HUSTLER Z Diesel General Service Manual
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HUSTLER Z Diesel General Service Manual

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Hustler
Z Diesel
®
General Service Manual
200 South Ridge Road
Hesston, Kansas
67062
115164
REV D

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  • Page 1 Hustler Z Diesel ® General Service Manual 200 South Ridge Road Hesston, Kansas 67062 115164 REV D...
  • 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 Service Program .
  • Page 4 Deck Adjustments..........6-1 Deck Leveling .

  • Page 5: General Information

    Clear away heavy build-up of grease, oil and dirt, especially in the engine compartment and under the seat platform areas; minute dust particles are abrasive to close-tolerance This manual is part of a service package for the Hustler ® engine and hydraulic assemblies.
  • Page 6 REV D 115164...

  • Page 7: Safety

    SAFETY • Do not smoke while refueling. Extinguish all cigarettes, cigars, pipes and other sources of ignition. • Do not remove fuel cap or fill tank with engine running or while engine is hot. Clean up any This safety alert symbol is used to call attention to a mes- gasoline spills.

  • Page 8: Operation Precautions

    Understand Machine Operation  Never leave machine unattended with ignition key in switch, especially with children present.  Only qualified and trained personnel should operate  Follow daily and weekly checklists, making sure hoses the equipment. are tightly secured and bolts are tightened. ...

  • Page 9: Maintenance Precautions

    • Hydrogen gas forms inside the battery. This gas them. is both toxic and flammable and may cause an  Use original Hustler replacement parts or parts that ® explosion if exposed to flame. Always disconnect are equivalent in overall performance.
  • Page 10 Sparks can cause a battery gas explosion which will Avoid the hazard by: result in personal injury. • Filling batteries in a well-ventilated area. • Prevent the battery terminals from touching any • Wearing eye protection and rubber gloves. metal mower parts when removing or installing •...

  • 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. Size ft-lbs N•m...
  • Page 12 REV D 115164...

  • Page 13: Power Unit Maintenance

    POWER UNIT MAINTENANCE Steering Adjustments 2. Chock the front tires. 3. Raise the seat platform and disconnect the mower harness from the seat switch. Bypass the seat switch Steering control lever neutral adjustment by connecting the two mower harness female spades The mower’s steering has been factory adjusted to together.
  • Page 14 Steering control lever in neutral position Mowers with serial number 1110 (first four digits) and later A. Steering control lever B. Park brake slot Figure 4-2 Mowers prior to serial number 1110 (first four digits) A. Pump linkage rod C. Jam nut B.
  • Page 15 To keep the pumps from bottoming out internally use sooner. Tighten the lock nut on the stop and test the following procedure: again. This adjustment is only required if the hydraulic pump(s) 3. Repeat this procedure until unit drives straight. have been replaced.
  • Page 16 6. Tighten the nut on the steering damper’s front ball Mowers with serial number 1110 (first four digits) and later stud. NOTE: The damper must not bottom out when the pump lever is fully stroked in either direction. 7. Reconnect the negative battery cable. 8.

  • Page 17: Park Brake Adjustment

    Align steering control lever ±.125” (3.175mm) Figure 4-11 Park Brake Adjustment A. Brake link – do not adjust Figure 4-12 NOTE: This procedure is only used on mowers produced with serial numbers 1110 (first four digits) and later. This procedure will require that the unit be raised and blocked up off of the ground.

  • Page 18: Park Brake Spring Adjustment

    Park Brake Spring Adjustment NOTE: This adjustment is only on mowers with serial numbers prior to 1110 (first four digits). 1. Occasionally check the park brake spring adjustment using the following method: 2. Shut engine off, place control levers in the park brake position, disengage deck clutch, remove ignition switch key and disconnect negative battery cable before doing any adjustments.

  • Page 19: Hydraulic Pump Belt Adjustment

    Replace the belt every 400 hours or every two (2) Fluid level should be 1” (25.4mm) from top of reservoir. years whichever comes first. Use only SAE 20W50 motor oil, 15W50 synthetic oil, or 20W50 synthetic oil. Hustler Full Synthetic 20W50 Hydrostatic ® Transmission Oil is recommended. Figure 4-18 If the transmission belt fails, loss of control will occur especially when operating on a slope.
  • Page 20 Hydraulic pump flow test The design purpose of the Bi-Directional Flow Test Kit is to allow the technician to isolate the pump from the wheel motor and determine if the pump is acceptable. The following information can be used to install and test the pump by simulating a wheel motor load.
  • Page 21 2. Open the restriction valve all the way. CAUTION: Damage to the flow meter and/or re-calibration may result from testing at input speeds that exceed 15 gpm 3. For the pump being tested, move the steering control (56.78 l/min). levers in full forward motion. (It will be necessary to lock the steering control levers into full forward 6.

  • Page 22: Warner Clutch Re-Gap Adjustment Procedures

    Test Example: TC (21) Pump RESTRICTION VALVE BI-DIRECTIONAL FLOW METER 300 psi (21 bar) reading 9 gpm (34 l/min) (1st reading) CONNECTIONS TO THE FWD/RVS LINES DISCONNECTED FROM WHEEL MOTOR RESTRICTION VALVE BI-DIRECTIONAL FLOW METER CONNECTIONS TO THE 1100 psi (76 bar) reading 5 gpm (19 l/min) (2nd reading) FWD/RVS LINES...
  • Page 23 Figure 4-22 A. Brake fastener E. Armature B. Brake spacer F. Re-gap shim C. Field shell G. Rotor D. Brake pole H. Gap A. Gap between the rotor and armature face must be Figure 4-21 greater than .070"prior to shim removal Figure 4-23 Procedure: 1.
  • Page 24 A. M6 x 1 bolt Figure 4-26 Figure 4-24 Figure 4-27 Figure 4-25 Perform Safety Check: ends of the brake pole as shown. Figure 4-26 and Figure 4-27 a. If the gap is less than .015” the clutch must be replaced Observe deck operation from the operator’s seat.

  • Page 25: Tires

    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 ®...
  • Page 26 2. Thoroughly pack the tapered roller bearings with multi- purpose grease. 3. Insert the new tapered roller bearings into the outer bearing race. Figure 4-31 4. Insert the new seals into the wheel housing. Make sure that the flat side of the seal is flush with the outside edge of the wheel housing.

  • Page 27: Engine Maintenance

    Check engine oil daily and after every 4 hours of operation. Machine must be setting level when checking oil. Refer to engine manual maintenance schedule recommendation and capacities. Hustler Motor Oil is ® recommended. Change the engine oil and filter after the first 5 hours of operation engine manufacturer’s...

  • Page 28: Engine Controller (Tier 4 Engines Only)

    2. Before installing a new element, inspect it by placing a Air restriction indicator bright light inside and rotating the element slowly, These units have an air restriction indicator installed in the looking for any holes or tears in the paper. Also check air cleaner.
  • Page 29 The following provides the necessary troubleshooting 2. If no errors are detected when the engine is started, information needed to interpret the error codes. the Engine Warning Light flashes once and then turns off. Before starting the engine: 3. If an error is detected when the engine is started or 1.
  • Page 30 Error Codes When Engine is Running Warning Problem Symptoms Suggested Remedies Light Code Oil pressure decline No error detection until after 180 seconds from engine Weak signal from oil pres- starting even in case of weak signal. Add engine oil. sure switch Goes into power cutback mode (Limp home mode) in Ensure harness and con-...
  • Page 31 Case 1: One error detected Code: 31 Light up 3 times, Flashing 1 time 1 sec. 1 sec. 1 sec. sec. sec. sec. 1 CYCLE (rEPEAT) 1 CYCLE Case 2: Combination of 2 errors (if 2 occur at the same time) Code: 31 Light up 3 times, Flashing 1 time Code: 04 Flashing 4 times 1 sec.
  • Page 32 A computer with APECS 4800 software loaded on it is required to connect to the diesel engine in order to perform ECU diagnostics using the Hustler Z Diesel Tier 4 Communication Kit. Be sure to close all programs on your computer prior to installing the software. ®...
  • Page 33 9. Confirm Level 1, and Log in. Figure 5-9. Assembly 1. Park the mower on a solid, level surface; set the park brakes; and shut-off the engine. 2. Begin with the computer on and located near the mower. Locate the two cables included in this kit. 3.
  • Page 34 Figure 5-12 Figure 5-13 Figure 5-14 Figure 5-15 REV D 115164...

  • Page 35: 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: Shibaura Model 773 ENGINE SPEED MODEL NO.
  • Page 36 REV D 5-10 115164...

  • Page 37: Deck Adjustments

    DECK ADJUSTMENTS Deck Leveling 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. Leveling the deck must be done in the following manner and order: XR7 Decks 1.
  • Page 38 60”/72” Rear Discharge Decks - Single Belt System 60” Rear Discharge Deck A. 3.75" Blocks B. 3.00" Blocks A. 3" Blocks Figure 6-5 Figure 6-3 7. Loosen the two nuts on the front of height indicator so that the foot pedal is free. Figure 6-7 60”/72”...
  • Page 39 1” 1” A. Nuts B. Foot pedal A. Lift block B. Deck lift rod Figure 6-7 Figure 6-8 11. 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.

  • Page 40: Blades

    23. Go to the left rear of the mower. Check the mower blades daily, they are the key to power efficiency and well groomed turf. Keep the blades sharp. A 24. Make sure that there is still slack in the chain. If not, dull blade will tear rather than cut the grass, leaving a brown loosen the two nuts on the block holding the threaded ragged top on the grass within a few hours.

  • Page 41: Belts

    The spring tension should be such holding the blade to the spindle shaft. NOTE: A blade holding that the belt does not slip under normal operating load tool (P/N 381442) is available from Hustler Turf Equipment. conditions, assuming the belt is not excessively worn or ®...
  • Page 42 IMPORTANT: Do not over tension the spring to 54”/60”/66”/72” VX4 Decks compensate for a badly worn belt or pulley. The spindle belt tension remains constant by means of a tension idler and spring. The spring tension should be such 54"/66"/72" XR7 Decks that the belt does not slip under normal operating load conditions, assuming the belt is not excessively worn or damaged.
  • Page 43 IMPORTANT: Do not over tension the spring to 5. Using a 15/16" wrench, turn the 3/4" nut until the compensate for a badly worn belt or pulley. spring compresses to a measured length of 1.80" (45.7mm). 60"/72" Rear Discharge Decks 6.
  • Page 44 60"/72" Rear Discharge Decks – Center Spindle to Right 60" Rear Discharge Decks Spindle Belt 1.80” (45.7mm) A. Idler spring A. Spring D. Belt B. Spring chain B. Idler pulley E. Pulley sled C. Spring chain anchor point C. 5/8" cap screw F.

  • Page 45: Deck Belt Routing & Tensioning

    Deck Belt Routing & Tensioning XR7 54”/66”/72” Side Discharge Deck NOTE: The following notes are the same for the three different decks shown. 1. Spring length after tensioning new belt. Measured from outside of hook to outside of hook with deck set at 3.50” (88.9mm) cut height.
  • Page 46 XR7 60” Side Discharge Deck 1. Spring length after tensioning new belt. Measured from outside of hook to outside of hook with deck set at 3.50” (88.9mm) cut height. 2. Route belt as shown. 9.3” – 10.3” (236 – 262mm) Figure 6-24 REV D 6-10...
  • Page 47 VX4 54”/60”/66”/72” Side Discharge Deck NOTE: The following notes are the same for the four different decks shown. 1. Spring length after tensioning new belt. Measured from outside of hook to outside of hook with deck set at 3” (76.2mm) cut height.
  • Page 48 60”/72” Rear Discharge Deck (Single Belt System) NOTE: The following notes are the same for the two different decks shown. 1. Spring length after tensioning new belt. Measured from outside of hook to outside of hook with deck set at 3¼” (82.6mm) cut height.
  • Page 49 60”/72” Rear Discharge Deck (Two Belt System – Early Style) NOTE: The following notes are the same for the two different decks shown. 1. Spring length after tensioning new belt. Measured from outside of hook to outside of hook with deck set at 3¼” (82.6mm) cut height.
  • Page 50 60” Rear Discharge Deck (Two Belt System – Later Style) 1. Spring length after tensioning new belt. Measured from outside of hook to outside of hook with deck set at 3¼” (82.6mm) cut height. 2. Route belt as shown. 9.3” – 10.3” (236 –...
  • Page 51 72” Rear Discharge Deck (Two Belt System – Later Style) 1. Spring length after tensioning new belt. Measured from outside of hook to outside of hook with deck set at 3¼” (82.6mm) cut height. 2. Route belt as shown. 9.3” – 10.3” (236 –...
  • Page 52 REV D 6-16 115164...

  • Page 53: Electrical

    ELECTRICAL Electrical Schematic – Shibaura Diesel Mowers built prior to serial number 0902000 Figure 7-1 115164 REV D...
  • Page 54 Electrical Schematic – Shibaura Diesel Mowers built between serial number 0902000 and serial number 1110 (first four digits) Figure 7-2 REV D 115164...
  • Page 55 Electrical Schematic – Shibaura Diesel Domestic mowers built between serial number 1110 (first four digits) and serial number 13110000 Export & CE mowers built after serial number 1110 (first four digits) Figure 7-3 115164 REV D...
  • Page 56 Electrical Schematic – Shibaura Diesel Domestic mowers built after serial number 13110000 Figure 7-4 REV D 115164...
  • Page 57 Electrical Schematic – Shibaura Diesel Domestic mowers built after serial number 1311000 Figure 7-5 115164 REV D...
  • Page 58 REV D 115164...
  • Page 59 Cooling system circuit cleaning (8) NOTES: 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.
  • Page 60 Perform initial hydraulic oil and filter change after 50 hours (one week) of operation. Thereafter, change oil and filter annually or every 500 hours ® whichever comes first. Hustler Full Synthetic 20W50 Hydrostatic Transmission Oil is recommended. Change engine oil filter per the engine manufacturer’s recommendations. Refer to Engine Owner’s Manual for recommendations and other maintenance items.
  • Page 61 Maintenance Locator Chart Figure 8-1 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 62 Side Discharge Deck 1. Deck Pusher Arm Zerks (2) 2. Deck Belt (1 or 2) 3. Spindle Housing Zerks (3) 4. Blades (3) Figure 8-5 Rear Discharge Deck Figure 8-6 Figure 8-7 REV D 115164...

  • Page 63: Troubleshooting

    TROUBLESHOOTING SUGGESTED SYMPTOMS PROBABLE CAUSES SUGGESTED REMEDIES SYMPTOMS PROBABLE CAUSES REMEDIES Mower jerky when start- Steering control linkage Adjust linkage Starting motor does not Steering control levers not Place steering control ing or operates in one needs adjustment crank in park brake position or levers in park brake posi- direction only switch not adjusted...
  • Page 64 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 adjust- ment section of the General Service Manual An anti-scalp wheel is not...
  • Page 65 INDEX PAGE PAGE Air Restriction Indicator ......5-2 Maintenance Schedule ......8-1 Avoid Acid Burns .

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