HUSTLER Super Z HD General Service Manual
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HUSTLER Super Z HD General Service Manual

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117592
General Service Manual
Super Z
®
200 South Ridge Road
Hesston, Kansas
67062
HD
REV C

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Raymond Kallner
April 15, 2025

how much oil for oil change of Kohler engine?

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1 comments:
Mr. Anderson
April 15, 2025

Approximately 3 U.S. gallons (11.35 liters) of 15W50 Mobil One oil are needed when replacing the oil and filter.

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Summary of Contents for HUSTLER Super Z HD

  • Page 1 Super Z ® General Service Manual 200 South Ridge Road Hesston, Kansas 67062 117592 REV C...
  • Page 2 WARNING WARNING 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.

  • Page 3: Table Of Contents

    Table of Contents General Information ........1-1 Service Program.
  • Page 4 72” Rear Discharge Deck Belt Routing & Tensioning ..6-8 Electrical ..........7-1 Electrical Schematic –...

  • Page 5: General Information

    GENERAL INFORMATION Service Program minute dust particles are abrasive to close-tolerance engine and hydraulic assemblies. This manual is part of a service package for the Hustler ® Daily inspect mower for grass clippings and wire and string Super Z ®...
  • Page 6 REV C 117592...

  • Page 7: Safety

    SAFETY • 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. This safety alert symbol is used to call attention to a message •...

  • Page 8: Operation Precautions

    Wrap the blade(s) or servicing. wear gloves and use extra caution when servicing them.  Do not touch hot parts of machine. ®  Use only genuine Hustler replacement parts to ensure General Maintenance Precautions that original standards are maintained. Maintenance Precautions ...
  • Page 9 tape openings after adding the inhibitor. Keep container parts water and one part baking soda when they tightly closed when not in use. become corroded.  Inspect electrical wiring for worn or frayed insulation.  Shorts caused by battery terminals or metal tools touch- Install new wiring if wires are damaged.
  • Page 10 REV C 117592...

  • Page 11: Torque

    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. 32.4 IN.-LBS.
  • Page 12 REV C 117592...

  • Page 13: Power Unit Maintenance

    POWER UNIT MAINTENANCE Steering Adjustments 1. On the other seat you will disconnect the wire harness from the two connectors as shown in Figure 4-2. 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.
  • Page 14 properly. Figure 4-1 & Figure 4-2 WARNING Do not operate the mower without plugging the mower’s Control wiring harness into the seat switch. This switch is an levers 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.
  • Page 15 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 Stop screw doing any adjustments. 2. Place the steering control lever in the neutral position. Figure 4-7 3.

  • Page 16: Park Brake Adjustment

    Steering control lever adjustment Park brake adjustment The steering control levers can be adjusted for operator comfort. 1. By loosening the cap screws that attach the upper control WARNING lever to the lower lever the upper control lever can be pivoted to fit the operator’s personal preference (see Figure 4-9) This procedure will require that the unit be raised and...

  • Page 17: Belts

    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. Bypass valve 13.

  • Page 18: Hydraulic System

    Inspect the machine and involve your dealer to resolve ing system oil. the problem. The system filter is located inside the hydraulic reservoir on the underneath side of the tank. Use a Hustler approved filter ® element only. When changing the filter use a 15/16” socket.

  • Page 19: Test Procedure For Ddc20 Pump

    3. Raise the seat platform and disconnect the mower harness 7. Install Hustler Test Gauge Kit (p/n 007898) as shown in from the seat switch. Bypass the seat switch by Figure 4-20 and Figure 4-21. Check the bypass valve connecting the two mower harness female spades (tow valve) to make sure it is fully seated.

  • Page 20: New Or Rebuilt Ddc20 Pump Startup Procedure

    Pressure Test Gauge Kit shown installed harness. Figure 4-21 2. Remove Hustler Pressure Test Gauge Kit. New or Rebuilt DDC20 Pump Startup 3. After all repairs are completed, check to make sure all Procedure tools and obstructions are removed from under the mower.
  • Page 21 Bypass valve (Tow valve) Seat switch Top of pump Mower Female harness spades Figure 4-23 RH Pump as viewed from rear of mower Figure 4-22 Pump replacement: 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.
  • Page 22 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 Prefill pump mower’s wiring harness.

  • Page 23: Warner Clutch Re-Gap Adjustment Procedures

    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 4-32).

  • Page 24: Tires

    Front wheels ..... 8-12 psi (55-83 KPa) Observe deck operation from the operator’s seat. If you wish to use non-pneumatic tires on your Hustler ®...

  • Page 25: Engine Maintenance

    ENGINE MAINTENANCE General Engine Maintenance IMPORTANT: All oil drips or spills must be cleaned off of the exhaust system before operating the machine. 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 levels with...
  • Page 26 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 Safety filter filter element changing. Air restriction indicator These units have an air restriction indicator installed in the air cleaner.

  • Page 27: Carbon Canister

    Fuel & evaporative system line routings There are two rubber hoses that are connected to the fuel Some Hustler Super Z HD mowers will have a carbon ® tanks. One is the fuel hose that is part of the fuel system. The canister incorporated into the fuel system.
  • Page 28 Fuel evaporation system filter Fuel tank Carbon canister Carbon canister Vapor line Fuel tank Figure 5-9 REV C 117592...

  • Page 29: Engine Rpm Settings

    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 FX850 & FX1000 ENGINE SPEED MODEL NO.
  • Page 30 REV C 117592...

  • Page 31: Deck Adjustments

    DECK ADJUSTMENTS Deck Leveling 3.75” Block 3.75” Block 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 .
  • Page 32 until there is slack in the deck lift chain. 21. Tighten the appropriate nut until the chain just becomes Foot pedal tight, and carries most of the deck weight. Check by Nuts moving the block—it should move with a slight drag. Figure 6-7 22.

  • Page 33: Blades

    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 ®...

  • Page 34: Belts

    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, Resharpening pattern otherwise, the belt will lose power and slip excessively.
  • Page 35 60” Rear Discharge Deck Idler spring Spring chain Spring chain anchor point Figure 6-13 72” Rear Discharge Deck Idler spring Spring chain Spring chain anchor point Figure 6-14 117592 REV C...

  • Page 36: 60", 66" & 72" Side Discharge Deck Belt Routing & Tensioning

    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 3¼” (8.2.6mm) cut height. 2. Route belt as shown. 60”, 66”...

  • Page 37: 60" Rear Discharge Deck Belt Routing & Tensioning

    60” Rear Discharge Deck Belt Routing & Tensioning 9.3” – 10.3” (23.6 – 26.2cm) 9.3” – 10.3” (236 – 262mm) Figure 6-16 117592 REV C...

  • Page 38: 72" Rear Discharge Deck Belt Routing & Tensioning

    72” Rear Discharge Deck Belt Routing & Tensioning 9.3” – 10.3” (236 – 262mm) 9.3” – 10.3” (236 – 262mm) Figure 6-17 REV C 117592...

  • Page 39: Electrical

    ELECTRICAL Electrical Schematic – Kawasaki Mowers prior to serial number 12122104 NOTE: If replacing this harness with the updated version the six pin connector pigtail that is attached to the engine will need to be removed. The updated version has individual connections for the following circuits: Charge, Start, Oil Pressure Light, Fuel Solenoid, and Coil Ground.
  • Page 40 Electrical Schematic – Kawasaki Mowers with serial number 12122104 and later REV C 117592...

  • Page 41: Electrical Schematic - Kawasaki Dfi

    Electrical Schematic – Kawasaki DFI 117592 REV C...

  • Page 42: Electrical Schematic - Briggs & Stratton

    Electrical Schematic – Briggs & Stratton REV C 117592...

  • Page 43: Maintenance

    MAINTENANCE Maintenance Schedule Figure 8-1, Figure 8-2, Figure 8-3,Figure 8-4 Figure 8-4, Figure 8-5, Figure 8-6 & Figure 8-7 WEEKLY MONTHLY ANNUALLY SERVICE AT OR 50 OR 100 OR 500 INTERVALS INDICATED 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...

  • Page 44: Maintenance Locator Chart

    Pump drive belt only - Inspect belt every 100 hours and replace if worn or cracking is noticed. Check spring tension adjustment. Otherwise, replace belt every 400 hours or 2 years whichever comes first. Check and adjust spring tension after 50 hours of use as outlined in the Hydraulic Pump Belt Adjustment sec- tion of the General Service Manual (117592).
  • Page 45 Figure 8-5 Figure 8-6 1. Engine Oil Fill & Dipstick 2. Fuel Filter 3. Engine Air Cleaner 4. Engine Oil Drain Plug 5. Battery 6. Fuel Tanks 7. Hydraulic Oil Reservoir 8. Hydraulic Oil Filter 9. Front Wheel Bearing Zerks (2) 10.

  • Page 46: Maintenance Record

    Maintenance Record Date: Maintenance/Service Performed: Dealer: Date: Maintenance/Service Performed: Dealer: Hour Meter Reading: Hour Meter Reading: Date: Maintenance/Service Performed: Dealer: Date: Maintenance/Service Performed: Dealer: Hour Meter Reading: Hour Meter Reading: Date: Maintenance/Service Performed: Dealer: Date: Maintenance/Service Performed: Dealer: Hour Meter Reading: Hour Meter Reading: Date: Maintenance/Service Performed:...

  • Page 47: Troubleshooting

    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.
  • Page 48 PROBABLE SUGGESTED SYMPTOMS CAUSES REMEDIES Uneven cutting height The blade(s) are not sharp Sharpen the blades A cutting blade(s) is/are Install new cutting blade(s) bent 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 Adjust the height of the...
  • Page 49 INDEX PAGE PAGE Belts..............4-5 Maintenance precautions ........2-2 Blades...............6-3 Maintenance schedule ..........8-1 Control lever stops ..........4-2 Mower blade maintenance ........6-3 Deck Belt adjustment ..........6-4 Mower blade removal ..........6-3 Deck Belt Routing & Tensioning......6-8 Operate machine safely ..........2-2 Deck leveling............6-1 Operation precautions ..........2-2 Electrical Schematic –...
  • Page 50 INDEX PAGE PAGE REV C 117592...

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