terrain After setting the cutting height adjust the front anti scalp wheels so they extend below the deck but do not contact the ground They should always be at least 1 4 to 3 4 6 35MM to 19 05MM below the deck With the unit sitting on a flat level surface the front wheel position can be adjusted up or down as needed from 3 4 to 1 3 4 19 05MM to 44 45MM below the blade surface Move the front wheels up or down in 1 2 12 70MM increments using the different axle mount holes in the wheel mount bracket Fig 3 18 When adjusting the rear anti scalp wheels the wheel should be in the lower axle mount hole when the front anti scalp wheels are in the lower or middle axle mount holes When the front wheels are in the upper axle mount hole the r
34. e the key from switch before leaving the tractor Figure 3 9 Moving tractor with stalled engine If it becomes necessary to move the tractor when the engine is inoperative the hydraulic pumps are equipped with bypass valves Before moving the unit turn bypass valves counter clockwise one half to one revolution The valve stems on each hydraulic pump are located near the top and are identified as a hex stud The valve is located per Figure 3 7 3 8 amp 3 9 The steering control levers must be placed in the neutral position to release the park brakes so that the tractor can be moved Do not tow the machine Move it by hand or use a winch to load on a trailer for transporting When transporting on another vehicle the tractor should be facing forward and it must be secured 18 Figure 3 10 IMPORTANT Always make certain the two bypass valves are returned to their operating position before running the tractor following repairs Fig 3 7 3 8 amp 3 9 ROPS Roll Over Protective Structure A Roll Over Protective Structure ROPS and seat belt is provided with the equipment Do not remove the ROPS and seat belt ROPS when used with seat belt is effective in reducing injuries during unit overturn accidents Overturning the unit without ROPS can result in serious injury or death NOTE Inspect the ROPS after the first 20 hours of operation Following the initial inspection check the ROPS after every 500 hours of operation or eve
35. e tires lose traction steering control is lost which could cause serious injury or death Ifit becomes necessary to turn downhill turn slowly and gradually if possible Do not remove or modify the stabilizer wheels Watch for holes ruts bumps rocks or other hidden objects Uneven terrain could overturn the machine Tall grass can hide obstacles Remove obstacles such as rocks tree limbs etc gt gt gt gt Keep all movement on slopes slow and gradual Do not make sudden changes in speed or direction Avoid starting and stopping on a slope If tires lose traction disengage the blades and proceed slowly straight down the slope Mow a safe distance minimum of 10 feet away from drop offs retaining walls drainage ditches embankments water and other types of hazards to avoid a wheel dropping over the edge or to avoid the ground from breaking away This will reduce the risk of the machine suddenly rolling over causing serious injury or death Use a walk behind push mower or hand held trimmer on slopes and near drop offs retaining walls drainage ditches embankments and water to avoid machine rollover and serious injury or death Do not mow on wet grass Slippery conditions reduce traction which could cause sliding and loss of control Do not tow on slopes The weight of the towed equipment may cause loss of traction and loss of control Do not try to stabilize the machine by putting your foot on the ground If the
36. e tractor DANGER Never make sudden stops or reverse direction especially when maneuvering on a slope The steering is designed for sensitive response Rapid movement of the control levers in either direction could result in a reaction of the tractor that can cause serious injury After starting engine engage the control levers and steer as follows To go forward push control levers forward an equal distance Fig 3 14 To go in reverse pull control levers rearward an equal distance Fig 3 14 To turn left move the right control lever farther forward from neutral than the left control lever Fig 3 14 To turn right move the left control lever farther forward from neutral than the right control lever Fig 3 14 0 degree turn move one control lever forward and the other control lever back of neutral This will allow the drive wheels to counter rotate Fig 3 14 To stop or decrease speed move control levers to neutral When going forward pull back gently on control levers When going in reverse push forward gently on control levers For emergency stop when traveling forward or rearward place the steering control levers in the park brake position immediately DANGER When moving in the rearward direction push forward gently on steering control levers and avoid sudden movement Any sudden movement could cause the front of the mower to come off of the ground resulting in possible loss of control causing serious inju
37. ear wheels should be in the upper axle mount hole as well NOTE When the anti scalp wheels are installed the minimum cutting height is 1 2 5 CM with the anti scalp wheels set at 3 4 1 91cm BAC VACTM Mounting If a BAC VAC is to be mounted to an Hustler ATZ tractor it will be necessary to remove the following from the unit 1 Drive wheel weights 2 Frame weights located between the drive wheels 3 The front and rear mount legs of the ROPS structure The two post ROPS structure will remain Fig 3 19 The weights included with the BAC VAC will be used instead of the Hustler ATZ tractor weights If a BAC VAC is mounted to the Hustler ATZ it will be necessary to remove the BAC VAC and front wheel weights from the tractor and it will be necessary to re attach the drive wheel weights frame weights and the front and rear mount legs to the tractor before operating the unit on a slope ATZ Tilt Seat ATZ units produced after 081100000 will have a tilt seat as standard equipment When the switch located on the right steering control lever is depressed the seat will tilt up to 15 degrees from center both directions Fig 3 20 601656_1108 601656_1108 Figure 3 20 23 24 601656_1108 MAINTENANCE amp ADJUSTMENTS 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 Service A Unl
38. efer to Fig 4 17 4 18 4 19 amp 4 20 WEEKLY MONTHLY ANNUALLY OR SERVICE AT INTERVALS INDICATED Dai Check coolant level Dai Verify safety start interlock system Visually inspect unit for loose hardware and or damaged parts Dai Visually inspect tires Daily Check oil level engine 1 Daily or every 4 hrs lean air intake screen 8 Daily or every 4 hrs lean oil heat exchanger 8 Daily or every 4 hrs Daily heck fuel level Daily ades sharpen amp securely fastened Daily C Cc Check radiator coolant level Cc B Di ischarge chute securely in place amp in lowest position Dai Check air cleaner service indicator 5 Dai Clean engine and pump compartment Dai Visually inspect radiator core 8 Grease deck pusher arms Grease pump idler Grease deck height pivots Grease gauge wheel bearings Change engine oil amp filter 1 4 Check battery connections Check tire pressure with a gauge Check hydraulic oil level Clean engine exterior a Check pump and deck belt tension amp condition 6 Check fuel and hydraulic lines 7 Check fuel valve and grommets 7 Tighten lug nuts on wheels 2 Change fuel filter Clean or replace hydraulic fill cap Change hydraulic filter and oil 3 Grease deck spindle housings Clean radiator core 8 Drain amp
39. ent near the immediate areas of potential hazards These decals should not be removed or obliterated Replace them if they become non readable The following illustrations show the various decals that are located on the machine A brief explanation for those requiring one is shown to help the operator understand the meanings of these decals Read Owner s Manual and Quick Reference Decal before attempting to operate this machine Do not remove or modify stabilizer wheels or injury can result Never stop suddenly while backing down slopes This action may result in a reaction of the tractor that can cause serious physical injury AWARNING A Do not remove or modify stabilizer wheels Keep shields or covers in place while machine is in operation Keep hands away from rotating pulleys and belts AWARNING Whirling blades Keep hands and feet away Beware of thrown objects ADANGER iV 601656_1108 Do not smoke while refueling Do not fill tank with engine running or while the engine is hot Allow engine to cool before storing machine inside a building Store away from open flame or spark if there is fuel in tank Clean up any fuel spills Do not refuel while in enclosed trailer or other enclosed areas Never operate the mower deck with side deflector damaged altered removed or in raised position except when the entire grass catcher attachment or mulching system is being used Hydraulic
40. ere is no roll over protection when the ROPS is in the lowered position e Lower the ROPS only when absolutely necessary Drive slowly and carefully Raise the ROPS as soon as clearance permits Read and follow slopes operation instructions and warnings Do not wear seat belt when the ROPS is in the lowered position Always pull from the tractor hitch Do not attach chains or ropes to the ROPS for pulling purposes as the machine can tip backwards 601656_1108 9 Hustler Z Super Z ATZ Only O Part Number 601980 Hustler Z Shibaura Diesel Only Part Number 601790 Fast Slow Choke Mower blade engage disengage switch Ignition switch insert key OFF ON or ON GLO Plug If warning light comes on check engine oil Before starting the engine Read Owner s Manual Disengage mower blades Place control levers in park brake position Glo plug If warning light comes on check charging system Engine start position If warning light comes on engine coolant at unsafe temperature Wear ear protection eye protection and safety shoes when operating this equipment Read Operator s Manual before attempting to operate this machine Read Operators Manual before attempting to service this manual 10 601656_1108 SLOPE GUIDE Use this diagram when determining the degree of slope to be mowed F 25 Hustler ATZ only Slope Guide Lines E 15 D 10 Hold this sheet of paper in front of you M
41. ess specifically required DO NOT have engine running when servicing or making adjustments to tractor 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 Repairs or maintenance requiring engine power should be performed by trained maintenance personnel only To prevent carbon monoxide poisoning be sure proper ventilation is available when engine must be operated in an enclosed area Read and observe safety warnings in front of manual Before working on or under the deck make certain engine cannot be accidentally started Shut engine off remove ignition switch key adn disconnect negative battery cable for maximum safety Repairs or maintenance requiring engine power should be performed by trained maintenance personnel only Except when changing or checking belt always keep belt covers on mower deck for safety as well as cleanliness Use a stick or similar instrument to clean under the mower making sure that no part of the body especially arms and hands are under mower Keep your machine clean and remove any deposits of trash and clippings which can cause engine fires and hydraulic overheating as well as excessive belt wear Clean up oil or fuel spillage Allow machine to cool before storing Clean flammable m
42. exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 601656_1108 601656_1108 HUSTLER Z HUSTLER Z SHIBAURA DIESEL SUPER Z HUSTLER ATZ TWO YEAR LIMITED WARRANTY FOR TRACTORS AND DECKS THREE YEAR LIMITED WARRANTY ON DECK SPINDLE BEARING amp DECK GAUGE FORK BEARING OR FOUR YEAR 500 HOURS LIMITED WARRANTY FOR TRACTORS AND DECKS OR 90 DAYS LIMITED WARRANTY IN RENTAL APPLICATIONS 601656_1108 WHAT IS COVERED BY THIS WARRANTY O He must promptly notify Hustler Turf Equipment or an Hustler Turf Equipment makes the following warranty to the original authorized dealer in writing of the defect In no event shall such purchaser only notification be received by Hustler Turf Equipment or an a Two 2 Year Limited Warranty authorized dealer later than 120 days from date of delivery Three 3 Year Limited Warranty Deck Spindle amp Deck Gauge O Within a reasonable time after such notification Hustler Turf Fork Bearings First and Second Year Hustler Turf Equipment Tractors and Power Units are warranted for two 2 years from date of delivery on all materials and workmanship If the Purchaser discovers within this warranty period a defect in materials or workmanship O He must promptly notify Hustler Turf Equipment or an authorized dealer in writing of the defect In no event shall such notification be received by Hustler Turf Equipment or a
43. ges contain suggested maintenance information and schedules which the operator should follow on a routine basis The following pages contain suggested maintenance information and schedules which the operator should follow on a routine basis For more detailed information order the correct parts manual for your unit Refer to the Product Literature section of this manual Remain alert for unusual noises they could be signaling a problem Visually inspect the machine for any abnormal wear or damage A good time to detect potential problems is while performing scheduled maintenance service Correcting the problem as quickly as possible is the best insurance Clear away heavy build up of grease oil and dirt especially in the engine and under the seat platform areas minute dust particle are abrasive to close tolerance engine and hydraulic assemblies Daily inspect mower for grass clippings and wire and string tangles The underside of the mower deck will collect a build up of grass clippings and dirt especially when grass is wet or has high moisture content This build up will harden restricting blade and air movement and will probably show a poorer quality of cutting Therefore it should be removed routinely To do this it will be necessary to raise and block the deck 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 at
44. gine coolant Clean radiator core 8 x lt gt x lt gt x gt x x gt lt Check ROPS mounting hardware 9 NOTES 1 Initial oil change is after 5 hours of operation Thereafter change oil after every 40 hours operation Change more often under dusty or dirty conditions and during hot weather periods 2 Torque initially and after first 2 hours of operation 3 Perform initial hydraulic filter change after 50 hours one week of operation 4 Change engine oil filter per the engine manufacturer s recommendations Refer to Engine Owner s Manual for recommendations and other maintenance items 5 Service more often under dusty or dirty conditions Use caution when servicing to prevent dust contamination in the engine Do not clean filter element Replace with a new one 6 Pump drive belt only Inspect every 100 hours and replace if worn or cracking is noticed Otherwise replace every 400 hours or 2 years whichever comes first 7 Check fuel line hoses fuel valve and grommet for any cracks or leaks 8 More often under dusty or dirty conditions and during hot weather 9 Inspect ROPS after the first 20 hours of operation and then after every 500 hours of operation or yearly whichever comes first REFERENCES a Refer to Engine Owner s Manual NOTE After completing maintenance cycle 500 hours repeat cycle 601656_1108 33 Hustler Z Shibaura Diesel Maintenance Schedule R
45. he chart are the standard preheating times for various temperatures This operation however is not required when the engine is warmed up Failure to follow these recommendations can lead to premature failure of the starter motor and the fuel shut off solenoid NOTICE Ether or other starting fluids must never be used as a starting aid with this engine Warranty will be denied when engine damage results from such use 5 Rotate ignition switch key full clockwise to engage starting motor Release key when engine starts IMPORTANT The engine starter should not be operated for periods longer than 30 seconds at a time An interval of at least two minutes should be allowed between such cranking periods to protect the starter from overheating and burn out 6 Perform test to make sure safety start interlock system is operating properly Refer to Safety start interlock system section 7 As soon as engine begins to run check to make certain the oil warning light is off If not stop engine immediately and check for the cause 8 Allow the engine to idle a few minutes before advancing the throttle and or engaging the deck clutch Stopping the engine Use the following procedure to shut off the engine after operating the equipment 1 Place the control levers in the park brake position 2 Disengage the deck clutch 3 Throttle back to low idle for a couple of minutes 4 Rotate ignition key counter clockwise to the OFF position Remov
46. hen approaching blind corners shrubs trees the end of a fence or other objects that may obscure vision 601656_1108 Control Panels Kohler EFI units only Choke Throttle Deck clutch switch Ignition switch Oil pressure light Check engine light Figure 3 1 IMPORTANT When access is required under the seat platform and the seat is equipped with the optional arm rests make certain to place the control arms in the park brake position and pivot the arm rests upward before placing the seat platform in the full forward position to prevent arm rest damage Control Panel A Choke control Fig 3 1 a cable is linked to manually operate the engine choke When the lever is in the down position the choke is in the off run position When the lever is pulled up the choke is in the on start position Do not operate the machine in the on start position NOTE The choke control is not used on Models 927053 amp 927061 or any diesel powered models B Throttle control Fig 3 1 3 2 a cable is linked to engine throttle for controlling engine speed Move lever forward to increase engine rpm move lever rearward to decrease engine rpm C Deck clutch switch Fig 3 1 this switch engages the deck Pull the switch up to engage and push switch down to disengage the clutch IMPORTANT Never engage clutch with engine running at high rpm or when the deck is under load Clutch belts or deck could be damaged D Ignition
47. ilure there will be no warranty 28 Figure 4 7 Figure 4 8 consideration if the air filter element has been cleaned or serviced in any manner A partially dirty air filter element works better than a new element Therefore a dirty filter element is not bad for the engine unless it is excessively restricting the air flow and engine performance is affected The reason is simple The media in the filter must be porous to allow air to pass through it When dirty air passes through the filter the dirt plugs some of the holes in the media and actually acts as part of the filter media When the next round of dirt enters the first dirt helps filter out even smaller particles making the filter more efficient at stopping dirt from entering the engine This is referred to as barrier filtration Of course at some point the filter media becomes too clogged to allow 601656_1108 Reset button Figure 4 9 air to pass The mowing conditions will determine the frequency of air filter element changing Air restriction indicator Some Hustler units have an air restriction indicator installed in the air cleaner Fig 4 9 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 Fig 4 9 Cooling system liquid cooled units Gasol
48. ine units DANGER Never remove radiator cap or overflow reservoir cap when engine is hot Pressurized hot steam and water may be released causing serious burns or possible blindness Fig 4 10 Engine cooling is accomplished with circulated water and Ethylene Glycol mixture The radiator is equipped with a pressure cap and overflow reservoir Follow the information found in the engine owner s manual for the recommended coolant solution Visually inspect the system daily prior to operating tractor Be sure the engine is level Check the coolant level only when the system is cold Check the coolant level only at the overflow reservoir Fig 4 10 The cooling system is a closed type Never open the radiator cap Doing so may induce air into the cooling system and may cause overheating The coolant level should be between the H and L marks Diesel Units DANGER Never remove radiator cap or overflow reservoir cap when engine is hot Pressurized hot steam and water may be released causing serious burns or possible blindness Fig 4 11 Engine cooling is accomplished with circulated water and Ethylene Glycol mixture The radiator is equipped with a pressure cap and recovery tank A 50 50 mixture is recommended for all season operation This mixture provides freeze protection to 32 degrees F 35 degrees C Should temperatures fall below this level additional Ethylene Glycol must be added to the mixture Visually inspect the sys
49. is machine The Quick Reference Decals are designed to give the operator brief information needed in the daily operation of the machine These decals are not intended to be used in place of this manual but instead are to be used as an extension of this manual These decals should not be removed or obliterated Replace these decals if they become unreadable It is the owner s responsibility to make certain that the operators and mechanics read and understand this manual and the Quick Reference Decals before operating this machine It is also the owner s responsibility to make certain that the operators and mechanics are qualified and physically able individuals properly trained in the operation of this equipment All operators and mechanics must become familiar with the safe operation of its equipment operator controls and safety signs before operating the equipment Never let children or untrained people operate or service the equipment Local regulations may restrict the age of the operator The owner user can prevent and is responsible for accidents or injuries occurring to themselves other people or property The owner should also ensure that the operator mechanic know that they are responsible for their own safety as well as the safety of other persons within the vicinity Remember the operator is responsible for accidents or hazards occurring to other people or their property A Specific safety warning decals are located on the equipm
50. l hours Connected to the ignition switch the meter records the accumulative time while the ignition key is switched to the RUN position NOTE The hour meter is found in various locations on different tractors K Glo plug light Fig 3 1 this light comes on when the ignition Control lever in park switch is turned to the Pre Heat Run position and held It shows brake position that power is going to the glo plugs y L Fuel tank gauge Fig 3 1 This gauge shows the fuel level for each fuel tank The red light indicates that the fuel tank is empty and the operator needs to re fuel immediately The upper gauge indicates the fuel level in the right fuel tank and the lower gauge indicates the fuel level in the left fuel tank Figure 3 3 Controls A Control levers Fig 3 3 amp 3 4 these levers control the tractor s speed direction stopping and park brake Levers are used to steer accelerate decelerate and change direction When the control levers Figure 3 4 are in the park brake position 3 3 the tractor will not move when the engine is on and drive pumps are operating 5 Deck lift parked on a slope Block or chock the machine when parked on a slope pedal WARNING The parking brake may not hold the tractor if oa B Deck lift pedal Fig 3 5 the deck lift pedal is used to raise or lower the deck Push on the pedal to raise the deck and then place the deck height locking pin into the desired cutti
51. lic system IMPORTANT Never use hydraulic or automatic transmission fluid in this system use only motor oil as specified Remember dirt is the primary enemy of any hydraulic system WARNING Hydraulic oil escaping under pressure can penetrate skin Hydraulic oil may cause infection in a minor cut or opening in the skin If exposed to hydraulic fluid see a doctor at once Before applying pressure to hydraulic system make sure all connections are tight and all hoses and lines are in good condition To find a leak under pressure use a piece of cardboard or wood never use your hands Relieve all pressure in the system before disconnecting or working on hydraulic lines To relieve pressure lower all attachments and shut off engine 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 2 54cm from top of reservoir Use only SAE 20W50 SL SM service motor oil Hydraulic reservoir Figure 4 2 601656_1108 Change hydraulic system filter element after first 50 hours of tractor operation then replace filter and oil in reservoir every 500 hours thereafter Fig 4 2 The system filter is located in front of the hydraulic reservoir A standard oil filter wrench is used to change filter threads are right handed Use a Hustler approved filter element only IMPORTANT Prefill the
52. lways remove the negative ground first and replace it last Do not overfill battery Electrolyte may overflow and damage paint wiring or structure When cleaning the battery use soap and water Be careful not to get soap and water into the battery Use soda mixed in water to clean corrosion off the terminals WARNING Shorts caused by battery terminals or metal tools touching metal tractor components can cause sparks Sparks can cause a battery gas explosion which will result in personal injury Prevent the battery terminals from touching any metal tractor parts when removing or installing the battery Do not allow metal tools to short between the battery terminals and metal tractor parts WARNING Incorrect battery cable routing could cause damage to the tractor and battery cables This can cause sparks which can cause a battery gas explosion which will result in personal injury Always disconnect the negative black battery cable s before disconnecting the positive red cable s Always connect the positive red battery cable s before connecting the negative black cable s NOTE The Hustler Z Shibaura Diesel tractors have a 50 amp in line fuse in the electrical system This is the main fuse to protect the complete electrical system It is located at the rear of the machine close to the battery Fig 4 1 26 Hustler Z Shibaura Diesel shown ar 50 amp fuse housing N wrens Tare AGTERMES Figure 4 1 Hydrau
53. ly for tightness and inspect hoses for holes or cracks 5 Periodically check the intake hose for signs of ingested dust Locate and repair the source of ingested dirt 6 Never operate a machine without an air filter installed Safety filter Some Hustler tractors are equipped with a safety filter The filter element slides over the safety filter NOTE The safety filter does not require servicing unless it becomes contaminated with dirt or moisture Fig 4 8 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 element 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 their control Therefore on a dust ingested engine fa
54. mower s tires lose traction when operating on slopes disengage the blades place the control levers in the park brake position turn the engine off and get help Never make sudden starts stops turns or reverse direction especially when maneuvering on slopes The steering is designed for sensitive response Rapid movement of the control levers in either direction could result in a reaction of the tractor that can cause serious injury Never stop suddenly while backing down slopes This action may result in a reaction of the tractor that can cause serious physical injury The Hustler mower is capable of operating horizontally traverse on moderately steep slopes When operating on slopes up to 15 degrees be aware of any conditions that may cause the tractor drive tires to lose traction resulting in a possible loss of control of the machine An operator should not operate on a slope until he is thoroughly familiar with the equipment Do not operate on slopes greater than 15 degrees Refer to Figure 2 1 page 7 when determining the degree of slope to be mowed IMPORTANT The Hustler ATZ only is capable of operating on slopes of 15 degrees or more maximum 25 degrees Do not operate the Hustler ATZ on slopes greater than 25 degrees Refer to Figure 2 1 page 7 when determining the degree of slope to be mowed It is strongly recommended that the operator drive the machine off of the slope using extreme caution if any sign of loss of
55. n authorized dealer later than twenty five 25 months from date of delivery O Within a reasonable time after such notification Hustler Turf Equipment will correct any defect in material or workmanship on the Hustler Turf Equipment by repairing or replacing part s with either new or used replacement parts O Such repair including parts and labor shall be at the expense of Hustler Turf Equipment and Third Year At the conclusion of the two year limited warranty described in paragraph a above there shall be an additional one year limited warranty on deck gauge fork bearings and deck spindle bearings only no labor If the Purchaser discovers within this warranty period a defect in either of these bearings O He must promptly notify Hustler Turf Equipment or an authorized dealer in writing of the defect In no event shall such notification be received by Hustler Turf Equipment or an authorized dealer later than thirty seven 37 months from date of delivery O Within a reasonable time after such notification Hustler Turf Equipment will provide new replacement bearing to install on the Hustler Turf Equipment O The installation of the deck gauge fork bearing and deck spindle bearing shall be at the expense of the owner and Four Year 500 Hours Limited Warranty Hustler Turf Equipment Tractors and Power Units are warranted for four 4 years or 500 hours whichever comes first from date of delivery on all materials a
56. nd others from accidental injury due to Limit of continuous use unintentional engine starting The engine starting motor will not engage until A Control levers are in the park brake position B Deck clutch switch is in the down OFF position WARNING The safety interlock system must not be disconnected or bypassed Doing so could cause the machine to operate unexpectedly resulting in personal injury NOTE The operator s seat is equipped with a separate safety switch If for any reason the operator should become unseated when the brake switches are disengaged or the deck clutch switch is engaged the engine will stop The following steps are the correct procedures for starting the engine If difficulty is encountered contact the Hustler Dealer in your area 1 Before starting tractor each day perform daily pre operation checking 2 Make sure the control levers are in the park brake position and deck clutch switch is disengaged Only start the engine from the operator s position 3 Set throttle at approximately 1 2 open position 4 Insert key in ignition switch and rotate it to the PRE HEAT RUN position It takes two seconds before the glo plug light will come on Wait for the glo plug light to go off approximately 6 seconds before rotating the key to the START position This is necessary only when the temperature is below 50 F This operation is not necessary when restarting a warm engine Shown in t
57. nd while backing up WARNING Roll over Slow down before turning Do not operate on slopes greater than 25 degrees Keep all movement on slopes slow and gradual Never make sudden changes in speed or direction Do not mow on slopes above a retaining wall or drop off WARNING Ejection Do not operate on slopes greater than 25 degrees e Keep all movement slow and gradual when going up or down slopes Do not remove or modify stabilizer wheels or injury can result e Do not remove ROPS 8 601656_1108 ATZ ROPS Only WARNING This structure s protective capability may be impaired by structural damage overturn Part Number or alteration If any of these conditions occur this 601792 structure must be replaced WARNING Rollover e Avoid crushing use seat belt e Do not jump if machine tips e Do not remove ROPS e Always pull from the tractor hitch e Do not attach chains or ropes to the ROPS for pulling purposes as the machine can tip backwards WARNING This structure s protective capability may be impaired by structural damage overturn or alteration If any of these conditions occur this structure must be replaced WARNING Rollover e Avoid crushing use seat belt Hustler Z Super Z Do not jump if machine tips Hustler Z Shibaura Diesel Only ROPS Part Number e Never operate machine on a spe With 601635 the ROPS folded down lowered position e Th
58. nd workmanship If the Purchaser discovers within this warranty period a defect in materials or workmanship O He must promptly notify Hustler Turf Equipment or an authorized dealer in writing of the defect In no event shall such notification be received by Hustler Turf Equipment or an authorized dealer later than forty nine 49 months from date of delivery O Within a reasonable time after such notification Hustler Turf Equipment will correct any defect in material or workmanship on the Hustler Turf Equipment by repairing or replacing part s with either new or used replacement parts O Such repair including parts and labor shall be at the expense of Hustler Turf Equipment and Rental Units 90 days Within 90 days of date of delivery Hustler Turf Equipment provides a limited warranty on all materials and workmanship for units used for rental purposes If the Purchaser discovers within this warranty period a defect in materials or workmanship Equipment will correct any defect in material or workmanship on the Hustler Turf Equipment by repairing or replacing part s with either new or used replacement parts O Such repair including parts and labor shall be at the expense of Hustler Turf Equipment and e Hustler Turf Equipment provides a limited warranty for the entire length of ownership by the original purchaser for the following items O Against all defects in the frame resulting from frame breakage O Against
59. ng height hole Push the deck lift pedal to raise the deck when going over obstructions Figure 3 5 Figure 3 2 Figure 3 6 16 601656_1108 Safety start interlock system The tractor is equipped with a safety start interlock system consisting of the park brake switches seat switch and deck clutch switch Check tractor safety start interlock system daily prior to operation This system is an important tractor safety feature It should be repaired immediately if it malfunctions The machine incorporates a separate seat switch which will stop the tractor engine when the operator is unseated for any reason while the tractor is operating This is a safety feature designed to prevent runaway or accidental entanglement To inspect the system 1 The operator must be on the seat when testing the seat switch 2 Set both control levers in the park brake position 3 Start the engine and allow it to warm up to operating temperature 4 With the deck clutch switch down and the control levers in the park brake position slowly raise off of the seat The engine should continue to run 5 With the deck clutch switch up and or the control levers in the neutral position slowly raise off of the seat The engine should stop 6 If the engine fails to stop when the deck clutch switch is up or one or both of the control levers is up and the operator is off the seat check the function of the seat switch If the seat switch is not operating properly
60. nnect 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 mowing WARNING Always wear adequate eye protection when grinding mower blades Mower blade removal Use a 15 16 wrench to remove the 5 8 cap screw holding the blade to the spindle shaft from underneath NOTE A blade holding tool part number 381442 is available from Hustler Turf Equipment It is designed to prevent the blades from rotating when they are being removed or installed on the spindle Contact your Hustler dealer for more information Sharpen the blades on a grinder following pattern as shown Fig 4 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 1 2 bolt Blade should not lean or tilt Spin the blade slowly blade should not wobble If blade is out of balance true it up before reinstalling Lay the blade on a flat surface and check for distortion Fig 4 13 and 4 14 Replace any distorted blade Resharpening Pattern Do not sharpen to original pattern below It is easier to get a straight cutting edge following the resharpening pattern shown above lt Original Edge Figure 4 12
61. ny associated equipment Cost of capital Cost of any substitute equipment facilities services or downtime The claims of third parties including customers and injury to property Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you TIME LIMIT a Two 2 Year Limited Warranty Any action for breach of warranty must be commenced within twenty five 25 months following delivery of the goods in a non rental application Three 3 Year Limited Warranty Deck Spindle amp Deck Gauge Fork Bearings Any action for breach of warranty must be commenced within thirty seven 37 months following delivery of the goods in a non rental application b Four Year 500 Hours Limited Warranty Any action for breach of warranty must be commenced within forty nine 49 months following delivery of the goods c Rental Any action for breach of warranty must be commenced within 120 days following delivery of the goods in a rental application NO OTHER WARRANTIES Unless modified in writing signed by both parties and approved by the President of Hustler Turf Equipment this agreement is understood to be the complete and exclusive agreement between the parties superseding all prior agreements oral or written and all other communications between the parties relating to the subject matter of this agreement No employee of Hustler Turf Equipment or any other
62. of Hot surface use owsa 44WARNING Motor Oil 0 77 ADANGER AWARNING Part Number 600899 AWARNING Avoid skin contact with battery acid Always wear eye protection when checking the battery acid can cause serious injury to skin and eyes If contact occurs flush area with clean water and call physician immediately Acid will also damage clothing Do not allow open flame near the battery when charging Hydrogen gas forms inside the battery This gas is both toxic and flammable and may cause an explosion if exposed to flame Always remove the negative ground first and replace it last Do not overfill battery Electrolyte may overflow and damage paint wiring or structure When cleaning the battery use soap and water Be careful not to get soap and water into the battery Use soda mixed in water to clean corrosion off the terminals Avoid crushing Do not jump if machine tips Use seat belt Seat belt must be fastened while operating this machine Failure to use seat belt will result in serious injury in the event of a roll over Keep engine and pump compartment s clean especially in exhaust area to prevent fire and provide maximum engine and hydraulic cooling If you loose steering control while operating the machine place the steering control levers in the park brake position immediately Inspect the machine and involve your Hustler dealer to resolve the
63. on of its equipment operator controls and safety signs before operating the equipment Never let children or untrained people operate or service the equipment Local regulations may restrict the age of the operator The owner user can prevent and is responsible for accidents or injuries occurring to themselves other people or property IMPORTANT For more detailed maintenance and adjustment information refer to the proper parts manual for your machine Refer to the Product Literature section of this manual for ordering information Using this manual General operation adjustment and maintenance guidance is outlined for both the experienced and novice Hustler user Operating conditions vary considerably and cannot all be addressed individually Through experience however operators should find no difficulty in developing good operating skills suitable to most conditions Directions used in this manual for example RIGHT or LEFT refer to directions when seated on tractor facing forward unless otherwise stated Photographs and illustrations used were current at the time of printing but subsequent production changes may cause your machine to vary slightly in detail Hustler Turf Equipment reserves the right to redesign and change the machine as deemed necessary without notification If a change has been made to your machine which is not reflected in this operator s manual or the parts manual see your Hustler dealer for current information
64. other operational instructions provided by Hustler Turf Equipment O Normal maintenance parts and service including but not limited to filters fuel lubricants tune up parts belts blades blade sharpening bearings brake or steering adjustments O Repairs necessary due to improper fuel contaminates in the fuel system or failure to properly prepare the fuel system prior to any period of non use over three months DISCLAIMER OF WARRANTY The foregoing warranties are in lieu of all other warranties expressed or implied including but not limited to the implied warranties of merchantability and fitness for a particular purpose However if the Hustler Turf Equipment is purchased as a consumer product any implied warranty of merchantability or fitness for a particular purpose is limited to the duration of this limited warranty Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state LIMITATION OF REMEDIES In no case shall Hustler Turf Equipment be liable for any special incidental or consequential damages based upon breach of warranty breach of contract negligence strict liability in tort or any other legal theory Such damages include but are not limited to O Loss of profits O Loss of savings or revenue O Loss of use of Hustler Turf Equipment or a
65. ple and pets when mowing Always stop machine if someone enters the area Always operate machine in daylight or with adequate working lights Follow daily and weekly checklists making sure hoses are tightly secured and bolts are tightened Always observe traffic laws while driving machine from one location to another Watch for traffic when operating near or crossing roadways Always be alert for hazards such as rocks metal objects and other debris which may be thrown or entangled by mower blades Watch out for holes or deep depressions Inspect area to be mowed for hazards such as rocks metal objects and other debris which may be thrown or entangled by mower blades Remove these objects before mowing Always inspect machine for damage after striking a foreign object If damage is found repair machine immediately Be sure to stop on level ground disengage deck clutch place steering control levers in park brake position stop tractor engine and remove ignition key when leaving operator s seat to inspect damage Always wear adequate ear protection such as earplugs when operating this equipment as prolonged exposure to uncomfortable or loud noises can cause impairment or loss of hearing Do not wear radios or music headphones while operating the machinery Safe operation requires your full attention Do not operate the equipment while wearing sandals tennis shoes sneakers shorts or any type of loose fitting clothing Long hair loos
66. problem before continuing to operate If pump belt fails steering control will be lost Refer to owner s manual for inspection and replacement intervals and refer to above paragraph for emergency procedures Hydraulic fluid escaping under pressure can penetrate skin Hydraulic fluid may also cause infection in a minor cut or opening in the skin if exposed to hydraulic fluid see a doctor at once Before applying pressure to hydraulic system make sure all connections are tight and all hoses and lines are in good condition Relieve all pressure in the system before disconnecting or working on hydraulic lines To find a leak under pressure use a piece of cardboard or wood never use your hands To relieve all pressure in system turn engine off and lower attachment WARNING Rotating fan blade Part Number 763805CE Y Keep hands feet and clothing clear of this area e Keep shields or covers in place while machine is in operation Teseosce n Keep a safe distance Part Number eS from the machine 779280CE mmc WARNING Hot surface WARNING DANGER Thrown objects Rotating blades pulleys amp belts Part Number 601603 e Always maintain a safe distance e Keep shields and covers in place from people and pets when while machine is in operation mowing Keep hands feet and clothing Always stop machine if away from rotating pulleys and someone enters
67. r if it contains a high degree of moisture Then mow it again with the cutting height set lower Height adjusting Ja stop Figure 3 18 If the machine s forward motion must be stopped while mowing a clump of grass clippings may drop onto your lawn To avoid this move onto a previously cut area with the blades engaged A Mower deck operation A With the engine running engage the deck clutch switch Fig 3 1 and advance engine throttle to full rpm NOTE Engaging the deck clutch at high engine rpm or when under heavy load in tall grass for example can cause belts and or electric clutch to slip resulting in premature wear or possible damage WARNING Never direct discharge of material from mower deck towards bystanders Do not operate the mower without either the discharge chute or the entire grass collection system in place Fig 3 16 DANGER Never attempt to make any adjustments to the mower deck while the engine is running or with the deck drive clutch engaged Mower blades cannot be seen and are located very close to deck housing Fingers and toes can be cut off instantly Deck cutting height adjustment Deck height is adjustable from 1 to 5 2 54 cM 12 7 CM in 1 4 64 cM increments The holes in the height adjusting bar are spaced at 1 2 1 27 cm intervals By turning the height adjusting stop around 1 4 64 CM increments can be attained due to the 1 4 64 Cm plate that is part of th
68. ral tries the engine still will not start contact your Hustler Dealer Engine oil and filter Check engine oil daily and after every 4 hours of operation Tractor must be setting level when checking oil Refer to engine manual and maintenance schedule for oil recommendation and capacities Change the engine oil and filter after the first 5 hours of operation 50 Figure 4 5 hours on a Hustler Z Shibaura diesel unit per the engine manufacturer s recommendations after that If tractor is being operated in extremely dirty conditions then it is recommended oil be changed more frequently Engine air filter Perform engine air filter maintenance per the Service Interval chart shown elsewhere in this manual A specially designed dry filter is standard equipment on these tractors and supplies clean combustion air to the engine Some examples of the air filter are shown in Fig 4 6 amp 4 7 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 rotate 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 cup Make sure it seals all the way around the air cleaner body then tighten the clamps 4 Check all fittings and clamps periodical
69. replace engine coolant Check ROPS mounting hardware 9 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 conditions and during hot weather periods 2 Torque initially and after first 2 hours of operation 3 Perform initial hydraulic oil and filter change after 50 hours one week of operation 4 Change engine oil filter per the engine manufacturer s recommendations Refer to Engine Owner s Manual for recommendations and other maintenance items 5 Service more often under dusty or dirty conditions Use caution when servicing to prevent dust contamination in the engine Do not clean filter element Replace with a new one 6 Pump drive belt only Inspect every 100 hours and replace if worn or cracking is noticed Otherwise replace every 400 hours or 2 years whichever comes first 7 Check fuel line hoses and fuel valve for any cracks or leaks 8 More often under dusty or dirty conditions and during hot weather 9 Inspect ROPS after the first 20 hours of operation and then after every 500 hours of operation or yearly whichever comes first REFERENCES a Refer to Engine Owner s Manual NOTE After completing maintenance cycle 500 hours repeat cycle Hustler Z Super Z 6 Maintenance Locator Chart
70. rt symbol is used to call attention to a message intended to provide a reasonable degree of PERSONAL SAFETY for operators and other persons during the normal operation and servicing of this equipment DANGER denotes immediate hazards which WILL result in severe personal injury or death WARNING denotes a hazard or unsafe practice which COULD result in severe personal injury or death This manual uses two other words to highlight information IMPORTANT calls attention to special mechanical information and NOTE emphasizes general information worthy of special attention All operators and mechanics should read this manual and be instructed about safe operating and maintenance procedures If the operators or mechanics cannot read or understand English it is the owner s responsibility to explain this material to them Improper use or maintenance by the operator or owner can result in injury To reduce the potential for injury comply with these safety instructions and always pay attention to the safety alert A symbol which means DANGER or WARNING personal safety instructions Failure to comply with the instructions may result in personal injury or death Safety and Instruction Decals Incorrect usage of this machine may result in severe injury Personnel operating and maintaining it should be trained in the proper use and should read the manuals completely and thoroughly before attempting to set up operate adjust or service th
71. ry or death To make a three point turn to the right move the left control lever farther forward from neutral than the right control lever and start the turn Next pull back on the control levers until they are past neutral and the machine starts to go rearward Pull right control lever farther rearward from neutral than the left control lever until the rear of the machine has pivoted around Then push the control levers forward until they are both past neutral and the machine starts to go forward Push the left control lever farther forward from neutral than the right control lever and finish the turn Fig 3 15 IMPORTANT Rapid movement of control levers is not recommended 20 as damage to the hydraulic system components may occur To increase speed increase control lever s distance from neutral The farther forward control levers are from neutral the faster tractor will travel forward The farther back control levers are from neutral the faster tractor will go in reverse Operating suggestions DANGER Prior to operating the tractor the operator should be thoroughly familiar with the proper use and operation of the equipment should read the manual completely and thoroughly and should have attempted slow moving maneuvers to become familiar with the operation of the equipment before attempting normal speed operation An inexperienced operator should not mow on slopes or on uneven terrain WARNING If you lose steering control
72. ry six months whichever comes first Fig 3 10 1 Check the torque of the ROPS mounting bolts Tighten the bolts to the correct torques as shown below if necessary Fig 3 11 3 12 amp 3 13 2 Inspect the operator s seat and the mounting parts for the seat belt Tighten the bolts to the correct torque as shown below if necessary and replace parts that show wear or damage Torque values are given below Ft Ibs Nm Hustler Z Super Z ROPS mounting bolts IEA 99 Hustler Z Shibaura Diesel ROPS mounting bolts TB a 99 Hustler ATZ ROPS mounting bolts 500 13 x 1 75 73 99 ROPS mounting bolts 625 11 x 2 00 145 197 Seat belt mounting hardware 4 AB une 65 The two post ROPS can be pivoted down by removing the right and left retaining rings and pulling out on the pins so that the machine can operate under low hanging tree limbs or other obstructions Do not wear the seat belt when the ROPS is in the lowered position Use the ROPS in the folded position only when it is absolutely necessary Fig 3 10 WARNING Do not operate the mower with the ROPS A folded lowered position as a standard operating mode A folded ROPS does not provide rollover protection 601656_1108 ROPS post ei ROPS mounting bolt Figure 3 11 WARNING Always wear your seat belt unless the tractor is not equipped with a ROPS or if the ROPS is folded down In this case the seat belt
73. s on shut down the machine as soon as possible Never risk continued operation when light remains on high temperatures can severely damage the engine Never risk continued operation when light remains on high temperatures can severely damage the engine Models 927558 and 927566 only an audible alarm will sound when the engine coolant is close to overheating Temperature gauge and alarm Fig 3 1 Hustler Z Shibaura Diesel units only this gauge reflects the engine coolant temperature If the coolant reaches an unsafe level during operation Control shut down the machine as soon as possible Never risk continued lever operation when the gauge needle is in the high range high temperatures can severely damage the engine Never risk continued operation when light remains on high temperatures can severely damage the engine An audible alarm will sound when the engine coolant is close to overheating I Alternator warning light Fig 3 1 this light comes on when the ignition switch is placed in the RUN position and stays lit until the engine is running and the battery is being charged If light comes on during operation shut engine off immediately locate and correct the problem If light remains on while engine is running it indicates that the battery is being discharged Shown with control levers J Electronic hour meter Fig 3 1 amp 3 6 registers 1 10 hour i in neutral position increments up to 9 999 9 tota
74. sition 601246 Hustler Z Shibaura Diesel shown Fuel shut off valve Right fuel tank position shown Figure 4 4 damaged Do not mix oil with gasoline A fuel shut off valve is located on each tractor operation of the fuel valve will vary depending upon the unit Close the fuel valve to prevent fuel flow to the engine The valve s two other positions will allow fuel to be drawn from either one or the other fuel tank Fig 4 3 The location and Diesel units The fuel tanks are located in the tractor s fenders These engines requires number 2 diesel fuel only Hustler Z Shibaura Diesel tractors are equipped with a fuel shutoff valve located to the right rear of the seat Rotate the valve to the middle position to allow fuel to flow from the right fuel tank to the fuel pump The right position prevents fuel flow to the fuel pump The left position allows fuel to flow from the left fuel tank to the fuel pump Close this valve to prevent fuel flow to the engine when servicing the fuel system or when transporting the unit on a trailer or truck Fig 4 4 If the diesel fuel system runs dry use the following procedure when re starting the engine 1 Refill the fuel tanks 2 Make sure the fuel shutoff valve is turned to the full fuel tank 3 Take the priming bulb and compress it until 1t becomes firm Fig 4 5 4 Try and start the engine If it will not start after 15 seconds of cranking repeat Step 3 5 If after trying seve
75. switch Fig 3 1 a three position switch OFF RUN and START With key inserted rotate it clockwise to START position release key when engine starts and switch will automatically return to the RUN position 601656_1108 15 Temperature warning light Temperature gauge Alternator warning light Hour meter Glo plug light Fuel gauge Hustler Z Shibaura Diesel units only a three position switch OFF PRE HEAT RUN and START With key inserted rotate it clockwise to the PRE HEAT RUN position After pre heat has occurred see Diesel engine starting page 13 rotate the key to the START position release key when engine starts and switch will automatically return to the RUN position Oil pressure light and alarm Fig 3 1 this light comes on when the ignition switch is placed in the RUN position and stays lit until the engine is running and a safe oil pressure is developed If light comes on during operation shut engine off immediately and locate and correct the problem Models 927558 and 927566 only an audible alarm will sound when the engine oil pressure drops below normal operating pressure Check engine light Fig 3 1 refer to Kohler engine owners manual for details Temperature warning light and alarm Fig 3 1 this light will come on when the engine coolant temperature reaches an unsafe level during operation If light come
76. t allow the machine to move when the engine is running and the drive wheels are rotating Use only certified jack stands Use only appropriate jack stands with a minimum weight rating of 2000 pounds to block the unit up Use in pairs only Follow the instructions supplied with the vehicle stands Do not touch hot parts of machine Keep nuts and bolts tight especially the blade attachment bolts Keep equipment in good working condition Never tamper with safety devices Check their proper operation regularly Stop the engine before removing the grass catcher or unclogging the discharge chute Never clear the discharge chute with the engine 601656_1108 gt gt gt A 25 running Turn off the engine and be sure the blades have stopped before cleaning Use a stick to clear a plugged discharge area Never use your hand Grass collection system components are subject to wear damage and deterioration which could expose moving parts or allow objects to be thrown Frequently check components and replace with manufacturer s recommended parts when necessary Exercise caution when working under the deck as the mower blades are extremely sharp Wrap the blade s or wear gloves and use extra caution when servicing them Use only genuine Hustler replacement parts to ensure that original standards are maintained A Introduction Regular maintenance is the best prevention for costly downtime or expensive premature repair The following pa
77. tem daily prior to operating tractor Check coolant level in the recovery tank located to the left rear of the engine Fig 4 11 When the engine is cold the coolant should be up to the cold mark on the recovery tank When the engine is hot the coolant should be up to the hot mark on the recovery tank When adding coolant pre mix the solution before adding it to the recovery tank It is not necessary to remove radiator cap for adding small amounts of coolant to system 601656_1108 29 Radiator Screen Er 1 Figure 4 10 NA Figure 4 11 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 IMPORTANT Refer to the Kohler EFI engine owner s manual for specific cleaning instructions 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 WARNING If the pump belt fails loss of control will occur especially when operating on a slope If
78. tempted by unskilled personnel Consult your Hustler service center when assistance is needed Torque values WARNING Particular attention must be given to tightening the drive wheel lug nuts and blade spindle bolts Failure to correctly torque these items may result in the loss of a wheel or blade which can cause serious damage or personal injury Torque values are given below Ft Ibs Nm Wheel lug nuts 2 2 2220 ceeenn GSTS iia 88 14 101 7 Blade spindle bolt top DAB ei tee ane a 160 01 Blade spindle bolt bottom AAA 160 01 Wheel motor nut S per ZATZ ios a sheers a 290 310 393 2 420 4 Wheel motor nut Hustler Z prior to serial number 07120009 350 375 474 6 508 5 Wheel motor nut Hustler Z beginning with serial number 07120009 200 210 271 2 284 7 Wheel motor nut Hustler Z Shibaura Diesel DIN es 339 Lug nuts only It is recommended that these be checked after the first 2 hours of operation initially every 50 hours and following removal for repair or replacement For all other torques refer to the various tractor parts manuals for standard torque chart See page 41 for ordering information For engine torque values see engine owner s manual Tires It is important for level mowing that the tires have the same amount of air pressure The recommended pressure are Drive wheels 8 12 psi 55 83 KPa Gauge wheels 8 12 psi 55 83 KPa Soli
79. tirii innnan a ie General engine maintenance ueneneesessnseneesensensnnnnnnnnnennennannn Hustler ATZ maintenance locator chart Hustler Z Super Z maintenance locator chart Hustler Z Super Z Hustler Z Shibaura Diesel Hustler ATZ troubleshooting uesssesennenenneenennennen 39 Hustler Z Super Z Hustler ATZ maintenance schedule 33 Hustler Z Super Z Rear Discharge Deck maintenance locator chart ueseseesesnesesnesensesnenennennnennenen 36 Hustler Z Super Z Hustler Z Shibaura Diesel Rear Discharge Deck maintenance locator chart 36 Hustler Z Shibaura Diesel maintenance locator chart 35 601656_1108 43 Hustler Z Shibaura Diesel maintenance schedule 33 Hydraulic syster iii N a N Lubrication a Maintenance amp adjustment introduction Model and serial number sesnneenesnsesnesensesnenenenensen nn 1 Moving tractor with stalled engine nennen 18 Mower blade maintenance uueeessesesenesensesnenennennenenne nennen 30 Mower blade removal Mower deck operation Operating suggestions OPM sh ooo ee a ANE Parts and Servicer etnias dd 1 Product literature Al ROPS er tele Eesti atin deans 18 Safe operating Practices eunncnnesnenennesensennenennennsennenennnn nennen 13 Safe Servicing practicidad 25 Safety and instruction decals eensennnennennnennennennn 5 Safet
80. traction is detected Wait until the condition that caused the problem is resolved before attempting to operate on the slope again Terrain conditions can affect traction resulting in possible loss of control of the machine Some of the conditions to be aware of are 1 Wet terrain Depressions in the ground i e holes ruts washouts Mounds of dirt Soil type i e sand loose dirt gravel clay Grass type density and height Extremely dry conditions of grass Tire pressure AN BD 14 A The attachments mounted to the tractor will also affect the way it handles on a slope Be aware that each attachment s characteristics vary Do not tow on slopes The weight of the towed equipment may cause loss of traction and loss of steering control Another consideration to safe mowing on slopes is to be aware of what is located at the bottom of the slope Extreme caution should be used when there is a hazard located at the bottom of the slope Some examples are 1 Water i e lake river 2 Cliffs retaining walls 3 Roads highways 4 Buildings 5 Rocks These are just a few examples of situations when caution must be used when operating on a slope There are many other possibilities too numerous to mention Just remember to always exercise extreme caution when operating on any slope When operating on terrain where there is a potential for a roll over it is important that a ROPS be installed on the equipment The ROPS will minimize ch
81. uel the equipment with its wheels on the ground If this is not possible then refuel such equipment on the truck or trailer using a portable container and not a fuel dispenser nozzle If a gasoline dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete Do not use a nozzle lock open device Read and observe safety precautions elsewhere in this manual WARNING Gasoline or diesel fuel is harmful or fatal if swallowed Long term exposure to vapors can cause serious injury and illness Avoid prolonged breathing of vapors Keep face away from nozzle and gas tank or fuel container opening Keep gas away from eyes and skin If fuel is spilled on clothing change clothing immediately WARNING Fuel System Under Pressure The EFI fuel system operates under high pressure and the fuel filter and fuel line used must be approved system components only Use of substitute parts can result in system failure gasoline leakage and possible explosion Gasoline units The fuel tanks are located in the tractor s fenders Use regular unleaded gasoline with an octane rating of 87 or higher IMPORTANT Never use methanol gasoline containing methanol or gasohol containing more than 10 ethanol because the fuel system could be 601656_1108 27 Right t position Left tank position MES Closed position shown Fuel shutoff position Left tank po
82. ulic Check level in reservoir oil supply Have dealer check hydraulic pump Poor compression See your dealer Steering linkage needs adjustment Adjust linkage Air in system Check filter amp fittings For additional causes See engine manual Low oil pressure Low oil level Add oil Oil diluted or too light Change oil and check for source of contamination Failed oil pump See your dealer High oil consumption Numerous See your dealer Tractor jerky when starting or operates in one direction only Steering control linkage needs adjustment Adjust linkage Pump or wheel motors faulty See your dealer Tow valves not closed completely Close tow valves Hydraulic system operates hot oil in reservoir smells rancid Tractor creeps when steering control levers are in neutral Low hydraulic oil level Fill reservoir Hydraulic pump faulty See your dealer Hydraulic oil cooler clogged Steering linkage needs adjustment Clean oil cooler core Adjust linkage Tractor circles or veers in one direction Steering linkage needs adjustment Adjust linkage Wheel motors faulty See your dealer Hydraulic pump faulty See your dealer Tractor creeps when parking brake engaged Steering linkage out of adjustment Adjust steering linkage Brakes need adjustment Adjust parking brakes 60
83. ways remove the negative ground first and replace it last This structure s protective capability may be impaired by structural damage overturn or alteration If any of these conditions occur this structure must be replaced Avoid crushing use seat belt Do not jump if machine tips To minimize chance of injury or death from rollover keep ROPS in the raised and locked position and use the seat belt Never operate machine on a slope with the ROPS folded down lowered position There is no roll over protection when the ROPS is in the lowered position Lower the ROPS only when absolutely necessary Drive slowly and carefully Raise the ROPS as soon as clearance permits Read and follow slopes operation instructions and warnings Do not wear seat belt when the ROPS is in the lowered position ATZ Only Part Number 601791 WARNING Read Owner s Manual and decals before attempting to operate this machine A WARNING Roll over BE e Mow a safe distance minimum of 10 feet away from drop offs retaining walls drainage ditches embankments water and other types of hazards to avoid a wheel dropping over the edge or to avoid the ground from breaking away WARNING Back over Do not carry passengers Always stop machine if someone enters the area Always be aware of what is behind the machine before backing up Do not mow in reverse unless absolutely necessary Always look down and behind before a
84. y start interlock system uesnsesnesennenensennenennenennennen een 17 Slope suide 2 a eee eee seanpesle 11 Slope Operation creta dla 11 Stopping the engine 17 RN 41 A O CO 26 To the Tew We cemntlasdana ni 1 Torgue VA ada 25 Using a ramp 13 Using this mamada iii idas 1 Warranty registration dnvstiadasae lr 1 XR7 deck maintenance locator Chart uneeeeseeeneeenennen 37 44 601656_1108
85. zed by Hustler Turf Equipment Service calls and or transportation expense of the product to and from the authorized dealer for warranty work will be paid by the owner of the product For warranty service you can contact an authorized dealer or write Hustler Turf Equipment 200 South Ridge Road Hesston Kansas 67062 or call 1 620 327 4911 WHAT IS NOT COVERED BY THIS WARRANTY Hustler Turf Equipment does not warranty O Some product components or parts not manufactured by Hustler Turf Equipment Repairs made by unauthorized persons Damage caused by use of the Hustler Turf Equipment for purposes other than those for which it was designed Damages caused by disasters such as fire flood wind and lightening Damages caused by foam filled or solid filled tires Damages caused by neglect abuse abnormal use improper or unreasonable use accident negligence or misuse O Repairs or replacement resulting from the use of unauthorized parts accessories or attachments O Repairs or replacement as the result if any alterations or modifications in the determination of Hustler Turf Equipment which adversely affects the operation performance or durability ofthe equipment O Hustler Turf Equipment which has the serial number removed or made illegible O Depreciation or damage caused by normal wear lack of reasonable and proper maintenance failure to follow the product s owner s manual operating maintenance and adjustment instructions or

Hustler Turf 927558 Lawn Mower User Manual

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