HUSTLER Z Diesel Operator's Manual
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HUSTLER Z Diesel Operator's Manual

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Hustler
®
Z Diesel
Operator's Manual
200 South Ridge Road
Hesston, Kansas
67062
603695
REV J

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Summary of Contents for HUSTLER Z Diesel

  • Page 1 Hustler ® Z Diesel Operator’s Manual 200 South Ridge Road Hesston, Kansas 67062 603695 REV J...
  • Page 2 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 To the New Owner .
  • Page 4 Mower Blade ..........4-7 Seat Adjustment .

  • Page 5: General Information

    To activate your warranty policy the mower must be registered, by your Dealer, with the Manufacturer of Hustler ® The Engine Owner’s Manual, included in the owner’s Turf Equipment within ten (10) days following the date of packet, contains engine information that will not be repeated purchase.
  • Page 6 REV J 603695...

  • Page 7: Safety Precautions

    SAFETY PRECAUTIONS Incorrect usage of this equipment may result in severe injury or death. Personnel operating and maintaining it should be trained in its proper use. They should read this manual completely and thoroughly before attempting to set-up, operate, adjust, or service this equipment. Safe Operating Practices This safety alert symbol is used to call attention to a This product is capable of amputating hands and feet and...
  • Page 8  Always wear adequate ear protection, such as  Stop the engine before removing the grass catcher or earplugs. Prolonged exposure to loud noise can cause unclogging the discharge chute. Never clear the impairment or loss of hearing. discharge chute with the engine running. Turn off the engine and be sure the blades have stopped before •...
  • Page 9 REMINDER: Only operate on slopes of 15 degrees or less. ®  Use extreme caution when operating on slopes.  The Hustler mower capable operating horizontally (traverse) on moderately steep slopes. • Be extremely careful changing directions on a When operating on slopes up to 15 degrees, be aware slope.

  • Page 10: Service Precautions

    Another consideration for safe mowing on slopes is to  Use care when approaching blind corners, shrubs, be aware of what is located at the bottom of the slope. trees, the end of a fence or other objects that may Extreme caution should be used when there is a obscure vision.
  • Page 11 ® Sparks can cause a battery gas explosion which will are equivalent in overall performance, that are result in personal injury. available from your local Hustler Dealer. ® • Prevent the battery terminals from touching any • The mower may not comply with the appropriate...

  • Page 12: Safety And Instructions Decals

     Keep fuel away from eyes and skin.  Read and observe safety precautions elsewhere in this manual. • Keep face away from nozzle and gas tank or fuel container opening. Safety and Instructions Decals • If fuel is spilled on clothing, change clothing The decals are designed to give the operator and mechanic immediately.
  • Page 13 DANGER: Thrown objects! 779280 • WARNING: Avoid skin contact with hot surface. Hot surface! • Never operate the mower deck with the rear deflector damaged, altered, or Part Number 779280 removed. 603391 Part Number 603391 WARNING: Thrown objects! • Always maintain a safe distance from people and pets when mowing.
  • Page 14 DANGER: Battery Hazards! Part Number 601815 601815 • Avoid skin contact • Do not overfill battery. • Do not allow open flame near the with battery acid battery when charging. • Electrolyte may overflow and damage • Hydrogen gas forms inside the paint, wiring or structure.
  • Page 15 Part Number 601993 WARNING: Read operator’s Manual and decals before attempting to operate this machine. WARNING: Roll over! • Mow a safe distance (minimum of 10 feet) away from drop-offs, retaining walls, drainage ditches, embankments, water, and other types of hazards to avoid a wheel dropping over the edge or to avoid the ground from breaking away.
  • Page 16 Part Number 600899 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 before continuing to operate. If pump belt fails, steering control will be lost. Refer to owner’s manual for inspection and replacement intervals and refer to above paragraph for emergency procedures.
  • Page 17 Used on mowers with Non Tier 4 engines 603758 Part Number 603758 Fast GLO-plug Slow If warning light comes on, check charging system Mower blade engage/disengage switch Engine start position Ignition switch - insert key If warning light comes on, engine coolant at unsafe temperature ON/GLO Plug Read Operator’s Manual before attempting to operate...
  • Page 18 Used on mowers with Tier 4 engines 604897 Part Number 604897 Read Operator’s Manual before attempting to operate Fast this machine. Wear ear protection, eye protection and Slow safety shoes when operating this equipment. Clutch engage Before starting the engine: Clutch disengage •...
  • Page 19 Slope Guide Use this diagram when determining the degree of slope to be mowed. E (15 Slope Guide Lines D (10 C (5 Line A 1. Hold this sheet of paper in front of you. Make sure that Line A is horizontal. 2.
  • Page 20 REV J 2-14 603695...

  • Page 21: Operation

    This light will also begin to flash an error code when a problem is detected by the engine controller. Refer to the Hustler Z Diesel General Service Manual (P/N ® 115164) for additional information. 603695...
  • Page 22 Temperature warning light (Figure 3-1, Figure 3-2, H. Temperature gauge and alarm (Figure 3-1, Figure 3-2, Figure 3-3) — this light will come on when the engine Figure 3-3) — this gauge reflects the engine coolant coolant temperature reaches an unsafe level during temperature.

  • Page 23: Controls

    25 amp fuse (Figure 3-7) — system controller - 25 amp blade type. (This fuse can be found behind the access Shown with steering control levers in neutral position cover located behind the seat.) A. Steering control lever Figure 3-8 Shown with steering control levers in park brake position K.

  • Page 24: Safety Start Interlock System

    If you cannot locate the problem contact your Hustler ® Dealer. The safety interlock system should always function per steps 4 and 5. If it does not function properly, correct it immediately. Do not operate machine without a properly functioning seat safety switch.

  • Page 25: Stopping The Engine

    Always make certain the two bypass valves are returned to Ambient Preheating time their operating position before running the mower following temperature Ordinary heat type repairs. Above 50°F (10°C) No need 50° (10°C) to 6 seconds 23°F (-5°C) (One cycle) Below 23°F (-5°C) 12 seconds (Cycle glo-plugs twice)
  • Page 26 Pivot the two-post ROPS down by removing the right and To minimize chance of injury or death from rollover: left hair pins (Figure 3-13), and pulling out on the spring • Keep ROPS in the raised and locked position loaded pins to allow the machine to operate under low and use the seat belt.

  • Page 27: Mower Operation

    Following an accident, check the ROPS, the operator’s seat, the seat belt, seat belt mountings and seat platform for possible damage. Before operating the machine, replace all damaged parts. IMPORTANT: Do not attempt to weld or straighten the ROPS. The ROPS structure’s protective capability may be impaired by structural damage, overturn or alteration.
  • Page 28 To stop or decrease speed, move steering control levers to FRONT OF MOWER FACES THIS DIRECTION neutral. When going forward pull back gently on steering control levers. When going in reverse push forward gently on steering control levers. For emergency stops, when traveling forward or rearward, place the steering control levers in the park brake position FORWARD TRAVEL immediately.
  • Page 29 If you lose steering control while operating the machine, place the steering control levers in the park brake position immediately. Inspect the machine and Step 1 involve your Hustler Dealer to resolve the problem ® before continuing to operate. The unit’s steering control levers are very...
  • Page 30 Discharge chute may vary from this illustration Never work with blades while the engine is running or deck clutch switch is engaged (on). Always place the deck clutch switch in the disengaged position, place steering control levers in the park brake position, turn the engine off and disconnect the negative battery cable.

  • Page 31: Deck Cutting Height Adjustment

    4. If the mower blades continue to rotate with the deck clutch switch down, discontinue operation immediately and contact your Hustler Dealer. ® A. Transport lever C. Cutting height holes Follow these procedures to maximize clutch life: B. Pin 1.

  • Page 32: Anti-Scalp Wheels

    Setting Conditions 60”/72” Decks Shown Dry, sparse grass. Particularly useful when Bottom set of mowing at a height of cut of 3" (76.2mm) or holes higher. This setting provides the maximum vacuum and minimal blowout. Manicured lawns. Provides the best vacuum for the best cut when removing weekly/bi-weekly set of holes growth.
  • Page 33 A. Anti-scalp wheel B. Adjusting holes A. Side anti-scalp rollers B. Center anti-scalp roller location Figure 3-22 Figure 3-24 Roller shown in upper adjusting hole A. Lower adjusting hole B. Rear center anti-scalp roller Figure 3-23 603695 3-13 REV J...
  • Page 34 REV J 3-14 603695...

  • Page 35: Maintenance & Adjustments

    Front wheels ....8–12 psi (55–83 KPa) tangles. The underside of the mower deck will collect a build- If you wish to use non-pneumatic tires on your Hustler ®...

  • Page 36: Electrical System

    Fluid level should be 1” (25.4mm) from top of reservoir. Use only SAE 20W50 motor oil, 15W50 synthetic oil, or 20W50 synthetic oil. Hustler Full Synthetic 20W50 Hydrostatic ® Transmission Oil is recommended. Figure 4-2 NOTE: The reservoir will require approximately 7 U.S.

  • Page 37: Fuel System

    Figure 4-4 4. Try and start the engine. If it will not start after 15 seconds of cranking, repeat Step 3. If after trying several times, the engine still will not start, contact your Hustler Dealer. ® 603695...

  • Page 38: Engine Oil And Filter

    Refer to the Hustler Z Diesel General Service Manual (P/N ® 115164) for code identification and troubleshooting. Shown in right fuel tank position A. Controller A. Fuel shutoff valve C. Left fuel tank Figure 4-7 B. Fuel shutoff position D. Right fuel tank...

  • Page 39: Engine Air Filter

    A. Safety filter A. Oil filter B. Oil drain plug Figure 4-10 Figure 4-8 Recommended service procedure Engine Air Filter 1. Release clamps and remove element. Clean the canister with a damp cloth. Perform engine air filter maintenance per the Maintenance 2.

  • Page 40: Cooling System

    the filter after servicing is completely out of the filter Cooling System 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 Never remove radiator cap or overflow reservoir element.

  • Page 41: Belts

    Lay the blade on a flat surface and check for distortion. immediately. Inspect the machine and involve your Replace any distorted blade. Figure 4-14 & Figure 4-15 Hustler Dealer to resolve the problem before ® continuing to operate.

  • Page 42: Seat Adjustment

    A 15/16" wrench is required to remove the 5/8" cap screw holding the blade to the spindle shaft. NOTE: A blade holding tool (P/N 381442) is available from Hustler Turf Equipment. ® A. Weight adjusting C.
  • Page 43 A. Back angle control Figure 4-19 A. Armrest control Figure 4-17 Seat (Option 2) This seat can be adjusted five different ways to obtain the most comfortable position: 1. Back angle (Figure 4-19) 2. Forward and rearward travel (Figure 4-18) 3.

  • Page 44: Steering Control Lever Adjustment

    The steering control levers can also be adjusted up and down. Remove the cap screws and slide the upper control lever up or down and align the holes in it with the holes in the lower lever. Re-install the cap screws and tighten. The steering control levers should be adjusted so that they align with each other when in the neutral position.
  • Page 45 Initial engine oil change is after 5 hours of operation. Thereafter, change oil after every 40 hours operation. Change more often under dusty or ® dirty conditions and during hot weather periods. Hustler Motor Oil is recommended. Torque initially and after first 2 hours of operation.
  • Page 46 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 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.
  • Page 47 Maintenance Locator Chart Figure 4-23 1. Engine Oil 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. Gauge Wheel Bearing Zerks (2) 10.
  • Page 48 Side Discharge Deck 1. Deck Pusher Arm Zerks (2) 2. Deck Belt (1 or 2) 3. Spindle Housing Zerks (3) 4. Blades (3) Figure 4-27 Rear Discharge Deck Figure 4-28 Figure 4-29 REV J 4-14 603695...

  • Page 49: Maintenance Record

    Maintenance Record Perform the initial hydraulic system oil and filter change after the first 50 hours of use. Date: Maintenance/Service Performed: Date: Maintenance/Service Performed: Dealer: Dealer: Hour Meter Reading: Hour Meter Reading: Date: Maintenance/Service Performed: Date: Maintenance/Service Performed: Dealer: Dealer: Hour Meter Reading: Hour Meter Reading: Date:...
  • Page 50 REV J 4-16 603695...

  • Page 51: 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, as outlined in the Maintenance section of this manual, will prevent many problems. The following chart is designed to help you locate a problem by suggesting probable causes and the recommended solutions.
  • Page 52 SUGGESTED SYMPTOMS PROBABLE 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 53: Storage

    Do not pressure wash the machine. Avoid 4. Replace the engine oil filter. excessive use of water, especially near the control 5. Refill with fresh oil of the proper viscosity. Hustler ® panel and engine. Motor Oil is recommended.
  • Page 54 4. Fill fuel tank(s) with fresh fuel. Run machine at half 5. Tighten any bolts that have loosened and make sure speed for 5 minutes, checking operation of steering all hair pins, cotter pins and clevis pins are in place. control levers.

  • Page 55: Product Literature

    If you would like to view or print a copy of the product manuals (Operator’s Manual, Parts Manual, or General Service Manual) for these mowers go online to www.hustlerturf.com. Contact your local Hustler dealer if you require another engine manual.
  • Page 56 REV J 603695...
  • Page 57 INDEX PAGE PAGE Air Flow Baffles .............3-11 Mower Operation ............ 3-7 Air Restriction Indicator ..........4-6 New Season Preparation ........6-1 Anti-scalp Wheels ..........3-12 Operating Suggestions .......... 3-9 Battery Service Precautions ........2-5 Operation ..............2-2 Belts .................4-7 Parts and Service ........... 1-1 Children ..............2-4 Personal Safety ............

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