Super Z® General Service Manual
Contents
1. y 9 y m e 9 3 10 3 236 262mm e Figure 6 17 6 8 113957 ELECTRICAL Electrical Schematic Kawasaki amp Kohler IGNITION 9 RED BLK 18 E 787 SWITCH K 8 14 CLUTCH SWITCH G 30 BLK 18 d T 2 12 18 I 20 ORG RED 18 SEAT SWITCH 13 18 21 TAN 18 NEUTRAL NEUTRAL SWITCH SWITCH t 14 ORG 18 Pt 22 TAN RED 18 di 23 TAN RED 18 E OIL l 5 55 N Ce 15 ORG 18 DN HA V MPY Ji MY JD Jh Am 16 ORG 18 HOUR 31 BLK 18 S i SPARK IGNITED CONTROLLER s 17 BLU 14 8 2 Fr __ mE _ e Se 2 __ AUX S SEA MEA IEA nek ITEM 32 14 N N N d 7 6 RED 14 E 18 18 E e 19 ORG 18 5 El El Ej lt 2 8 8 E el 8 4 H 8 40 p d 3 RED 12 1 PUR 10 ofstakT ON E ux TOIL PRESS Da FAN CLUTCH 2 KILL 12VDC O Sn BATTERY da I 1 1 1 1 2 36 BLK GROUND SPLICE ENGINE H 34BLK2. Spring chain Spring chain anchor point Figure 6 13 72 Rear Discharge Deck Idler spring Spring Spring chain anchor point Figure 6 14 113957 6 5 REVE 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 34 82 6mm cut height 2 Route belt as shown 60 66 amp 72 Side Discharge Deck Belt Routing amp Tensioning Figure 6 15 REVE 6 6 113957 60 Rear Discharge Deck Belt Routing amp Tensioning 9 3 10 3 236 262mm D 9 3 10 3 236 262mm Figure 6 16 113957 6 7 REVE 72 Rear Discharge Deck Belt Routing amp Tensioning REVE E 3 9 3 10 3 236 262mm
3. 2 2 Maintenance 2 2 Rei de a o a EE 3 1 Standard Torques ee Ea 3 1 Special TOQUES atts static os eee koe ee 3 1 Power Unit 4 1 Steering 5 4 1 Park brake adjustment 4 4 BES pte Dia a 4 5 Hydraulic Pump Belt 4 5 Hydraulic system 4 5 Test Procedure for DDC20 Pump 4 6 New or Rebuilt DDC20 Pump Startup Procedure 4 7 Warner Clutch Re gap Adjustment Procedures 4 9 EET 4 11 Engine Maintenance 5 1 General Engine 5 1 Engine Oiland Filtet xx dt aes esos ea ees 5 1 Engine Ait Fiter e ca ce rar E AAG t a ee 5 1 sea rus se EE 5 2 Fuel evaporation system filter 5 2 Fuel amp evaporative system line 05 5 3 Engine RPM 5 5 5 5 Deck Adjustments e cord d oe 6 1 Deck be Velit sa nere ree 6 1 Blades a Ne 6 3 Bells sow du suis mo d tai ide 6 4 Deck Bel
4. 3 1 Steering adiusiments 4 1 Steering control lever adjustment 4 3 Steering control lever neutral adjustment 4 1 Steering 4 2 Warner Clutch Re gap Adjustment Procedures 4 9 Warranty end idee dee de eee deze 1 1 REV E REVE 1 2 113957
5. 3 Block Rear Discharge Deck shown Figure 6 2 setting process Otherwise spring pressure from the deck lift springs will tend to pull the stop away from the handle Figure 6 3 6 Loosen all nuts on the deck lift threaded rods and the hardware on the height indicator bar on the right front until all the deck lift chains are loose and the deck is sitting tightly on all four blocks Figure 6 4 Figure 6 5 amp Figure 6 8 7 Loosen the two nuts on the front of height indicator so that the foot pedal is free Figure 6 4 amp Figure 6 8 8 Start the leveling process on the left front of the mower 9 Set the amount of threads protruding on the deck lift rod from the lift block at approximately 1 25 4mm left amp right side Figure 6 5 10 Jam both nuts against the block Clamp here d Stop handle Deck adjustment stop Figure 6 3 REVE 12 13 14 15 16 17 18 Foot pedal Nuts O O Figure 6 4 Push or pull on the deck lift foot pedal until the chain on the left front just becomes tight making sure that the deck stays tight against the block While keeping the chain tight tighten the nuts against the deck lift block on the height indicator rod just enough to carry most of the deck weight on that side the block should be able to move with only a slight drag Figure 6 5 Jam nuts ti
6. Tires improperly inflated Adjust air pressure to 8 12 psi 55 83 KPa Hydraulic pump faulty Contact your dealer Numerous See engine manual Engine Runs with continuous mis firing or engine runs unevenly or erratically Numerous See engine manual Mower creeps when park ing brake engaged Steering linkage out of adjustment Adjust steering linkage Brakes need adjustment Adjust parking brakes Loss of power or system will not operate in either direction Restrictions in air cleaner Service air cleaner Hydraulic line blockage See your dealer Internal interference or leakage in wheel motor See your dealer Insufficient hydraulic oil supply Check level in reservoir Have dealer check hydrau lic pump Poor compression See your dealer Steering linkage needs adjustment Adjust linkage There is abnormal vibra tion he engine mounting bolts are loose Tighten the engine mount ing bolts he engine pulley idler pul or blade pulley is loose Tighten the appropriate pul ley he engine pulley is dam aged Contact your dealer he 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
7. 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 For additional causes See engine manual 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 Low engine oil pressure High oil consumption Low oil level Add oil Oil diluted or too light Change oil and check for source of contamination Failed oil pump Numerous Contact your dealer Contact your dealer 113957 REVE SYMPTOMS PROBABLE CAUSES SUGGESTED REMEDIES Uneven cutting height The blade s are not sharp Sharpen the blades A cutting blade s is are bent Install new cutting blade s The deck is not level Level the deck per the Deck leveling and height adjustment section of the General Service Manual An anti scalp wheel is not set correctly Adjust the height of the anti scalp wheel The underside of the deck is dirty Clean the underside of the deck Tires improperly inflated Adjust air pressure to 8 12 psi 55 83 KPa A blade spindle is bent Contact your dealer RE
8. a Loosen the brake linkage jam nuts Figure 4 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 b Place the control lever in the park brake slot The tire should not rotate when the control lever is in the park brake position Figure 4 12 c Place the control lever in the neutral position The tire should rotate freely 9 Close the hydraulic pump s bypass valve Figure 4 11 10 Repeat steps 4 through 9 for the other side 11 Check to make sure all tools or obstructions are removed from under the mower 12 Raise the rear of the mower and remove the jack stands Lower the mower 13 Reconnect the negative battery cable 14 Lower and secure the seat platform 2 Figure 4 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 otherwise the belt will lose power and slip excessively Never pr
9. 60 Rear Discharge Deck 16 17 19 72 Rear Discharge Deck 113957 8 5 PWONOARON gt 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 Spindle Housing Zerk 3 Blades Fuel Evaporation System Filter Hydraulic Oil Heat Exchanger Carbon Canister REVE REVE 8 6 113957 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 SYMPTOMS PROBABLE CAUSES SUGGESTED REMEDIES Starting motor does not crank Steering control levers not in park brake position or switch not adjusted Place steering control levers in park brake posi tion or re adjust switch Deck clutch switch engaged Disengage clutch swit
10. below It is i easier to get a straight cutting edge following Deck Belt Adjustment the resharpening pattern shown above The spindle belt tension remains constant by means of a tension idler and spring The spring tension should be such that the belt does not slip under normal operating load conditions assuming the belt is not excessively worn or damaged As the belt stretches and wears in adjustment may become necessary To increase belt tension move the spring chain one or more link s at the anchor point on the deck frame Figure 6 12 Figure 6 13 Figure 6 14 Figure 6 15 Figure 6 16 amp Figure 6 Original edge 17 IMPORTANT Do not over tension the spring to compensate for a badly worn belt or pulley Figure 6 9 ir Spring chain anchor point Warped Blade Replace Cutting plane 55 A Straight Blade Comparison of Warped and Straight Blades Figure 6 10 Cutting edge Figure 6 12 Twisted Blade Edge replace Cutting Plane Cutting edge Straight Blade Edge End view of blades comparing twisted and straightened blades Figure 6 11 Belts Inspect belts frequently for wear and serviceability Replace a belt that shows signs of severe cuts tears separation weather checking and cracking or burns caused by slipping Slight REVE 6 4 113957 60 Rear Discharge Deck
11. 8 4 20 Mowers prior to serial number 12071770 Figure 8 5 Carbon canister equipped machines Mowers prior to serial number 12071770 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 10 Engine Oil Filter 11 Deck Height Pivot Zerks 4 12 Park Brake Switch 13 Drive Tires 14 Pump Idler Zerk 1 15 Pump Belt 16 Deck Pusher Arm Zerks 2 17 Deck Belt 18 Spindle Housing Zerk 3 19 Blades 20 Fuel Evaporation System Filter 21 Hydraulic Oil Heat Exchanger 22 Carbon Canister REVE Figure 8 6 Figure 8 7 Mowers after to serial number 12071770 Carbon canister equipped machines Mowers after to serial number 12071770 8 4 113957 Figure 8 8
12. 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 REVE 113957 Table of Contents General Information 1 1 Semice AAA Saws wie we wees Phen ees 1 1 Maintenance 1 1 1 Warranty een 1 1 ecards aa a a 2 1 Safe Servicing Practices 2 1 Pre Operation lt 2 1 Operation 5 2 2 Operate Machine 5 2 2 General Maintenance
13. Open the hydraulic pump s bypass valve on the side that is being adjusted by turning the bypass valve counter clockwise one half to one revolution Figure 4 11 Figure 4 11 6 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 4 12 NOTE When the steering control lever is against the outside edge of the slot the brakes should not be engaged plied with the vehicle stands 1 Shut engine off place steering control levers in the park brake position disengage deck clutch remove ignition switch key and disconnect negative battery cable before doing any adjustments 2 Raise the rear of the mower and block with certified jack stands The rear wheels need to be able to rotate freely and clear of all obstructions 3 Chock the front tires 4 Position the steering control levers in the neutral position NOTE The front brake link is not to be adjusted Figure 4 10 3 175mm Figure 4 12 Figure 4 10 8 Rotate the tire If the brake is adjusted properly the tire will still rotate but friction will start to become noticeable REVE 4 4 113957 here However if no brake resistance is noticed the brake needs adjusted as follows
14. Then slowly move steering control lever in reverse You should easily get a 2600 PSI reading from the other gauge Caution do not hold steering control lever in rearward position for more than 10 seconds as oil will become extremely hot If pressure is less than 2600 PSI causes are internal relief valve is faulty or internal pump parts are damaged NOTE Anytime a hydraulic pump is replaced the drive motor hydraulic lines and oil cooler must be inspected and from the seat switch Bypass the seat switch by 12 connecting the two mower harness female spades 13 together Figure 4 1 Female spades Seat switch harness Figure 4 17 cleaned or replaced due to possible contamination 4 Remove the tire and wheel assembly After testing is concluded 5 Clean hydraulic oil lines connecting to motor thoroughly 1 IMPORTANT With the engine off disconnect the two Contamination allowed to enter in the hydrostatic system can cause pump and motor failures After cleaning remove oil supply lines from the motor and loosen supply lines at the pump One wheel motor 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 properly Figure 4 1 fitting may need to be removed to assist with test line installation Cap the wheel motor ports or fittings 7 Test procedures are the same for both the right and left sides 8 Install Hustle
15. batteries in an open well ventilated area away from sparks and flames Unplug charger before connect ing or disconnecting from battery Wear protective cloth ing and use insulated tools A Avoid skin and clothing contact with battery acid Always wear eye protection when checking the battery acid can cause serious injury to skin and eyes If con tact occurs flush area with clean water and call physi cian immediately Acid will also damage clothing Do not drink the battery electrolyte Do not allow open flame near the battery when charg ing Hydrogen gas forms inside the battery This gas is both toxic and flammable and may cause an explosion if exposed to flame Always disconnect the negative black battery cable s before disconnecting the posi tive red cable s Always connect the positive red battery cable s before connecting the negative black cable s Do not overfill battery Electrolyte may overflow and damage paint wiring or structure When cleaning the battery use soap and water Be careful not to get soap and water into the bat tery Clean the battery terminals with a solution of four 113957 2 3 parts water and one part baking soda when they become corroded A Shorts caused by battery terminals or metal tools touch ing metal mower components can cause sparks Sparks can cause a battery gas explosion which will result in per sonal injury Prevent the battery terminals from touching any metal mo
16. 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 Lower and secure the seat platform New or Rebuilt DDC20 Pump Startup Procedure NOTE Use this startup procedure any time a DDC20 pump has been removed for service or replaced 11 Run engine at mid throttle for one or two minutes or until top of pump is warm to the touch 113957 4 7 REVE Pressure Test Gauge Kit shown installed REVE Figure 4 19 4 8 Bypass valve Tow valve RH Pump as viewed from rear of mower Figure 4 20 Pump replacement WARNING A This procedure will require that the unit to be raised and blocked up off of the ground It is necessary for the wheels to rotate without coming in contact with the floor or any object that would permit the unit to propel itself Stay clear and exercise caution when rotating wheels to prevent injury Use only appropriate vehicle stands with a minimum weight rating of 2000 pounds to block the unit up Use in pairs only Follow the instructions sup plied with the vehicle stands WARNING A Untrained maintenance personnel should never attempt to make any adjustments or repairs to the mower s drive system while the engine is running The following proce dures should be performed by trained maintenance personnel only 1 Raise the rear of the mower and bl
17. which is rotating too fast and turn the stop set screw inward to stop the steering control lever sooner Tighten the lock nut on the stop and test again 3 Repeat this procedure until unit drives straight NOTE Since this is a hydrostatic drive variables such as temperature of oil efficiency of pumps and motors tire pressure etc may effect the consistency of the ability to rely on the stops to drive straight without the operator making minor steering adjustments with the control arms Steering 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 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 4 6 3 Loosen the steering damper s rear ball stud Figure 4 7 4 Pull the damper spring housing past the point that the internal spring is engaged Figure 4 7 113957 Steering control F lever Figure 4 5 Release the damper spring housing and allow the internal spring to bring the housing back to the neutral position Tighten the nut on the steering damper s front ball stud NOTE The damp
18. 16 35 BLK 16 113957 7 1 REVE REVE 7 2 113957 Maintenance Schedule Figure 8 1 Figure 8 2 Figure 8 3 Figure 8 4 Figure 8 5 Figure 8 6 Figure 8 7 Figure 8 8 amp Figure 8 9 SERVICE AT INTERVALS INDICATED WEEKLY MONTHLY ANNUALLY OR 50 OR 100 OR 500 HOURS HOURS HOURS Verify safety start interlock system Prior to each use Visually inspect unit for loose hardware and or damaged parts Prior to each use Visually inspect tires Prior to each use Check oil level engine 1 Prior to each use or every 4 hours Clean oil heat exchanger 8 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 pump 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 x Xx Xx Clean engine exterior a Grease deck pusher arms 5 Grease pump idler 5 Grease deck height pivots 5 Grease front wheel bearings 5 Clean amp regap spark plugs a Check pump and deck belt tension and conditi
19. N Fuel evaporation tank SY system filter Carbon canister Lo z Fuel evaporation 2 system filter Figure 5 13 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 FX730 FX850 FX1000 8 DFI FX850 ENGINE SPEED MODEL NO ENDING WITH HIGH IDLE MODEL NO WITHOUT EXTENSION 3600 RPM Kohler CV730 amp CV740 ENGINE SPEEDS MODEL NO ENDING WITH HIGH IDLE MODEL NO WITHOUT 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 113957 5 5 REVE REVE 5 6 113957 DECK ADJUSTMENTS Deck Leveling Leveling the deck must be done in the following manner and order 1 Check tire pressures to make certain they are properly inflated before starting to level deck The recommended pressures are as follows Drive wheels 8 12 psi 55 83 KPa Front wheels 8 12 psi 55 83 KPa A Stop engine Make sure deck clutch switch is in the down OFF positi
20. Repeat for the opposite side if necessary 9 When both wheels remain in neutral tighten the jam nuts to lock the turnbuckle in place 10 Test again by moving the steering control levers forward and backward before returning them to the neutral position If the tires are in neutral the unit is now ready for operation 11 After adjusting for neutral it may be necessary to re adjust the control lever stop and or damper 12 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 properly Figure 4 1 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 WARNING A WARNING Never operate the mower with a 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 14 Raise the rear of the mower and remove the jack stands Lower the mower 15 Lower and secure the seat platform Conirol lever stops The steering control lever stops see Figure 4 4 are designed to do two things First and most important they must keep the pumps from bottoming out internal
21. Super Z General Service Manual 200 South Ridge Road Hesston Kansas 67062 2097 113957 REV E A WARNING A The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm NOTICE OF REQUIREMENT OF SPARK ARRESTER MUFFLER This equipment may create sparks that can start fires around dry vegetation California Public Resources Code Section 4442 6 provides that it is unlawful to use or operate an internal combustion engine on any forest covered brush covered or grass covered land unless the engine is equipped with a spark arrester maintained in effective working order A spark arrester is a device constructed of nonflammable materials specifically for the purpose of removing and retaining carbon and other flammable particles over 0 0232 of an inch in size from the exhaust flow of an internal combustion engine that uses hydrocarbon fuels or which is qualified and rated by the United States Forest Service Other states or federal areas may have similar laws The Operator Should Contact Local Fire Agencies For Laws or Regulations Relating to Fire Prevention Requirements THIS EQUIPMENT DOES NOT HAVE A SPARK ARRESTER AND YOU SHOULD CONTACT YOUR AUTHORIZED DEALER FOR THE PURCHASE OF A SPARK ARRESTER Inspect spark arrester daily replace every 500 hours or as needed The Engine Owner s Manual provides information regarding the U S Environmental Protection
22. VE 9 2 113957 Ie ees 4 5 6 4 Blades iia edil 6 3 Control lever stops 2 4 2 Deck Belt 6 4 Deck Belt Routing Tensioning 6 6 6 7 6 8 Deck leveling etc eet ete Pets 6 1 Electrical Schematic Kawasaki amp Kohler 7 1 Engine ait flIter iiie tI ei i tin 5 1 Engine oil and filter 5 1 Engine RPM 5 5 Fuel amp evaporative system line routings 5 3 Fuel evaporation system filter 5 2 General engine 5 1 General maintenance precautions 2 2 Hydraulic pump belt adjustment 4 5 Hydraulic 8 4 5 113957 Maintenance 1 1 Maintenance 2 2 Maintenance schedule 8 1 Mower blade maintenance 6 3 Mower blade removal 6 3 Operate machine safely 2 2 Pre operation Drecautonsg 2 1 Safe servicing 2 1 Service Program 1 1 Standard
23. ands 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 Untrained service 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 service person nel only WARNING The drive system of this mower consists of two independent pump motor combinations and will need to be tested separately The oil supply reservoir filtering system located in the bottom of the reservoir and oil cooler are shared between the two independent systems The testing sequence below is testing the hydrostatic pumps only If the test shows satisfactory results but performance is still deemed unacceptable the motors filtering oil cooler and reservoir should be inspected 1 Raise the rear of the mower and block with certified jack stands The rear wheels need to be able to rotate freely and clear of all obstructions 2 Chock the front tires 3 Raise the seat platform and disconnect the mower harness 113957 Increase engine speed to full throttle Slowly move the steering control lever forward You should easily get a 2600 PSI reading from one of the gauges Return steering control lever to neutral Caution do not hold steering control lever in forward position for more than 10 seconds as oil will become extremely hot
24. any distorted blade Do not re use spindle bolts which have stripped worn or undercut threads Torque bolts on spindles to 118 foot pounds 160 0 N m when reinstalling blades Properly compressed cup washers maintain the correct compression load on the blades Replace the cup washers if they are cracked or flattened IMPORTANT The blade sail curved part must be point ing upward toward the inside of the deck to ensure proper cut ting IMPORTANT When mounting blades rotate them after installation to ensure blade tips do not touch each other or sides of the mower Failure to correctly torque the bolt may result in the loss of the blade which can cause serious injury Mower blades are sharp and can cut Wrap the blade s or wear gloves and use extra caution when servicing them WARNING WARNING REVE 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 Resharpening bottom of the groove Replace the pulley when this is the case pattern 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 Do not sharpen to original pattern
25. bon canister and grommets Repair as needed More often under dusty or dirty conditions and during hot weather 8 1 REVE 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 for engine service information NOTE After completing maintenance cycle 500 hours repeat cycle REVE 8 2 113957 Maintenance Locator Chart 2 11 Mowers prior to serial number 12071770 Figure 8 1 OPASDARON 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 Spindle Housing Zerk 3 Blades Fuel Evaporation System Filter Hydraulic Oil Heat Exchanger Carbon Canister Mowers after serial number 12071770 Figure 8 2 113957 8 3 REVE Figure 8 3 Figure
26. ch Weak or dead battery Recharge or replace Mower jerky when starting or operates in one direc tion only Steering control linkage needs adjustment Adjust linkage Pump or wheel motors faulty Contact your dealer Tow valves not closed com pletely Close tow valves 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 Hydraulic system oper ates hot oil in reservoir smells rancid Low hydraulic oil level Fill reservoir Hydraulic pump faulty Contact your dealer Hydraulic oil heat exchanger clogged Clean oil heat exchanger core Fuel valve is turned off Open the fuel valve Mower creeps when steering control levers are in neutral Steering linkage needs adjustment Adjust linkage 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 Mower circles or veers in one direction Steering linkage needs adjustment Wheel motors faulty Adjust linkage Contact your dealer
27. ed below Figure 4 25 the brake pole and around the aluminum spacers Figure 1 Loosen both brake mounting bolts 1 2 to 1 full turn as 4 24 shown in Figure 4 26 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 4 28 and Figure 4 29 a If the gap is less than 015 the clutch must be replaced REVE 4 10 113957 Figure 4 27 b If sufficient gap is present then proceed to safety check outlined below Figure 4 28 Perform safety check WARNING Observe deck operation from the operator s seat 1 Start the engine and the deck should not be engaged with 113957 4 11 Figure 4 29 the PTO switch off and clutch de energized Engage and disengage the PTO switch to ensure the proper function of the clutch 2 If clutch still does not engage then follow troubleshooting procedure outlined in Warner Electric P1177 installation troubleshooting guide available on Warner Electric s web site www Warnerelectric com and consult owner s manual Tires It is important for level mowing that the tires have the same amount of air pressure The recommended pressures are Drive wheels 8 12 psi 55 83 KPa Front wheels 8 12 psi 55 83 KPa If you wish to use non pneumatic tires on your Hustler mower the tires must be an appr
28. er must not bottom out when the pump lever is fully stroked in either direction Reconnect the negative battery cable Lower and secure the seat platform 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 Steering control lever shown in park brake position Figure 4 6 Steering control lever adjustment The steering control levers can be adjusted for operator comfort 113957 4 3 1 Steering damper spring housing Figure 4 7 By loosening 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 Figure 4 8 The steering control levers should be adjusted so that they align vertically with each other when in the neutral position Figure 4 9 REVE Align steering control lever 1 125 3 175mm Figure 4 9 Park brake adjustment WARNING This procedure will require that the unit be raised and blocked up off of the ground It is necessary for the wheels to rotate without coming in contact with the floor or any object that would permit the unit to propel itself Stay clear and exercise caution when rotating wheels to prevent injury Use only appropriate vehicle stands with a minimum weight rating of 2000 pounds to block the unit up Use in pairs only Follow the instructions sup
29. f the mower Make sure that there is still slack in the chain If not loosen the two nuts on the block holding the threaded rod until there is slack in the deck lift chain Figure 6 8 Tighten the appropriate nut until the chain just becomes tight and carries most of the deck weight Check by moving the block it should move with a slight drag Figure 6 8 Tighten the other nut on the opposite side of the block and jam them tightly together against the block Compress the deck lift assist springs so that there is 1 25 4mm of space between the front nut on the spring and the rear nut on the deck lift block Typical both sides Figure 6 5 When completed all chains will be tight and deck 113957 cutting height will be set to the deck height indicator Nut dn Deck lift threaded fod PL ee Chains Figure 6 8 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 Replace any blade which is bent cracked or broken WARNING A A Never attempt to straighten a bent blade by heating or weld a cracked or broken blade as the blade may break and cause serious injury Replace worn or damaged blades Never work with blades while engine is running or deck clutch sw
30. ghtly together against the deck lift block Go to the right front of the mower Loosen the 5 16 jam nut on the adjuster lift chain and back the adjuster bolt out to allow the adjuster to move up and down freely Figure 6 6 Tighten the adjuster bolt until the chain just becomes tight Then tighten just enough to carry the weight of the front of the deck on that side to check move the blocks back and forth they should move with a slight drag Figure 6 6 Tighten the adjuster bolt jam nut to prevent the adjuster bolt from moving Figure 6 6 Tighten the hardware holding the chain and adjuster onto the deck lift arm Figure 6 6 Lift block L Deck lift rod E 19 20 REVE Figure 6 5 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 6 2 21 22 23 24 25 26 27 28 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 6 7 Tighten the other nut on the opposite side of the block and jam them tightly together against the block L 516 I Figure 6 6 Chains O Figure 6 7 Go to the left rear o
31. h 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 WARNING Untrained maintenance personnel should never attempt to make any adjustments or repairs to the mower s drive system while the engine is running The following proce dures should be performed by trained maintenance personnel only 1 Raise the rear of the mower and block with certified jack stands The rear wheels need to be able to rotate freely and clear of all obstructions 2 Chock the front tires 3 Raise the seat platform and disconnect the mower harness from the seat switch Bypass the seat switch by connecting the two mower harness female spades together Figure 4 1 Start the engine 5 Position the steering control lever in the neutral position and observe which way the wheels are rotating Figure 4 gt 113957 4 1 6 7 8 spades Control lever 4 2 If wheel s rotating forward loosen the jam nuts on the pump linkage rods and rotate the rod to lengthen the steering control linkage until the wheel s come to a stop Figure 4 3 Repeat for the opposite side if necessary Pump linkage rod Figure 4 3 If wheel s are rotating in reverse then loosen the jam nuts on the pump linkage rods and rotate the rod to REVE shorten the steering control linkage until the wheel s come to a stop Figure 4 3
32. igure 5 1 1 Locate the oil drain valve on the engine 2 Locate the oil drain hose that was supplied with the machine Be sure to clean and clear it of debris that might block the flow of the engine oil 3 Attach one end of the hose onto the oil drain valve nipple Make sure the hose is pushed all the way onto the valve 4 Position the loose end of the hose out thru the slot cut in the engine base plate so that it can drain into a suitable oil drain container 5 With the hose position twist the valve counterclockwise to open the valve Allow 10 minutes for engine oil to adequately drain 6 After oil is drained close the valve by twisting it clockwise 7 Once the valve is closed carefully remove the oil drain hose and clean up any spilled oil IMPORTANT All oil drips or spills must be cleaned off of the exhaust system before operating the machine 8 Clean the oil drain hose and store it appropriately Engine Air Filter Perform engine air filter maintenance per the Maintenance Schedule shown elsewhere in this manual These mowers are equipped with a safety filter The filter 113957 5 1 Oil drain hose Figure 5 1 element slides over the safety filter The safety filter does not require servicing unless it becomes contaminated with dirt or moisture Figure 5 2 Figure 5 2 Cartridge type filter A specially designed dry filter is standard equipment on Super Z mowers which supplies clean combustion a
33. ing at all times until fueling is com plete Do not use a nozzle lock open device Never use gasoline or diesel fuel for cleaning parts Read and observe safety precautions elsewhere in this manual A Gasoline and diesel fuel is harmful or fatal if swallowed Long term exposure to vapors can cause serious injury and illness Avoid prolonged breathing of vapors Keep face away from nozzle and gas tank or fuel con tainer opening Keep fuel away from eyes and skin If fuel 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 opera
34. ir to the engine An example of the air filter is shown in Figure 5 3 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 REVE 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 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 a 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 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 i
35. itch is engaged on Always place deck clutch switch in the disengaged position place steering control levers in the park brake position and turn engine off and disconnect negative battery cable Block up mower when you must work under it Wear gloves when handling blades Always check for blade damage if mower strikes a rock branch or other foreign object during mow ing Always wear adequate eye protection when grinding mower blades WARNING WARNING A 113957 6 3 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 6 9 Touch up sharpening can be done with a file Check the blades for balance following grinding A commercial balancing tool is available through most hardware supply stores or balancing can be done by placing the blade on an inverted line punch or 5 8 bolt Blade should not lean or tilt Spin the blade slowly blade should not wobble If blade is out of balance true it up before reinstalling Lay the blade on a flat surface and check for distortion Figure 6 10 amp Figure 6 11 Replace
36. levers in the park brake position immediately Inspect the machine and involve your dealer to resolve the problem A WARNING Bottom View e of o e kn C l Hydraulic pump belt 8 25 8 75 Spring 209 222mm Figure 4 14 Hydraulic system IMPORTANT Never use hydraulic or automatic transmis sion fluid in this system use only motor oil as specified Remember dirt is the primary enemy of any hydraulic system A A WARNING Hydraulic fluid escaping under pressure may have suffi cient force to penetrate skin and cause serious injury For eign fluid injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result REVE Before applying pressure to hydraulic system make sure all connections are tight and all hoses and lines are in good condition To find a leak under pressure use a piece of cardboard or wood never use your hands Relieve all pressure in the system before disconnecting or work ing on hydraulic lines To relieve pressure lower all attachments and shut off engine Check oil level in hydraulic system after every 50 hours of operation or weekly whichever occurs first Check more often if syste
37. ly Secondly the stops may be adjusted to help drive straight when the steering control levers are pushed forward against the stops To keep the pumps from bottoming out internally use the following procedure This adjustment is only required if the hydraulic pump s have been replaced Pump damage will occur if these stops are set incor rectly WARNING A 1 To make the first adjustment the mower engine must not be running 2 Check to make sure the steering control levers are against REVE 4 2 the stops before the pumps are bottomed out internally 3 To do this gently and slowly move the steering control levers forward and feel if there is some resistance on the pump lever before the control levers hit 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 Figure 4 4 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 control panel see Figure 4 5 2 Then stop the mower and loosen the lock nut on the side
38. m appears to be leaking or otherwise malfunctioning Fluid level should be 1 25 4mm from top of reservoir Use only 15W50 Mobil One service motor oil Figure 4 15 Change hydraulic system filter element and oil after first 50 hours of machine operation then replace filter and oil in reservoir every 500 hours thereafter Figure 4 15 The Super Z system filter is located inside the hydraulic reservoir on the underneath side of the tank Use a 15 16 socket to change the filter threads are right handed Use a Hustler Turf Equipment approved filter element only Hydraulic reservoir Figure 4 15 Hydraulic oil heat exchanger The Super Z is equipped with a hydraulic oil heat exchanger The heat exchanger coils must be kept clean to insure that the hydraulic oil is operating within the correct temperature range Check and clean the heat exchanger daily and more often in dirty dusty conditions Figure 4 16 Test Procedure for DDC20 Pump Equipment required Hustler Pressure Test Gauge Kit part number 007898 REV E 4 6 d Heat exchanger Eu Figure 4 16 Pump test procedure WARNING This procedure will require that the unit to be raised and blocked up off of the ground It is necessary for the wheels to rotate without coming in contact with the floor or any object that would permit the unit to propel itself Stay clear and exercise caution when rotating wheels to prevent injury Use only appropriate vehicle st
39. n Do not remove fuel cap or fill tank with engine run ning or while engine is hot Clean up any fuel spills Allow engine to cool before storing machine inside a building Keep fuel away from open flame or spark and store machine away from open flame or spark or pilot light such as on a water heater or appliances Use extreme care when handling gasoline and other fuels They are extremely flammable and vapors are explosive A fire or explosion from fuel can burn you and others and can damage property 113957 2 1 Refuel outdoors Never refuel or drain the fuel from the machine indoors Never attempt to start engine when there is a strong odor of gasoline or diesel fuel fumes present Locate and correct cause Store fuel in an approved container and keep it out of the reach of children Never buy more than a 30 day supply of fuel Do not fill fuel containers inside a vehicle or on a truck or trailer bed with interior carpets or plastic truck bed liners Always place fuel containers on the ground away from your vehicle before filling When practical remove gas or diesel fuel powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground If this is not possible then refuel such equipment on the truck or trailer using a portable container and not a fuel dis penser nozzle If a fuel dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container open
40. nder the deck as the mower blades are extremely sharp Wrap the blade s or wear gloves and use extra caution when servicing them A Use only genuine Hustler replacement parts to ensure that original standards are maintained Maintenance Precautions Avoid Fire Hazards A Be prepared if an accident or fire should occur Know where the first aid kit and the fire extinguishers are located and how to use them A Provide adequate ventilation when charging batteries A Do not smoke near battery A Never check fuel level with an open flame A Never use an open flame to look for leaks anywhere on the equipment A Never use an open flame as light anywhere on or around the equipment A When preparing engine for storage remember that fuel stabilizer is volatile and therefore dangerous Seal and 113957 tape openings after adding the inhibitor Keep container tightly closed when not in use A Inspect electrical wiring for worn or frayed insulation Install new wiring if wires are damaged Prepare For Emergencies A Be prepared if a fire starts A Keep a first aid kit and fire extinguishers available A Keep emergency numbers for doctor ambulance service hospital and fire department near the telephone Prevent Battery Explosions A Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling A Charge
41. ock with certified jack stands The rear wheels need to be able to rotate freely and clear of all obstructions 2 Chock the front tires 3 Raise the seat platform and disconnect the mower harness from the seat switch Bypass the seat switch by connecting the two mower harness female spades together Figure 4 21 4 Before installing pump on machine either new or rebuilt fill pump case with fresh clean oil by removing case drain plug and add 6 8 oz of 15W50 Mobil oil then install the hose fitting Figure 4 22 113957 Female spades Mower harness Prefill pump here Right side pump Left side pump Prefill pump here 113957 Figure 4 22 4 9 Install pump on machine and install lines 6 Check reservoir for contamination metal particles dirt water etc and clean if necessary Replace hydraulic filter and fill reservoir with oil until it is just below the reservoir neck 7 Do not open tow valves 8 Place the steering control levers in the neutral position 9 Set engine throttle to the half throttle position 0 Start engine Run at idle for 30 seconds 11 Stroke steering control lever to the forward position NOTE If wheel motor does not rotate in 15 seconds return steering control lever to neutral and shut off engine Check hydraulic oil level and replenish if needed Repeat steps 8 thru 11 12 After wheel motor starts to rotate increase engine speed to half th
42. on 6 Check fuel system 7 Check hydraulic lines Check fuel valve and grommet 7 XJ X X X X X XxX X x x Tighten lug nuts on wheels 2 Change fuel filter 7 Clean or replace hydraulic fill cap Change hydraulic filter amp oil 3 Grease deck spindle housings Replace spark plugs Check ROPS mounting hardware 9 Replace fuel evaporation system filter 8 X X XxX X Xx Xx Xx NOTES 1 RON gt 113957 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 ing hot weather periods Torque initially and after first 2 hours of operation Perform initial hydraulic oil and filter change after 50 hours one week 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 car
43. on Place control levers in the brake position before leaving machine A WARNING 2 Park the unit on a flat surface 3 Side Discharge Decks Place 3 high deck support blocks two stacked 2 x 4 blocks can be used to create a 3 76 2mm high support at the four corners of the deck marked with the locator triangle as shown Figure 6 1 NOTE Back of deck will automatically be set 1 4 6 35mm higher Rear Discharge Deck all Figure 6 2 Place two 3 75 95 3mm high deck support blocks two stacked 2 x 4 blocks and one 1 x 4 can be used to create a 3 75 95 3mm high support at the front of the deck as shown Place two 3 high deck support blocks two stacked 2 x 4 blocks can be used to create a 3 76 2mm high support at the sides of the deck as shown 4 VX4 Side Discharge Decks Place the height stop in the 3 76 2mm hole with the pin side of the height adjusting stop against the stop handle Rear Discharge Decks all Place the height stop in the 3 25 82 6mm hole with the plate side of the height adjusting stop against the stop handle Locator triangle Figure 6 1 5 Clamp the height adjusting stop against the stop handle This will assure that the height will not move during the 113957 6 1
44. oved tire purchased from Hustler Turf Equipment Warranty claims will be denied on any mower equipped with unapproved non pneumatic tires REVE REVE 4 12 113957 ENGINE MAINTENANCE General Engine Maintenance IMPORTANT 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 servic ing lubricating oil levels with quality and viscosity recommen dations 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 oil recommendation and capacities Change the engine oil and filter after the first 5 hours of operation and per the engine manufacturer s recommendations after that If mower is being operated in extremely dirty conditions then it is recommended oil be changed more frequently IMPORTANT When removing the oil filter take precautions to minimize oil spillage on the exhaust system Draining the engine oil F
45. platform areas minute dust particles are abrasive to close tolerance engine and hydraulic assemblies 113957 1 1 Daily inspect mower for grass clippings and wire and string tangles The underside of the mower deck will collect a build up of grass clippings and dirt especially when grass is wet or has high moisture content This build up will harden restricting blade and air movement and will probably show a poorer quality of cutting Therefore it should be removed routinely To do this it will be necessary to raise and block the deck using jack stands or blocks in the full up position and scrape the build up from underneath Some repairs require the assistance of a trained service mechanic and should not be attempted by unskilled personnel Consult your Hustler Turf Equipment service center when assistance is needed Information included in this manual was current at the time of printing but subsequent production changes may cause your machine to vary slightly in detail Hustler Turf Equipment reserves the right to redesign and change the machine as deemed necessary without notification If a change has been made to your machine which is not reflected in this service manual contact the Customer Service Department at Hustler Turf Equipment for additional information Warranty Warranty repair must be performed by a Hustler Turf Equipment Authorized Dealer before warranty credit can be allowed Work performed by anyone other
46. r Test Gauge Kit p n 007898 as shown in Figure 4 18 and Figure 4 19 Check the bypass valve tow valve to make sure it is fully seated Figure 4 20 9 Recheck hose and fittings to ensure they are tight 10 Check oil reservoir for proper oil level and make sure hydraulic filter is in good condition A A Hydraulic fluid escaping under pressure may have 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 2 familiar with this form of injury or gangrene may 3 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 Never operate the mower with a non functioning seat switch Always reconnect the seat switch to the mower harness WARNING WARNING Remove Hustler Pressure Test Gauge Kit After all repairs are completed check to make sure all 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 tools and obstructions are removed from under the mower Raise the rear of the mower and remove the jack stands Lower the mower use a piece of cardboard or wood never use your 5
47. re 5 4 Replace the element whenever the restriction indicator reaches the change filter red line Check the indicator daily and replace element as needed or annually whichever occurs first Reset the indicator by pushing in on the yellow button after each element change Figure 5 4 Carbon canister Super Z mowers with OxxxxxCA model number i e 922222CA have a carbon canister incorporated into the fuel system Figure 5 5 amp Figure 5 6 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 REV E 5 2 ET e 24402 Hab aUSONIAN 831713 Indicator z Figure 5 4 Fuel evaporation system filter Super Z mowers with a 9xxxxx or 9xxxxxCA i e 922222 or 922222CA model number have a fuel evaporation system filter Refer to the following table for more detailed information Figure 5 5 Figure 5 6 Figure 5 7 amp Figure 5 8 Super Z mowers with a 9xxxxxCE 9xxxxxAU or 9xxxxxEX i e 922222CE 922222AU or 922222EX model number may or may not have a have a fuel evaporation system filter Refer to the following table for more detailed information This filter must be replaced every 500 hours or annually whichever comes 113957 Mowers prior to serial number 12071770 Mowers prior to serial number 12071770 Fuel evaporation system fil
48. re that no part of the body especially arms and hands are under mower A Keep your machine clean and remove any deposits of trash and clippings which can cause engine fires and hydraulic overheating as well as excessive belt wear Clean up oil or fuel spillage Allow machine to cool before storing A Always wear adequate eye protection when servicing the hydraulic system and battery or when grinding mower blades and removing accumulated debris A Never attempt to make any adjustments or repairs to the mower drive system mower deck or any attachment while the engine is running or deck clutch is engaged A Exercise caution when releasing spring tension from any of the belt idlers or when working with any of the deck lift components A Never work under the machine or attachment unless it is safely supported with jack stands Make certain machine is secure when it is raised and placed on the jack stands The jack stands should not allow the machine to move when the engine is running and the drive wheels are rotating Use only certified jack stands Use only appro priate jack stands with a minimum weight rating of 2000 pounds to block the unit up Use in pairs only Follow the instructions supplied with the vehicle stands A Keep nuts and bolts tight especially the blade attachment bolts Keep equipment in good working condition A Never tamper with safety devices Check their proper operation regularly A Exercise caution when working u
49. rews nuts and set screws to these values unless a different torque is shown in the Special Torques section SIZE FT LBS SIZE FT LBS 10 32 4 IN LBS 3 6 M3 12 IN LBS 1 3 250 98 4 IN LBS 11 1 M4 26 4 IN LBS 3 312 204 IN LBS 23 M5 54 IN LBS 6 1 375 30 40 M6 92 4 IN LBS 10 4 438 48 65 M8 222 IN LBS 25 500 73 99 M10 37 50 562 105 143 M12 64 87 625 145 200 M14 103 140 750 260 350 M16 160 215 875 420 565 M20 320 435 Special Torques DESCRIPTION FT LBS Wheel lug nuts 70 95 Blade spindle bolt top 70 95 Blade spindle bolt bottom 118 160 01 Electric clutch mounting bolt 45 48 61 65 Front wheel axle bolt 100 136 Wheel motor hub nut 230 312 Hydraulic pump pulley bolt 45 55 61 74 6 Engine torques 2 N A N A NOTE 1 Lug nuts only It is recommended that these be checked 113957 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 3 1 A A Particular attention must be given to tightening the drive 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 ca
50. rottle and stroke the steering control lever forward and reverse several times until the wheel motor operates smoothly through the entire speed range 13 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 properly Figure 4 21 A WARNING A Do not operate the mower without plugging the mower s wiring harness into the seat switch This switch is an important part of the safety start interlock system Serious injury can result if the seat switch is not plugged into the mower s wiring harness WARNING A Never operate the mower with a non functioning seat switch Always reconnect the seat switch to the mower harness 14 Check to make sure all tools or obstructions are removed from under the mower 15 Raise the rear of the mower and remove the jack stands Lower the mower 16 Lower and secure the seat platform Warner Clutch Re gap Adjustment Procedures The air gap is only adjustable on clutches that have a removable shim see Figure 4 27 When to remove shim When a clutch has worn to the extent that the existing air gap is too large to allow for complete clutch engagement clutch may engage easily when cold but has problems engaging when hot the brake shim can be removed to reduce air gap and allow the clutch to continue to function After verif
51. s important to note that whenever an air filter element is cleaned by any method the person or company performing the cleaning assumes responsibility for the integrity of the filter from then on The warranty for air filters expires upon cleaning or servicing in any manner because the condition of the filter after servicing is completely out of the engine 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 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 Air restriction indicator These units have an air restriction indicator installed in the air cleaner Figu
52. t Adjustment 6 4 o RM EIE E e ed 7 1 113957 toc 1 REVE Maintenance 8 1 Troubleshooting s ds 4 455302 2 2er ee 9 1 REVE toc 2 113957 GENERAL INFORMATION Service Program This General Service Manual is a service guide for use by Service Technicians It provides the necessary information needed to perform normal maintenance requirements on these units The Parts Manual provides a complete parts listing for the unit Use this manual when ordering parts The Operator s Manual provides fundamental operational information and operational safety that is needed when operating the mower The component manuals are furnished by the various manufacturers to be used for the troubleshooting and servicing of their products Maintenance Introduction Regular maintenance is the best prevention for costly downtime or expensive premature repair The following pages contain suggested maintenance information and schedules which the operator mechanic should follow on a routine basis Remain alert for unusual noises they could be signaling a problem Visually inspect the machine for any abnormal wear or damage A good time to detect potential problems is while performing scheduled maintenance service Correcting the problem as 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
53. t is running A Never attempt to start engine when there is a strong odor of gasoline fumes present Locate and correct cause A Keep all safety shields and covers in place except for servicing A Do not touch hot parts of machine General Maintenance Precautions A Repairs or maintenance requiring engine power should be performed by trained maintenance person nel only A Never run the engine in an enclosed area unless exhaust is vented to the outside Exhaust gases contain carbon monoxide which is an odorless and deadly poison A Unless specifically required DO NOT have engine run ning when servicing or making adjustments to mower Park the machine on level ground Place steering control levers in the park brake position disengage deck clutch lower deck remove ignition switch key and disconnect negative battery cable before doing any maintenance Wait for all movement to stop before adjusting cleaning or repairing To prevent carbon monoxide poisoning be REVE 2 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 su
54. ter d LO Fuel evaporation system filter lo Ih Carbon canister Hydraulic reservoir T Fuel evaporation system filter M 792 Figure 5 5 Mowers after serial number 12071770 Fuel evaporation system filter ANS o ug N U e Carbon 0 canister amp A Lees U R o E o Es a 5 Hydraulic Ate reservoir T Fuel evaporation TE system filter H 0 2 Fuel evaporation system filter Figure 5 6 first Figure 5 6 Figure 5 7 amp Figure 5 8 Figure 5 8 MODEL MODEL Fuel amp evaporative system line routings EXTENSION EXAMPLE SEN NUMBERS There are two rubber hoses that are connected to the fuel NONE SS EE tanks One is the fuel hose that is part of the fuel system The CA 922222CA ALL HAVE FILTER other is the vapor line that is part of the fuel evaporative system EX 922222EX PRIOR TO SERIAL NUMBER The fuel hose is connected to the fuel tank as shown It 12071770 HAVE FILTER connects the fuel tank to the fuel shu
55. than an Authorized Dealer will invalidate the warranty claim and warranty credit will not be approved REVE REVE 1 2 113957 SAFETY This safety alert symbol is used to call attention to a message intended to provide a reasonable degree of PERSONAL SAFETY for operators and other persons during the normal operation and servicing of this 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 A DANGER WARNING Safe Servicing Practices This product is capable of amputating hands and feet and throwing objects Always follow all safety instructions to avoid serious injury or death Understand correct service A Be sure you understand a service procedure before you work on the machine A Unauthorized modifications to the machine may impair the function and or safety and affect machine life A If it is necessary to make checks with the engine running always use two people with the operator at the controls able to see the person doing the checking Pre Operation Precautions Fuel Handling A To avoid personal injury or property damage use extreme care in handling fuel Fuel is extremely flamma ble and the vapors are explosive A Observe usual fuel handling precautions e Do not smoke while refueling Extinguish all ciga rettes cigars pipes and other sources of ignitio
56. ting this equipment as prolonged exposure to uncomfortable or loud noises can cause impairment or loss of hearing REVE Do not wear radios or music headphones while operat ing the machinery Safe operation requires your full attention Operation Precautions Avoid Fire Hazards A Clean flammable material from machine Prevent fires by keeping engine compartment top of deck exhaust area battery hydraulic lines fuel line fuel tank and operator s station clean of accumulated trash grass clippings and other debris Always clean up spilled fuel and oil Start Engine Safely A Avoid possible injury or death from machine runaway A Do not start engine by shorting across starter terminals A Before you start the engine Sit on the operator s seat Move control levers to the neutral brake position Operate Machine Safely A Refer to the unit s operator s manual for complete safety information on safe machine operation A Always maintain a safe distance from people and pets when mowing A Always be aware of what is behind the machine before backing up A Never leave machine unattended with ignition key in switch especially with children present A Follow daily and weekly checklists making sure hoses are tightly secured and bolts are tightened A Always keep engine and machine clean removing accu mulated dirt trash and other material from machine A Never put hands or feet under any part of the machine while i
57. toff valve Figure 5 9 amp Figure 5 10 AFTER SERIAL NUMBER 12071770 The vapor line is connected to the fuel tank as shown It BENSTIRANERIEIER connects the fuel tank to the engine s vapor port Figure 5 11 CE 922222CE PRIOR TO SERIAL NUMBER Figure 5 12 amp Figure 5 13 12071770 HAVE FILTER AFTER SERIAL NUMBER 12071770 DO NOT FILTER AU 922222AU PRIOR TO SERIAL NUMBER 12071770 HAVE FILTER AFTER SERIAL NUMBER 12071770 DO NOT HAVE FILTER 113957 5 3 REVE Mowers prior to serial number 1206 Fuel tank Mowers prior to serial number 1206xxxx D pu E ale gt a 00 Fuel line shutoff Fuel line y fo a Fuel evaporation system filter Tee Fuel line gt Figure 5 10 REVE 5 4 uel evaporation system filter 2 oN Figure 5 12 113957 Mowers after serial number 1206 Fuel O
58. use serious damage or personal injury WARNING REVE REVE 3 2 113957 POWER UNIT MAINTENANCE Steering Adjustments Steering control lever neutral adjustment The mower s steering has been factory adjusted to eliminate creeping when the steering control levers are in the neutral 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 WARNING This procedure will require that the unit be raised 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 wit
59. wer parts when removing or installing the battery Do not allow metal tools to short between the battery terminals and metal mower parts A Incorrect battery cable routing could cause damage to the mower and battery cables This can cause sparks which can cause a battery gas explosion which will result in per sonal injury Always disconnect the negative black bat tery cable s before disconnecting the positive red cable s Always connect the positive red battery cable s before connecting the negative black cable s Avoid Acid Burns A Sulfuric acid in battery electrolyte is poisonous It is strong enough to burn skin eat holes in clothing and cause blindness if splashed in eyes Avoid the hazard by Filling batteries in a well ventilated area Wearing eye protection and rubber gloves Avoiding breathing fumes when electrolyte is added Avoiding spilling or dripped electrolyte If you spill acid on yourself Flush your skin with water Apply baking soda or lime to help neutralize the acid Flush your eyes with water for 10 15 minutes Get medical attention immediately If acid is swallowed Drink large amounts of water or milk Then drink milk of magnesia beaten eggs or vegetable oil Get medical attention immediately REVE REVE 2 4 113957 TORQUE Standard Torques The following chart lists the standard torque values for the threaded fasteners found in this manual Torque all cap sc
60. y 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 25 8 75 209 222mm when 113957 4 5 measured from the inside of the hook to the inside of the other hook Figure 4 14 To increase belt tension loosen the jam nut on the eye bolt Then tighten the nut on the eyebolt until the 8 0 8 5 203 216mm dimension is attained Lock the eyebolt in place by tightening the jam nut Figure 4 14 IMPORTANT Do not over tension the spring to compensate for a badly worn belt or pulley Figure 4 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 control will occur especially when operating on a slope If you lose steering control while operating the machine place the steering control
61. ying that proper voltage and current are supplied to the clutch follow the procedure outlined below REVE NOTE Before proceeding the clutch must be installed on the engine crankshaft and the retaining bolt torqued to 45 48 ft Ibs Armature Figure 4 23 Be certain that the gap between the Procedure rotor and armature face is greater than 070 prior to shim removal WARNING Figure 4 25 Always wear adequate eye protection when servicing the WARNING mower With engine off key removed and clutch disengaged and Do not remove brake pole from field shell armature The using a pneumatic line blow out any debris from under the brake pole tracks match with the clutch brake and need to brake pole and around the aluminum spacers Figure 4 24 continue to match after shim is removed to ensure proper brake torque Figure 4 23 M6 x 1 Figure 4 24 4 _ Check the air gap between rotor amp armature with feeler gage Figure 4 26 If the gap is less than 070 then follow the troubleshooting 2 Using needle nose pliers or by hand take hold of the tab procedure outlined in Warner Electric P1177 installation and remove shim do not discard shim until proper clutch troubleshooting guide available on Warner Electric s web site function has been confirmed Figure 4 27 www Warnerelectric com If the air gap is over 070 follow the 3 Using a pneumatic line blow out any debris from under procedure outlin
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