Hustler® X-ONE i General Service Manual
Contents
1. REV C 9 2 117604 Figure 9 5 16 Engine Fill amp Dipstick 17 Fuel Filter Engine Air Cleaner Engine Oil Drain Plug Battery Fuel Tanks Hydraulic Oil Reservoir Hydraulic Oil Filter Front Wheel Bearing Zerks 2 Engine Oil Filter Deck Height Pivot Zerks 4 Park Brake Switch Drive Tires Pump Idler Zerk 1 Pump Belt Deck Pusher Arm Zerks 2 Deck Belt Blades Fuel Evaporation System Filter Carbon Canister 16 117604 9 3 REV REV C 9 4 117604 TROUBLESHOOTING The majority of operating problems that occur with a system can be traced to improper adjustments or delayed service A consistently applied preventative maintenance program will prevent many problems The following chart is designed to help you locate a problem by suggesting probable causes and the recommended solutions SYMPTOMS PROBABLE CAUSES SUGGESTED REMEDIES Starting motor does not crank Steering control levers not in park brake position or Switch not adjusted Place stee2. Figure 6 5 Fuel evaporation System filter Seat s Carbon canister Figure 6 8 Figure 6 6 117604 6 3 REV C Engine RPM Settings The engine rpm s are set at the factory for maximum mowing efficiency Occasionally it may be necessary to check and adjust the settings The high idle speeds with no load should be set as follows Kawasaki FX691 amp FX730 ENGINE SPEED MODEL NO ENDING WITH HIGH IDLE MODEL NO WITHOUT EXTENSION 3600 RPM MODEL NO WITH EX EXTENSION 3600 RPM MODEL NO WITH US EXTENSION 3600 RPM NOTE Model numbers may or may not end with an extension after the number There are several different extensions that may be shown i e EX or CE Example 922222 no extension 922222 EX 922222 CE 922222 US REV C 6 4 117604 DECK ADJUSTMENTS Deck Leveling Leveling the deck must be done in the following manner and order 1 Check tire pressures to make certain they are properly inflated before starting to level deck The recommended press
3. 8 12 psi 55 83 KPa Front wheels 8 12 psi 55 83 KPa 117604 If you wish to use non pneumatic tires on your Hustler any mower equipped with unapproved non pneumatic tires mower the tires must be an approved tire purchased from Hustler Turf Equipment Warranty claims will be denied on 117604 5 9 REV REV C 5 10 117604 ENGINE MAINTENANCE General Engine Maintenance Detailed instructions and recommendations for break in and regular maintenance are specified in the Engine Owner s manual Please refer to this manual for engine servicing lubricating oil levels with quality and viscosity recommendations bolt torques etc The engine warranty is backed by the engine manufacturer Engine Oil and Filter A WARNING A If the engine has been running and is up to operating tem perature allow the engine to cool before changing the oil Engine and engine oil will be very hot so be very careful when changing oil and wear the appropriate protective gear to avoid being burned or exposed to engine oil Check engine oil daily and after every 4 hours of operation Machine must be setting level when checking oil Refer to engine manual and maintenance schedule for recommendation and capacities IMPORTANT Change the engine oil and filter after the first 5 hours of operation and per the engine manufacturer s rec ommendations after that If mower is being operated in extremely dirty conditions then
4. m a bs ire m 117604 8 1 REV C 8 2 117604 Maintenance Schedule Figure 9 1 Figure 9 2 Figure 9 3 Figure 9 4 amp Figure 9 5 WEEKLY MONTHLY ANNUALLY OR 50 OR 100 OR 500 HOURS HOURS HOURS SERVICE AT INTERVALS INDICATED Verify safety start interlock system Prior to each use Visually inspect unit for loose hardware and or damaged parts Prior to each use Visually inspect tires Prior to each use Check oil level engine 1 Prior to each use or every 4 hours Clean air intake screen 8 Prior to each use or every 4 hours Check fuel level Prior to each use Blades sharpen amp securely fastened Prior to each use Discharge chute securely in place amp in lowest position Prior to each use Clean engine and transaxle compartment Daily Replace air cleaner paper element 5 As needed Change engine oil and filter 1 4 Clean cylinder and head fins a Check battery connections Check tire pressure with a gauge Check hydraulic oil level X XxX XxX Xx Xx Clean engine exterior a Grease deck pusher arms 8 Grease pump idler 8 Grease deck height pivots 8 Grease gauge wheel bearings 8 Clean amp regap spark plugs a Check pump and deck belt tension and condition 6 Check fuel system 7 Check hydraulic lines Check fuel valve and grommet 7 XJ X X X X X XxX X X Xx Tighten lug nuts o
5. Hydraulic reservoir Hydraulic filter Figure 5 16 may engage easily when cold but has problems engaging when hot the brake shim can be removed to reduce air gap and allow the clutch to continue to function After verifying that proper voltage and current are supplied to the clutch follow the procedure outlined below NOTE Before proceeding the clutch must be installed on the engine crankshaft and the retaining bolt torqued to 45 48 ft Ibs Figure 5 17 117604 5 7 Procedure WARNING Always wear adequate eye protection when servicing the mower With engine off key removed and clutch disengaged and using a pneumatic line blow out any debris from under the brake pole and around the aluminum spacers Figure 5 18 Figure 5 18 Check the air gap between rotor amp armature with feeler gage If the gap is less than 070 then follow the troubleshooting procedure outlined in Warner Electric P1177 installation troubleshooting guide available on Warner Electric s web site www Warnerelectric com If the air gap is over 070 follow the procedure outlined below Figure 5 19 certain that the gap between the rotor and armature face is greater than 070 prior to shim removal Figure 5 19 1 Loosen both brake mounting bolts 1 2 to 1 full turn as REV shown in Figure 5 20 WARNING Do not remove brake pole from field shell armature The brake pole tracks match with the clutch bra
6. 1 10 12 13 14 15 16 that the foot pedal is free Figure 7 3 amp Figure 7 7 Start the leveling process on the left front of the mower Set the amount of threads protruding on the deck lift rod from the lift block at approximately 1 2 54cm left amp right side Figure 7 4 Jam both nuts against the block Clamp here 3 AT Stop c handle Deck adjustment stop Figure 7 2 Foot pedal 7 3 Push or pull on the deck lift foot pedal until the chain the left front just becomes tight making sure that the deck stays tight against the block While keeping the chain tight tighten the nuts against the deck lift block on the height indicator rod just enough to carry most of the deck weight on that side the block should be able to move with only a slight drag Figure 7 4 Jam nuts tightly together against the deck lift block Go to the right front of the mower Loosen the 5 16 jam nut on the adjuster and back the adjuster bolt out to allow the adjuster to move up and down freely Figure 7 5 Tighten the adjuster bolt until the chain just becomes tight Then tighten just enough to carry the weight of the REV 17 18 front of the deck on that side to check move the blocks back and forth they should move with a slight drag Figure 7 5 Tighten the adjuster bolt jam nut to prevent the adjuster bolt from moving Figure 7 5 Tighten the hard
7. 4 1 Steering adjustments 5 1 Steering control lever adjustment 5 3 Steering control lever neutral adjustment 5 1 Steering damper pp 5 3 BBC TT 5 8 Warner Clutch Re gap Adjustment Procedures 5 6 Warranty REV
8. IN LBS 3 6 12 IN LBS 1 3 250 98 4 IN LBS 11 1 4 26 4 IN LBS 3 312 204 IN LBS 23 M5 54 IN LBS 6 1 375 30 40 M6 92 4 IN LBS 10 4 438 48 65 M8 222 IN LBS 25 500 73 99 M10 37 50 562 105 143 M12 64 87 625 145 200 M14 103 140 750 260 350 M16 160 215 875 420 565 M20 320 435 Special Torques DESCRIPTION FT LBS NM Wheel lug nuts 1 70 95 Blade spindle bolt top 70 95 Blade spindle bolt bottom 118 160 Electric clutch mounting bolt 47 63 Front wheel axle bolt 100 136 Wheel motor hub nut 200 271 Hydraulic pump pulley bolt 50 68 Engine torques N A N A NOTE 1 117604 Lug nuts only It is recommended that these be checked after the first 2 hours of operation and every 50 hours and following removal for repair or replacement Engine torque values Refer to the respective engine owner s manual If clutch mounting bolt is loosened or removed do not re use Replace with a new bolt Use only hand tools to install this fastener 4 1 WARNING Particular attention must given to tightening wheel lug nuts and blade spindle bolts Failure to cor rectly torque these items may result in the loss of a wheel or blade which can cause serious damage or personal injury REV 117604 REV C 4 2 POWER UNIT MAINTENANCE Steering Adjustments Steering control lever neutral adjustmen
9. 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 117604 3 1 Refuel outdoors Never refuel or drain the fuel from the machine indoors Never attempt to start engine when there is a strong odor of gasoline or diesel fuel fumes present Locate and correct cause Store fuel in an approved container and keep it out of the reach of children Never buy more than a 30 day supply of fuel Do not fill fuel containers inside a vehicle or on a truck or trailer bed with interior carpets or plastic truck bed liners Always place fuel containers on the ground away from your vehicle before filling When practical remove gas or diesel fuel powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground If this is not possible then refuel such equipment on the truck or trailer using a portable container and not a fuel dis penser nozzle If a fuel dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is com plete Do not use a nozzle lock open device Never use gasoline or diesel fuel for cleaning parts Read and observe saf
10. check gaskets for cuts or tears Do not attempt to use a damaged element which will allow abrasive particles to enter the engine 3 Reinstall the dust cap Make sure it seals all the way around the air cleaner body then tighten the clamps Figure 6 2 4 Check all fittings and clamps periodically for tightness and inspect hoses for holes or cracks 5 Periodically check the intake hose for signs of ingested dust Locate and repair the source of ingested dirt 6 Never operate the machine without an air filter installed Overservicing Overservicing occurs when an air filter element is removed for cleaning or replacement before it is necessary Each time the filter is removed a small amount of dirt and dust could fall in the intake system This accumulated dirt can cause a dusted engine It only takes a few grams of ingested dirt over the normal service life of an engine to cause a dusted engine Do not clean the element but replace with a new element only Cleaning used air filter elements through improper cleaning procedures can get dust on the inside of the filter causing dirt ingestion and engine failure It is important to note that whenever an air filter element is cleaned by any method the person or company performing the cleaning assumes responsibility for the integrity of the filter from then on The warranty for air filters expires upon cleaning or servicing in any manner because the condition of the filter after servicing is
11. completely out of the filter manufacturer s control Therefore on a dust ingested engine failure there will be no warranty consideration if the air filter element has been cleaned or serviced in any manner A partially dirty air filter element works better than a new element Therefore a dirty filter element is not bad for the engine unless it is excessively restricting the air flow and engine performance is affected The reason is simple The media in the filter must be porous to allow air to 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 REV C 6 2 from entering the engine This is referred to as barrier filtration Of course at some point the filter media becomes too clogged to allow air to pass The mowing conditions will determine the frequency of air filter element changing Carbon Canister Some Hustler X ONE i mowers will have a carbon canister incorporated into the fuel system Figure 6 4 This is a mandatory feature that is required on all mowers using gasoline engines that are put into operation in California These canisters should be replaced every 5 years or if they become damaged Fuel evaporation system filter o CES gt Carbon ca
12. engine fires and hydraulic overheating as well as excessive belt wear Clean up oil or fuel spillage Allow machine to cool before storing A Always wear adequate eye protection when servicing the hydraulic system and battery or when grinding mower blades and removing accumulated debris A Never attempt to make any adjustments or repairs to the mower drive system mower deck or any attachment while the engine is running or deck clutch is engaged A Exercise caution when releasing spring tension from any of the belt idlers or when working with any of the deck lift components A Never work under the machine or attachment unless it is safely supported with jack stands Make certain machine is secure when it is raised and placed on the jack stands The jack stands should not allow the machine to move when the engine is running and the drive wheels are rotating Use only certified jack stands Use only appro priate jack stands with a minimum weight rating of 2000 pounds to block the unit up Use in pairs only Follow the instructions supplied with the vehicle stands Keep nuts and bolts tight especially the blade attachment bolts Keep equipment in good working condition A Never tamper with safety devices Check their proper operation regularly A Exercise caution when working under the deck as the mower blades are extremely sharp Wrap the blade s or wear gloves and use extra caution when servicing them A Use only genuine Hustler
13. it is recommended oil be changed more frequently IMPORTANT When removing the oil filter take precau tions to minimize oil spillage on the exhaust system Draining the engine oil 1 Locate the oil drain valve on the engine Figure 6 1 2 Position a suitable oil drain container under the machine below the oil drain valve 3 Twist the valve counterclockwise to open the valve Allow 10 minutes for engine oil to adequately drain 4 After oil is drained close the valve by twisting it clockwise 5 Clean up any spilled oil 117604 61 IMPORTANT oil drips or spills must be cleaned off of the exhaust system before operating the machine Figure 6 1 Engine Air Filter Perform engine air filter maintenance per the Maintenance Schedule shown elsewhere in this manual A specially designed dry filter is standard equipment on these mowers and supplies clean combustion air to the engine Figure 6 2 These mowers are equipped with a safety filter The filter element slides over the safety filter Figure 6 3 The safety element does not require servicing unless it becomes contaminated with dirt or moisture p y gt p Figure 6 2 Recommended service procedure 1 Release clamps and remove element Clean the canister with a damp cloth 2 Before installing a new element inspect it by placing a bright light inside and rotating the element slowly REV C Figure 6 3 looking for any holes or tears in the paper Also
14. replacement parts to ensure that original standards are maintained Maintenance Precautions Avoid Fire Hazards A Be prepared if an accident or fire should occur Know where the first aid kit and the fire extinguishers are located and how to use them A Provide adequate ventilation when charging batteries A Do not smoke near battery A Never check fuel level with an open flame A Never use an open flame to look for leaks anywhere on the equipment A Never use an open flame as light anywhere on or around the equipment A When preparing engine for storage remember that fuel stabilizer is volatile and therefore dangerous Seal and 117604 tape openings after adding the inhibitor Keep container tightly closed when not in use A Inspect electrical wiring for worn or frayed insulation Install new wiring if wires are damaged Prepare For Emergencies Be prepared if a fire starts Keep a first aid kit and fire extinguishers available Keep emergency numbers for doctor ambulance service hospital and fire department near the telephone Prevent Battery Explosions A Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling A Charge batteries in an open well ventilated area away from sparks and flames Unplug charger before connect ing or disconnecting from battery Wear protective c
15. For additional causes See engine manual Low engine oil pressure Low oil level Add oil Oil diluted or too light Change oil and check for source of contamination Failed oil pump Contact your dealer High oil consumption Numerous Contact your dealer Mower jerky when starting or operates in one direc tion only Steering control linkage needs adjustment Adjust linkage Transaxle component faulty Tow valves not closed com pletely Loose steering linkage Contact your dealer Close tow valves Tighten linkage 117604 10 1 SYMPTOMS PROBABLE CAUSES SUGGESTED REMEDIES Mower creeps when steering control levers are in neutral Steering linkage needs adjustment Adjust linkage Mower circles or veers in one direction Steering linkage needs adjustment Adjust linkage Loose steering linkage Tighten linkage Tires improperly inflated Adjust air pressure to 8 12 psi 55 83 KPa Transaxle component faulty Contact your Dealer Mower creeps when park ing brake engaged There is abnormal vibra tion Steering linkage out of adjustment Adjust steering linkage Brakes need adjustment he engine mounting bolts are loose Adjust parking brakes Tighten the engine mount ing bolts he engine pulley idler pul ey or blade pulley is loose Tighten the appropriate pul ley The engine pulley i
16. Hustler X ONE i General Service Manual 200 South Ridge Road Hesston Kansas 67062 117604 REV C AA WARNING A The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm NOTICE OF REQUIREMENT OF SPARK ARRESTER MUFFLER This equipment may create sparks that can start fires around dry vegetation California Public Resources Code Section 4442 6 provides that it is unlawful to use or operate an internal combustion engine on any forest covered brush covered or grass covered land unless the engine is equipped with a spark arrester maintained in effective working order A spark arrester is a device constructed of nonflammable materials specifically for the purpose of removing and retaining carbon and other flammable particles over 0 0232 of an inch in size from the exhaust flow of an internal combustion engine that uses hydrocarbon fuels or which is qualified and rated by the United States Forest Service Other states or federal areas may have similar laws The Operator Should Contact Local Fire Agencies For Laws or Regulations Relating to Fire Prevention Requirements THIS EQUIPMENT DOES NOT HAVE A SPARK ARRESTER AND YOU SHOULD CONTACT YOUR AUTHORIZED DEALER FOR THE PURCHASE OF A SPARK ARRESTER Inspect spark arrester daily replace every 500 hours or as needed The Engine Owner s Manual provides information regarding the U S Environmental Protectio
17. and component manuals will provide the information necessary to service and maintain Hustler X ONE i mowers This General Service Manual is a service guide for use by Service Technicians It provides the necessary information needed to perform normal maintenance requirements on these units The Parts Manual provides a complete parts listing for the unit Use this manual when ordering parts The Operators Manual provides fundamental operational information and operational safety that is needed when operating the mower The component manuals are furnished by the various manufacturers to be used for the troubleshooting and servicing of their components Maintenance Introduction Regular maintenance is the best prevention for downtime or premature failure The following pages contain suggested maintenance information and schedules which the operator mechanic should follow on a routine basis Remain alert for unusual noises they could be signaling a problem Visually inspect the machine for any abnormal wear or damage A good time to detect potential problems is while performing scheduled maintenance service Correcting the problem as quickly as possible is the best insurance Clear away heavy build up of grease oil and dirt especially in the engine compartment and under the seat platform areas 117604 2 1 minute dust particles are abrasive to close tolerance engine and hydraulic assemblies Daily inspect mower for grass clippings a
18. atic Kawasaki 9 RED BLK 18 IGN TIONS 87 SWITCH N 8 RED 14 7 CLUTCH SWITCHx 630 us SSC S m 12 ORG 18 20 ORG RED 18 a o SEAT SWITCHx 13 ORG 18 E 2 TAN 18 ME us NEUTRAL NEUTRAL 99 SWITCH SWITCH UIT 14 ORG 18 i 22 TAN REDI 23 TAN RED 18 be ot 18 le ot a OIL PRESS CN N 15 ORG 18 y Jed J1 P Y J1 NY stem git Ji ste 16 ORG I8XHOUR 3 BLK 18 LMETERI lt ege SPARK IGNITED CONTROLLER 5i 17 BLU 14 c E AUX JI 6 JI F JI E JI D JI C JI B JIA 3 lt 6 RED 18 ORG 18 CA ER gt 6 19 ORG 18 lt o o o el _ SE se x a 1 E Z oS INS oO a 9 i e CD Ka CN SLE 2 N 40A Oo c gt of RS 3 RED 12 o o N e Des Si PUR 10 START iu pus PRESS phe pe FUR CHARGE Iu d e S CAN CLUTCH FUEL 306 4 a pe ee ENG KILL i 12VDC 4 CHARGE BATTERY B IT 2252 x M ES CD al 36 BLK 8 GROUND ST SPLICE a ENGINE e x lt a
19. battery cable routing could cause damage to the mower and battery cables This can cause sparks which can cause a battery gas explosion which will result in per sonal injury Always disconnect the negative black bat tery cable s before disconnecting the positive red cable s Always connect the positive red battery cable s before connecting the negative black cable s Avoid Acid Burns A Sulfuric acid in battery electrolyte is poisonous It is strong enough to burn skin eat holes in clothing and cause blindness if splashed in eyes Avoid the hazard by Filling batteries in a well ventilated area Wearing eye protection and rubber gloves Avoiding breathing fumes when electrolyte is added Avoiding spilling or dripped electrolyte If you spill acid on yourself Flush your skin with water Apply baking soda or lime to help neutralize the acid Flush your eyes with water for 10 15 minutes Get medical attention immediately If acid is swallowed Drink large amounts of water or milk Then drink milk of magnesia beaten eggs or vegetable oil Get medical attention immediately REV REV C 3 4 117604 TORQUE Standard Torques The following chart lists the standard torque values for the threaded fasteners found in this manual Torque all cap screws nuts and set screws to these values unless a different torque is shown in the Special Torques section SIZE FT LBS N M SIZE FT LBS N M 10 32 4
20. both wheels remain in neutral tighten the jam nuts to lock the turnbuckle in place Test again by moving the steering control levers forward and backward before returning them to the neutral position If the tires are in neutral the unit is now ready for operation After adjusting for neutral it may be necessary to re adjust the control lever stop and or damper IMPORTANT With the engine off disconnect the two female spade connectors from each other from step 3 and reconnect them to the seat switch This must be completed so that the safety circuit is functioning REV Steering control lever Steering control lever in neutral position Figure 5 2 Pump linkage Figure 5 3 properly Figure 5 1 WARNING Do not operate the mower without plugging the mower s wiring harness into the seat switch This switch is an important part of the safety start interlock system Serious injury can result if the seat switch is not plugged into the mower s wiring harness REV C 5 2 WARNING Never operate mower with non functioning seat switch Always reconnect the seat switch to the mower harness 13 Check to make sure all tools or obstructions are removed from under the mower Raise the rear of the mower and remove the jack stands Lower the mower Lower and secure the seat platform 14 15 Control lever stops The internal steering control lever stops s
21. brake position disengage deck clutch remove ignition switch key and disconnect negative battery cable before doing any adjustments 2 Place the steering control lever in the neutral position Figure 5 6 Figure 5 7 Steering control lever adjustment The steering control levers can be adjusted for operator comfort 1 Byloosening the cap screws that attach the upper control lever to the lower lever the upper control lever can be pivoted to fit the operator s personal preference see 3 Loosen the steering damper s rear ball stud Figure 5 7 Figure 5 8 4 Pull the damper spring housing past the point that the 2 The steering control levers should be adjusted so that internal spring is engaged Figure 5 7 they align vertically with each other when in the neutral 5 Release the damper spring housing and allow the internal position Figure 5 9 117604 spring to bring the housing back to the neutral position 5 3 REV Park Brake Adjustment AA WARNING AA This procedure will require that the unit be raised and blocked up off of the ground It is necessary for the wheels to rotate without coming in contact with the floor or any object that would permit the unit to propel itself Stay clear and exercise caution when rotating wheels to prevent injury Use only appropriate vehicle stands with a minimum weight rating of 2000 pounds to block the unit up Use in pairs only Follow the instructions sup plied with
22. control panel see Figure 5 5 2 Then stop the mower and loosen the lock nut on the side which is rotating too fast and turn the stop set screw inward to stop the steering control lever sooner Tighten the lock nut on the stop and test again 3 Repeat this procedure until unit drives straight NOTE Since this is a hydrostatic drive variables such as temperature of oil efficiency of pumps and motors tire pressure etc may effect the consistency of the ability to rely on the stops to drive straight without the operator making minor steering adjustments with the control arms 117604 6 Tighten the nut on the steering damper s front ball stud NOTE The damper must not bottom out when the pump lever is fully stroked in either direction 7 Reconnect the negative battery cable 8 Lower and secure the seat platform 9 To check move the steering control lever to the reverse position and release The steering control lever should return to the neutral position If not repeat steps 1 through 6 Control levers shown in park brake position Steering damper spring housing Figure 5 5 Steering damper The steering dampers are spring loaded to return the control levers to the neutral position from the reverse position This gives the operator a sense of neutral during operation To set the steering dampers in the correct operating position follow these steps 1 Shut engine off place steering control levers in the park
23. d check for distortion Warped Blade Replace Figure 7 9 amp Figure 7 10 Replace any distorted blade A Do not re use spindle bolts which have stripped worn or Cutting undercut threads Torque bolts on spindles to 118 foot pounds plane 160 0 Nm when reinstalling blades i Properly compressed cup washers maintain the correct compression load on the blades Replace the cup washers if they Straight Blade are cracked or flattened IMPORTANT The blade sail curved part must be point ing upward toward the inside of the deck to ensure proper cut Figure 7 9 ting Original edge Figure 7 8 Comparison of Warped and Straight Blades 117604 7 3 REV C Cutting edge Twisted Blade Edge replace Cutting Plane Cutting edge dE Straight Blade Edge End view of blades comparing twisted and straightened blades Figure 7 10 Belts Inspect belts frequently for wear and serviceability Replace a belt that shows signs of severe cuts tears separation weather checking and cracking or burns caused by slipping Slight raveling of belt covering does not indicate failure trim ravelings with a sharp knife Inspect the belt pulley grooves and flanges for wear A new belt or one in good condition should never run against the bottom of the groove Replace the pulley when this is the case otherwise the belt will lose power and slip excessively Never pry a belt to get it on a pulley as this
24. ed position place steering control levers in the park brake position and turn engine off and disconnect negative battery cable Block up mower when you must work under it Wear gloves when handling blades Always check for blade damage if mower strikes a rock branch or other foreign object during mow Resharpening ing pattern WARNING A Always wear adequate eye protection when grinding mower blades Do not sharpen to original pattern below It is easier to get a straight cutting edge following the resharpening pattern shown above 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 Figure 7 8 Touch up sharpening can be done with a file Check the blades for balance following grinding A commercial balancing tool is available through most hardware supply stores or balancing can be done by placing the blade on an inverted line punch or 5 8 bolt Blade should not lean or tilt Spin the blade slowly blade should not wobble If blade is out of balance true it up before reinstalling Lay the blade on a flat surface an
25. ee Figure 5 4 are designed to keep the pumps from bottoming out internally The external steering control lever stops Figure 5 5 may be adjusted to help the mower drive straight when the steering control levers are pushed forward against the stops To keep the pumps from bottoming out internally use the following procedure This adjustment is only required if the hydraulic pump s have been replaced WARNING Pump damage will occur if these stops set incor rectly 1 To make the first adjustment the mower engine must not be running 2 Check to make sure the steering control levers are against the stops before the pumps are bottomed out internally 3 do this gently and slowly move the steering control levers forward and feel if there is some resistance on the pump lever before the control levers hit the stops Check one side at a time If you sense that the pump arms are stopping the forward motion of the control arms loosen the jam nut on the adjustable stop of the corresponding side turn the stop set screw inward to stop the steering control levers slightly before the pump bottoms out Lock in place when the adjustment is correct by re tightening the jam nut Do this for each side To adjust the stops for driving straight when steering control levers are against the stops during operation 1 Determine which drive tire is rotating too fast when both steering control levers are against the stops in the
26. ety precautions elsewhere in this manual A Gasoline and diesel fuel is harmful or fatal if swallowed Long term exposure to vapors can cause serious injury and illness Avoid prolonged breathing of vapors Keep face away from nozzle and gas tank or fuel con tainer opening Keep fuel away from eyes and skin If fuel is spilled on clothing change clothing immedi ately Understand Machine Operation A Only qualified and trained personnel should operate the equipment A Carefully read the operator s manual and all manuals fur nished with the attachments Learn the location and pur pose of all controls instruments indicators and labels Wear Protective Clothing A Do not operate or service the equipment while wearing sandals tennis shoes sneakers shorts or any type of loose fitting clothing Long hair loose clothing or jew elry may get tangled in moving parts Always wear long pants safety glasses ear protection and safety shoes when operating or servicing this machine A Always wear adequate eye protection when servicing the hydraulic system and battery or when grinding mower blades and removing accumulated debris A Prolonged exposure to loud noise can cause impairment or loss of hearing Always wear adequate ear protection such as earplugs when operating this equipment as prolonged exposure to uncomfortable or loud noises can cause impairment or loss of hearing REV Do not wear radios or music head
27. fans on top of the transmissions Exercise extreme caution WARNING A WARNING WARNING Untrained maintenance personnel should never attempt to make any adjustments or repairs to the mower s drive system while the engine is running The following proce dures should be performed by trained maintenance personnel only NOTE Before adjustment make certain hydraulic system oil is at operating temperature 1 Raise the rear of the mower and block with certified jack 117604 5 1 10 11 12 stands The rear wheels need to be able to rotate freely and clear of all obstructions Chock the front tires Raise the seat platform and disconnect the mower harness from the seat switch Bypass the seat switch by connecting the two mower harness female spades together Figure 5 1 Figure 5 1 Start the engine Position the steering control lever in the neutral position and observe which way the wheels are rotating Figure 5 2 If wheel s are rotating forward loosen the jam nuts on the pump linkage rods and rotate the rod to lengthen the steering control linkage until the wheel s come to a stop Figure 5 3 Repeat for the opposite side if necessary If wheel s are rotating in reverse then loosen the jam nuts on the pump linkage rods and rotate the rod to shorten the steering control linkage until the wheel s come to a stop Figure 5 3 Repeat for the opposite side if necessary When
28. in place except for servicing A Do not touch hot parts of machine General Maintenance Precautions Repairs or maintenance requiring engine power should be performed by trained maintenance person nel only A Never run the engine in an enclosed area unless exhaust is vented to the outside Exhaust gases contain carbon monoxide which is an odorless and deadly poison Unless specifically required DO NOT have engine run ning when servicing or making adjustments to mower Park the machine on level ground Place steering control levers in the park brake position disengage deck clutch lower deck remove ignition switch key and disconnect negative battery cable before doing any maintenance Wait for all movement to stop before adjusting cleaning or repairing To prevent carbon monoxide poisoning be REV C 3 2 sure proper ventilation is available when engine must be operated in an enclosed area A Before working on or under the deck make certain engine cannot be accidentally started Shut engine off remove ignition switch key and disconnect negative bat tery cable for maximum safety A Except when changing or checking belt always keep belt covers on mower deck for safety as well as cleanliness A Use a stick or similar instrument to clean under the mower making sure that no part of the body especially arms and hands are under mower A Keep your machine clean and remove any deposits of trash and clippings which can cause
29. ke and need to continue to match after shim is removed to ensure proper brake torque Figure 5 17 2 Using needle nose pliers or by hand take hold of the tab and remove shim do not discard shim until proper clutch function has been confirmed Figure 5 21 Figure 5 21 3 Using a pneumatic line blow out any debris from under the brake pole and around the aluminum spacers Figure 5 18 4 Re torque each bolt M6 X 1 to 120 in Ibs 5 Using a 015 thick feeler gage verify that a gap is present between the rotor and armature face on both ends of the brake pole as shown Figure 5 22 and Figure 5 23 a If the gap is less than 015 the clutch must be replaced b If sufficient gap is present then proceed to safety check outlined below REV C 5 8 Figure 5 23 Perform safety check WARNING Observe deck operation from the operator s seat 1 Start the engine and the deck should not be engaged with the PTO switch oft and clutch de energized Engage and disengage the PTO switch to ensure the proper function of the clutch 2 If clutch still does not engage then follow the troubleshooting procedure outlined in Warner Electric P1177 installation troubleshooting guide available on Warner Electric s web site www Warnerelectric com and consult owner s manual Tires It is important for level mowing that the tires have the same amount of air pressure The recommended pressures are Drive
30. loth ing and use insulated tools A Avoid skin and clothing contact with battery acid Always wear eye protection when checking the battery acid can cause serious injury to skin and eyes If con tact occurs flush area with clean water and call physi cian immediately Acid will also damage clothing Do not drink the battery electrolyte Do not allow open flame near the battery when charg ing Hydrogen gas forms inside the battery This gas is both toxic and flammable and may cause an explosion if exposed to flame Always disconnect the negative black battery cable s before disconnecting the posi tive red cable s Always connect the positive red battery cable s before connecting the negative black cable s Do not overfill battery Electrolyte may overflow and damage paint wiring or structure When cleaning the battery use soap and water Be careful not to get soap and water into the bat tery Clean the battery terminals with a solution of four 117604 3 3 parts water and one part baking soda when they become corroded A Shorts caused by battery terminals or metal tools touch ing metal mower components can cause sparks Sparks can cause a battery gas explosion which will result in per sonal injury Prevent the battery terminals from touching any metal mower parts when removing or installing the battery Do not allow metal tools to short between the battery terminals and metal mower parts Incorrect
31. m appears to be leaking or otherwise malfunctioning Figure 5 16 When checking the hydraulic system s oil level 1 Always check oil level with the mower on level ground 2 Always check oil level when the oil is cold mower has not run for at least 1 5 hours 3 Always check oil level with the dipstick installed and tightened 4 Full level when oil is cold is at the line on the dipstick Dipstick A Figure 5 15 Change hydraulic system filter element and oil after first 750 hours of mower operation then replace filter and oil in reservoir every 500 hours thereafter The following is a list of the oils that are approved for use in the Hustler X ONE i hydraulic system A Castrol Edge 5W 50 B Shell Rotella T6 5W 40 C Lucas Magnum High TBN CI 4 15W40 D Amsoil AW ISO 68 IMPORTANT Use only the approved oils listed above Use of any unapproved oils will void your warranty The Hustler X ONE 1 system filter is located at the bottom of the integrated transmission with access to it from the front Use a Hustler approved filter element only When changing the filter use a 3 4 hex wrench The threads are right hand Warner Clutch Re gap Adjustment Procedures The air gap is only adjustable on clutches that have a removable shim see Figure 5 21 When to remove shim When a clutch has worn to the extent that the existing air gap is too large to allow for complete clutch engagement clutch 117604 Dipstick cap
32. n Agency EPA and the California Emission Control Regulation of emission systems maintenance and warranty Keep Engine Owner s Manual with your unit Should the Engine Owner s Manual become damaged or illegible replace immediately Replacements may be ordered per the information found in the Product Information section of the owner s manual Federal law and California State law prohibit the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair replacement of any device or element of design incorporated into any equipment for the purposes of emissions control prior to or after its sales or delivery to the ultimate purchaser or while it is in use or 2 The use of the equipment after such device or element of design has been removed or rendered inoperative by any person REV 117604 Table of Contents General Information uoo ER NEE ee S o Eee 2 1 Service Program LL CU 2 1 Maintenance Introduction 2 1 WA WAYS oo sea ess Ad tied eg ped 2 1 sra 3 1 Sale Servicing Practices 3 1 Pre Operation Precautions ossa Wek eee es 3 1 Operation Precautions wei aeuo Seo edo aora ratu iod Boe n s 3 2 Operate Machine 5 3 2 General Maintenance Precautions 3 2 Mai
33. n wheels 2 Change fuel filter 7 X Change hydraulic filter amp oil 3 X Replace spark plugs X Check ROPS mounting hardware 9 X Replace fuel evaporation system filter 8 X NOTES 1 Initial oil change is after 5 hours of operation Thereafter change oil after every 40 hours operation Change more often under dusty or dirty conditions and dur A Pon ing hot weather periods Torque initially and after first 2 hours of operation Perform initial hydraulic oil and filter change after 750 hours of operation Change engine oil filter per the engine manufacturer s recommendations Refer to Engine Owner s Manual for recommendations and other maintenance items 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 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 Check fuel system for any crack or leaks including but not limit to fuel line hoses fuel valve vent line hoses vent valve vapor valve carbon canister and grommets Repair as needed More often under dusty or dirty conditions and during hot weather Inspect ROPS after the first 20 hours of operation and then after every 500 hours of operation or yearly whichever comes first REFERENCES A Refer to e
34. nd wire and string tangles The underside of the mower deck will collect a build up of grass clippings and dirt especially when grass is wet or has high moisture content This build up will harden restricting blade and air movement and will probably show a lesser quality of cut Therefore it should be removed routinely To do this it will be necessary to raise and block the deck using jack stands or blocks in the full up position and scrape the build up from underneath Some repairs require the assistance of a trained service mechanic and should not be attempted by unskilled personnel Consult your Hustler Turf Equipment service center when assistance is needed Information included in this manual was current at the time of printing but subsequent production changes may cause your machine to vary slightly in detail Hustler Turf Equipment reserves the right to redesign and change the machine as deemed necessary without notification If a change has been made to your machine which is not reflected in this service manual contact the Customer Service Department at Hustler Turf Equipment for additional information Warranty Warranty repair must be performed by a Hustler Turf Equipment Authorized Dealer before warranty credit can be allowed Work performed by anyone other than an Authorized Dealer will invalidate the warranty claim and warranty credit will not be approved REV 117604 REV C 2 2 SAFETY This safety alert symb
35. ngine owner s manual for engine service information NOTE After completing maintenance cycle 500 hours repeat cycle 117604 9 1 RENG Maintenance Locator Chart Figure 9 1 10 11 12 13 14 15 16 17 18 19 20 O OOO A ON oa Engine Oil Fill amp Dipstick Fuel Filter Engine Air Cleaner Engine Oil Drain Plug Battery Fuel Tanks Hydraulic Oil Reservoir Hydraulic Oil Filter Front Wheel Bearing Zerks 2 Engine Oil Filter Deck Height Pivot Zerks 4 Park Brake Switch Drive Tires Pump Idler Zerk 1 Pump Belt Deck Pusher Arm Zerks 2 Deck Belt Blades Fuel Evaporation System Filter Carbon Canister Figure 9 2 Figure 9 3 Figure 9 4 Carbon canister equipped mower
36. nister o Figure 6 4 Fuel Evaporation System Filter Some Hustler X ONE i mowers have a fuel evaporation system filter This filter must be checked and replaced every 500 hours or annually whichever comes first Figure 6 5 Fuel amp Evaporative System Line Routings There are two rubber hoses that are connected to the fuel tanks One is the fuel hose that is part of the fuel system The other is the vapor line that is part of the fuel evaporative system The fuel hose connects to the outer most fitting with the fitting barb pointed toward the inside of the frame It connects the fuel tank to the fuel shutoff valve Figure 6 6 The vapor line connects to the inner fitting with the fitting barb pointed towards the rear of the frame It connects the fuel tank to the engine s vapor port Figure 6 7 amp Figure 6 8 117604 Fuel evaporation System filter by Fuel evaporation System filter
37. ntenance 3 2 4 1 Standard aot ege beg 4 1 Special TOI Abee DERE 4 1 Power Unit 5 1 Steering Ad USITehls ger Eege echo t ole 5 1 Park Brake Adjustment 5 4 Bell riot dw Lies 5 5 Hydraulic Pump Belt 5 5 Hydraulic SYSIOMN e235 deno 5 6 Warner Clutch Re gap Adjustment Procedures 5 6 Bcc MP C RR 5 8 Engine Maintenance saure e Bic ene e e bun 6 1 General Engine Maintenance 6 1 Engine Oil and Filter OO xe uen oou eg 6 1 Engine Air Filter troie tee vont 6 1 Garbon Ken 6 2 Fuel Evaporation System Filter 6 2 Fuel Evaporative System Line Routings 6 2 Deck Adjustments 2254 x E s 7 1 117604 toc 1 REV Blades ee E tard 7 2 o CP NUR MM EC 7 4 Deck Adjustment oua dt Rem iet 7 4 2555 IL LI as 8 1 Ve ele DEE 10 1 REV C toc 2 117604 GENERAL INFORMATION Service Program This manual is part of a service package for the Hustler X ONE i mowers Use of this manual in conjunction with other Hustler mower
38. ol is used to call attention to a message intended to provide a reasonable degree of PERSONAL SAFETY for operators and other persons during the normal operation and servicing of this equipment denotes immediate hazards which WILL result in severe personal injury or death denotes a hazard or unsafe practice which COULD result in severe personal injury or death DANGER WARNING Safe Servicing Practices This product is capable of amputating hands and feet and throwing objects Always follow all safety instructions to avoid serious injury or death Understand correct service A Be sure you understand a service procedure before you work on the machine A Unauthorized modifications to the machine may impair the function and or safety and affect machine life A If it is necessary to make checks with the engine running always use two people with the operator at the controls able to see the person doing the checking Pre Operation Precautions Fuel Handling A To avoid personal injury or property damage use extreme care in handling fuel Fuel is extremely flamma ble and the vapors are explosive Observe usual fuel handling precautions Do not smoke while refueling Extinguish all ciga rettes cigars pipes and other sources of ignition Do not remove fuel cap or fill tank with engine run ning or while engine is hot Clean up any fuel spills Allow engine to cool before storing machine inside
39. ol will occur especially when operating on a slope If you lose steering control while operating the machine place the steering control levers in the park brake position immediately Inspect the machine and involve your dealer to resolve the problem WARNING Adjusting holes Tension pre Wr Spring mount ww Hydraulic pump belt Spring Extension 0 5 8 0 8 20 3 21 6cm Figure 5 14 Hydraulic System IMPORTANT Never use hydraulic or automatic transmis sion fluid in this system use only specified oil Remember dirt is the primary enemy of any hydraulic system Figure 5 16 Hydraulic fluid escaping under pressure sufficient force to penetrate skin and cause serious injury Foreign fluid injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result Before applying pressure to hydraulic system make sure all connections are tight and all hoses and lines are in good condition To find a leak under pressure use a piece of cardboard or wood never use your hands Relieve all pressure in the system before dis connecting or working on hydraulic lines To relieve pressure lower all attachments and shut off engine WARNING Check oil level in hydraulic system after every 50 hours of REV 5 6 operation or weekly whichever occurs first Check more often if syste
40. otherwise the belt will lose power and slip excessively Never pry a belt to get it on a pulley as this will cut or damage the fibers of the belt covering Keep oil and grease away from belts and never use belt dressings Any of these will destroy the belt composition in a very short time Hydraulic Pump Belt Adjustment The transmission drive belt tension remains constant by means of a tension idler and spring The spring tension should be such that the belt does not slip under normal operating load conditions assuming the belt is not excessively worn or damaged As the belt stretches and wears in adjustment may become necessary The proper belt tension is achieved when the tension spring is stretched to a dimension of 8 0 8 5 20 3 21 6cm when measured from the inside of the hook to the inside of the other hook Figure 5 14 To increase belt tension remove the spring hook from the idler spring mount Unbolt the idler spring mount from the mower frame and move it to a set of holes in the frame that allow for the spring to be extended to the proper extension Attach the mount and then re attach the spring hook to it Figure REV 5 14 IMPORTANT Do not over tension the spring to compensate for a badly worn belt or pulley Figure 5 14 Inspect the belt every 100 hours and replace as needed Replace the belt every 400 hours or every two 2 years whichever comes first If the transmission belt fails loss of contr
41. phones while operat ing the machinery Safe operation requires your full attention Operation Precautions Avoid Fire Hazards A Clean flammable material from machine Prevent fires by keeping engine compartment top of deck exhaust area battery hydraulic lines fuel line fuel tank and operator s station clean of accumulated trash grass clippings and other debris Always clean up spilled fuel and oil Start Engine Safely Avoid possible injury or death from machine runaway A Do not start engine by shorting across starter terminals A Before you start the engine e Sit on the operator s seat Move control levers to the neutral brake position Operate Machine Safely A Refer to the unit s operator s manual for complete safety information on safe machine operation A Always maintain a safe distance from people and pets when mowing A Always be aware of what is behind the machine before backing up A Never leave machine unattended with ignition key in switch especially with children present A Follow daily and weekly checklists making sure hoses are tightly secured and bolts are tightened A Always keep engine and machine clean removing accu mulated dirt trash and other material from machine A Never put hands or feet under any part of the machine while it is running A Never attempt to start engine when there is a strong odor of gasoline fumes present Locate and correct cause A Keep all safety shields and covers
42. rake resistance is noticed the brake needs adjusted as follows Loosen the brake linkage jam nuts Figure 5 13 Rotate the tire and at the same time rotate the turnbuckle to shorten the length of the brake linkage to increase the brake pressure When you feel the brake begin to engage stop adjusting the turnbuckle Re tighten the jam nuts on the turnbuckle Place the steering control lever in the park brake slot The tire should not rotate when the control lever is in the park brake position Figure 5 12 Place the control lever in the neutral position The tire should rotate freely Close the integrated transmission s bypass valve Figure 5 5 5 11 Repeat steps 4 through 9 for the other side Check to make sure all tools or obstructions are removed from under the mower Raise the rear of the mower and remove the jack stands Lower the mower Reconnect the negative battery cable Lower and secure the seat platform 10 11 12 13 14 Figure 5 13 Belts Inspect belts frequently for wear and serviceability Replace a belt that shows signs of severe cuts tears separation weather checking and cracking or burns caused by slipping Slight raveling of belt covering does not indicate failure trim ravelings with a sharp knife Inspect the belt pulley grooves and flanges for wear A new belt or one in good condition should never run against the bottom of the groove Replace the pulley when this is the case
43. ring control levers in park brake posi tion or re adjust switch Deck clutch switch engaged Disengage clutch switch Weak or dead battery Recharge or replace Electrical connections are corroded or loose Check the electrical con nections For additional causes See engine manual The engine will not start starts hard or fails to keep running No fuel or line plugged Fill tank or replace line See Fuel System section for more details Fuel valve is turned off Open the fuel valve There is incorrect fuel in the fuel system Drain the tank and replace the fuel with the proper type There is dirt in the fuel filter Replace the fuel filter Dirt water or stale fuel in the fuel system Contact your dealer The choke is not on Move the choke lever to ON Numerous See engine manual Engine Runs with continuous mis firing or engine runs unevenly or erratically Numerous See engine manual Loss of power or system will not operate in either direction Restrictions in air cleaner Service air cleaner Internal interference or leakage in wheel motor See your dealer Poor compression See your dealer Steering linkage needs adjustment Adjust linkage Tow valve open Close tow valve The traction drive belt is worn loose or broken Install a new traction drive belt Air in system Check filter and fittings
44. s dam aged Contact your dealer The cutting blade s is are bent or unbalanced Install new cutting blade s A blade mounting bolt is loose Tighten the blade mounting bolt Spindle bearing is worn or loose Replace or tighten spindle bearing A blade spindle is bent Contact your dealer Blades do not rotate The deck drive belt is worn loose or broken Install a new deck drive belt The deck drive belt is off the pulley Install the deck drive belt and check for a reason Electric clutch is not engag ing Check and or replace 10 amp fuse Contact your dealer Uneven cutting height The blade s are not sharp Sharpen the blades A cutting blade s is are bent Install new cutting blade s The deck is not level Level the deck per the Deck leveling and height adjustment section of the General Service Manual An anti scalp wheel is not set correctly Adjust the height of the anti scalp wheel The underside of the deck is dirty Clean the underside of the deck Tires improperly inflated Adjust air pressure to 8 12 psi 55 83 KPa A blade spindle is bent Contact your dealer REV 117604 REV C 10 2 PAGE trei estu 5 5 7 4 Blades the TREE 7 2 Carbon Canister 6 2 Control lever stops 2 5 2 Deck Belt adjustment 7 4 Deck Bel
45. t The mower s steering has been factory adjusted to eliminate creeping when the steering control levers are in the neutral position However should the mower begin to creep the steering control lever linkage can be adjusted Before considering any adjustment check the tire air pressure Unequal tire pressure will cause the mower to drift to one side Refer to tire pressure information in the Tires section for detailed information NOTE Proper park brake adjustment must be completed before the steering control lever neutral adjustment can be done Refer to the Park Brake Spring Adjustment section for detailed information Fine adjustment to the unit s steering is made with the transmission s control rod Neutral is properly adjusted when the steering control levers are in the park brake position and the transmissions do not whine If this occurs the steering control linkage may be adjusted as follows This procedure will require that the unit be raised and blocked up off of the ground It is necessary for the wheels to rotate without coming in contact with the floor or any object that would permit the unit to propel itself Stay clear and exercise caution when rotating wheels to prevent injury Use only appropriate vehicle stands with a minimum weight rating of 2000 pounds to block the unit up Use in pairs only Follow the instructions sup plied with the vehicle stands Keep hands hair clothing etc clear of the cooling
46. t Routing 8 Tensioning 7 5 Deck leveling 7 1 Electrical Schematic Kawasaki 8 1 Engine air 6 1 Engine oil and 6 1 Engine RPM settings 6 4 Fuel evaporative system line routings 6 2 Fuel evaporation system filter 6 2 General engine maintenance 6 1 General maintenance precautions 3 2 Hydraulic pump belt adjustment 5 5 Hydraulic system pe 5 6 Maintenance introduction 2 1 Maintenance Locator Chart 9 2 117604 i PAGE Maintenance precautions 3 2 Maintenance schedule 9 1 Mower blade maintenance 7 2 Mower blade removal 7 3 Operate machine safely 3 2 Park brake adjustment 5 4 Pre operation precautions 3 1 Safe servicing practices 3 1 Service Program pp 2 1 Special torques 4 1 Standard torques pp
47. the vehicle stands 1 125 3 175mm Shut engine off place steering control levers in the park brake position disengage deck clutch remove ignition switch key and disconnect negative battery cable before doing any adjustments Raise the rear of the mower and block with certified jack stands The rear wheels need to be able to rotate freely and clear of all obstructions Chock the front tires Position the steering control levers in the neutral position NOTE The front brake link is not to be adjusted Figure 5 10 Figure 5 10 5 Open the integrated transmission s bypass valve on the side that is being adjusted by turning the bypass lever counter clockwise until it stops The bypass levers on each integrated transmission are located near the bottom front Figure 5 11 Try and rotate the tire by hand The tire should rotate Remember hydraulic oil resistance will prevent the tire from rotating freely even with the bypass valves open There should be no resistance from the brakes at this point Move the steering control lever to where it is just inside 1 8 3 175mm the park brake slot Figure 5 12 NOTE When the steering control lever is against the outside edge of the slot the brakes should not be 117604 117604 a hi OY 175mm Figure 5 12 Rotate the tire If the brake is adjusted properly the tire will still rotate but friction will start to become noticeable here However if no b
48. ures are as follows Drive wheels 8 12 psi 55 83 Front 8 12 psi 55 83 KPa Stop engine Make sure deck clutch switch is the down OFF position Place control levers in the brake position before leaving machine WARNING 2 Parkthe unit on a flat surface 3 Place 3 high deck support blocks two stacked 2 x 4 blocks can be used to create 3 7 62cm high support at the locations as shown Figure 7 1 NOTE Back of deck will automatically be set 1 4 6 35mm higher 3 Block Ke H i H AA UL MOM H Ber 3 Block 3 Block Figure 7 1 4 Place the height stop in the 3 7 62cm hole with the plate side of the height adjusting stop against the stop handle 5 Clamp the height adjusting stop against the stop handle This will assure that the height will not move during the setting process Otherwise spring pressure from the deck lift springs will tend to pull the stop away from the handle Figure 7 2 6 Loosen all nuts on the deck lift threaded rods and the hardware on the height indicator bar on the right front until all the deck lift chains are loose and the deck is sitting tightly on all four blocks Figure 7 3 Figure 7 4 amp Figure 7 7 7 Loosen the two nuts on the front of height indicator so 117604 7
49. ut on the deck lift block Typical both sides Figure 7 4 28 When completed all chains will be tight and deck cutting height will be set to the deck height indicator Deck lift threaded foe Figure 7 7 Blades Mower blade maintenance Check the mower blades daily they are the key to power efficiency and well groomed turf Keep the blades sharp A dull blade will tear rather than cut the grass leaving a brown ragged top on the grass within a few hours A dull blade also requires more power from the engine 117604 Replace any blade which is bent cracked or broken IMPORTANT When mounting blades rotate them after WARNING 4 installation to ensure blade tips do not touch each other or sides of the mower WARNING 4 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 Failure to correctly torque the bolt may result in the loss blades of the blade which can cause serious injury Never work with blades while engine is running or deck Mower blades are sharp and can cut Wrap the blade s or clutch switch is engaged on Always place deck clutch wear gloves and use extra caution when servicing them switch in the disengag
50. ware holding the chain and adjuster onto the deck lift arm Figure 7 5 Lift block is Deck lift rod 19 20 21 22 23 24 25 REV C o Figure 7 4 Go to the right rear of the mower Make sure that there is still slack in the chain If not loosen the two nuts on the block holding the threaded rod until there is slack in the deck lift chain Tighten the appropriate nut until the chain just becomes tight and carries most of the deck weight Check by moving the block it should move with a slight drag Figure 7 6 Tighten the other nut on the opposite side of the block and jam them tightly together against the block Figure 7 5 Go to the left rear of the mower Make sure that there is still slack in the chain If not loosen the two nuts on the block holding the threaded rod until there is slack in the deck lift chain Figure 7 7 Tighten the appropriate nut until the chain just becomes tight and carries most of the deck weight Check by 7 2 O O Figure 7 6 moving the block it should move with a slight drag Figure 7 7 26 Tighten the other nut on the opposite side of the block and jam them tightly together against the block 27 Compress the deck lift assist springs so that there is 1 2 54cm of space between the front nut on the spring and the rear n
51. will cut or damage the fibers of the belt covering Keep oil and grease away from belts and never use belt dressings Any of these will destroy the belt composition in a very short time Deck Belt Adjustment The spindle belt tension remains constant by means of a tension idler and spring The spring tension should be such that the belt does not slip under normal operating load conditions assuming the belt is not excessively worn or damaged As the belt stretches and wears in adjustment may become necessary To increase belt tension move the spring chain one or more link s at the anchor point on the deck frame Figure 7 11 IMPORTANT Do not over tension the spring to compensate for a badly worn belt or pulley REV C 7 4 Spring chain anchor point Spring chain Idler spring Figure 7 11 117604 NOTE The following notes are the same for the different decks shown 1 Spring length after tensioning new belt Measured from outside of hook to outside of hook with deck set at 314 8 26cm cut height 2 Route belt as shown 52 amp 60 Deck Belt Routing amp Tensioning 9 3 10 3 23 6 26 2cm m Figure 7 12 117604 7 5 REV 117604 REV C 7 6 ELECTRICAL Electrical Schem
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