HUSTLER X-ONE General Service Manual
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HUSTLER X-ONE General Service Manual

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Hustler
X-ONE
®
®
General Service Manual
200 South Ridge Road
Hesston, Kansas
67062
123940
REV C

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Summary of Contents for HUSTLER X-ONE

  • Page 1 Hustler X-ONE ® ® General Service Manual 200 South Ridge Road Hesston, Kansas 67062 123940 REV C...
  • 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 ..........3-1 Service Program .
  • Page 4 Electrical ............9-1 Electrical Schematic –...

  • Page 5: General Information

    Information included in this manual was current at the time servicing of their components. of printing, but subsequent production changes may cause Maintenance Introduction your machine to vary slightly in detail. Hustler Turf ® Equipment reserves the right to redesign and change the machine as deemed necessary, without notification.
  • Page 6 REV C 123940...

  • Page 7: Safety

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

  • Page 8: Operation Precautions

     Carefully read the operator’s manual and all manuals  Always keep engine and machine clean, removing furnished with the attachments. Learn the location accumulated dirt, trash and other material from and purpose of all controls, instruments, indicators machine. and labels. ...

  • Page 9: Maintenance Precautions

    (black) battery cable(s) before them. disconnecting the positive (red) cable(s). Always  Use original Hustler replacement parts or parts that ® connect the positive (red) battery cable(s) before are equivalent in overall performance.
  • Page 10  Incorrect battery cable routing could cause damage to • Avoiding breathing fumes when electrolyte is the mower and battery cables. This can cause sparks added. which can cause a battery gas explosion which will • Avoiding spilling or dripped electrolyte. result in personal injury.

  • 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 C 123940...

  • Page 13: Power Unit Maintenance

    POWER UNIT MAINTENANCE Steering Adjustments Untrained maintenance personnel should never Steering Control Lever Neutral Adjustment attempt to make any adjustments or repairs to the The mower’s steering has been factory adjusted to mower’s drive system while the engine is running. The following procedures should be performed by eliminate creeping when the steering control levers are in the trained maintenance personnel only.
  • Page 14 With the engine off, disconnect the two IMPORTANT: Steering control lever in neutral position 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.
  • Page 15 To do this, gently and slowly move the steering control NOTE: Because this is a hydrostatic drive, variables such levers forward and feel if there is some resistance on the as temperature of oil, efficiency of pumps and motors, tire pump lever before the control lever hits the stops.
  • Page 16 9. To check, move the steering control lever to the Steering Control Lever Adjustment reverse position and release. The steering control lever The steering control levers can be adjusted for operator should return to the neutral position. If not, repeat comfort.

  • Page 17: Park Brake Adjustment

    Park Brake Adjustment 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. • Use only certified jack stands. Use only appropriate jack stands, with a minimum weight rating of 2000 pounds (907 kg) to block the unit up.
  • Page 18 Mowers prior to serial number 18124866 A. Bypass (tow) valve lever in open A. Bypass (tow) valve lever in drive A. Bypass (tow) valve lever in open position position position Mowers beginning with serial number 18124866 A. Bypass (tow) valve lever in open A.

  • Page 19: Belts

    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.

  • Page 20: Hydraulic System

    Change hydraulic system filter element and oil after first 750 hours of mower operation, then replace filter and oil in reservoir every 500 hours thereafter. The following is a list of the oils that are approved for use in the Hustler X-ONE hydraulic system. ®...

  • Page 21: Warner Clutch Re-Gap Adjustment Procedures

    ® ® of the integrated transmission with access to it from the front. (Figure 6-17) Use a Hustler approved filter element ® only. When changing the filter use a 3/4” hex wrench. The threads are right hand.
  • Page 22 2. Using needle-nose pliers, or by hand, take hold of the tab and remove the shim (do not discard the shim until proper clutch function been confirmed). Figure 6-21 A. Gap between the rotor and armature face must be greater than .070"prior to shim removal B.

  • Page 23: Tires

    Front wheels ....8–12 psi (55–83 KPa) 1. Insert the 1/4”–28 straight thread zerk fitting into the grease port and tighten. If you wish to use non-pneumatic tires on your Hustler ® mower, the tire must be a Hustler approved tire.

  • Page 24: Tapered Wheel Bearing Replacement

    7. Make sure the bearings outer race is correctly aligned 10. Install the upper bearing. Figure 6-26 before pressing the outer race into the fully-seated position against caster pocket shoulder. Figure 6-24 A. Upper bearing B. Tapered roller bearing race Figure 6-26 11.
  • Page 25 A. Wheel D. Flat washer B. Fork E. Lock nut C. Axle bolt Figure 6-29 6. Remove and discard the tapered roller bearings and outer bearing races. Figure 6-30 FULLY ASSEMBLED A. Top cap B. Plug Figure 6-28 2. Place mower securely on jack stands and do not allow the mower to move.
  • Page 26 Assembly 6. Push the dust caps onto the wheel housing. Figure 6-33 1. Press the new outer bearing races into the wheel housing until they are fully seated against the housing 7. Slide the wheel assembly between the caster fork legs shoulder.

  • Page 27: Engine Maintenance

    Machine must be sitting level when checking oil. Refer to engine manual maintenance schedule Kohler engine shown 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 The safety element does not require servicing unless it Kohler engine shown becomes contaminated with dirt or moisture. Kawasaki engine shown A. Safety filter Figure 7-5 A. Pre-cleaner C. Dust cap Recommended Service Procedure B. Canister 1. Release clamps and remove element. Clean the air cleaner canister with a damp cloth.
  • Page 29 Do not clean the element, but replace with a new element only. Cleaning used air filter elements, through improper Kawasaki engine shown cleaning procedures, can get dust on the inside of the filter causing dirt ingestion and engine failure. It is important to note that whenever an air filter element is cleaned by any method, the person or company performing the cleaning assumes responsibility for the integrity of the filter from then on.

  • Page 30: Fuel Evaporation System Filter

    A. Fuel evaporation system filter Figure 7-10 A. Fuel evaporation system filter B. Carbon canister Figure 7-9 Fuel Evaporation System Filter Hustler X-ONE mowers have a fuel evaporation system ® ® filter. Figure 7-10 & Figure 7-11 A. Fuel evaporation system filter Figure 7-11 Fuel &...
  • Page 31 The fuel hose is connected to the port on the fuel tank as Vapor Line Routing – Kawasaki shown. It connects the fuel tank to the fuel shutoff valve. Figure 7-12 & Figure 7-14 The vapor line is connected to the port on the fuel tank as shown.
  • Page 32 Fuel Line Routing – Kawasaki EFi & Kohler Vapor Line Routing – Kawasaki EFi & Kohler A. Fuel tank A. Fuel tank C. Fuel shut-off valve B. Vapor line B. Fuel line D. Seat support C. Tee D. Fuel evaporation system filter Figure 7-14 Figure 7-15 REV C...
  • Page 33 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 ENGINE SPEED MODEL NO.
  • Page 34 REV C 123940...

  • Page 35: Deck Adjustments

    DECK ADJUSTMENTS Deck Leveling Side discharge deck shown 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 level deck. recommended pressures are as follows: Drive wheels .

  • Page 36: Blades

    6. Adjust the nut on each deck level rod end over the three blocks so that the deck is sitting on the block and the nut is on the deck level spacer. Figure 8-3 A. Nut C. Rod end B. Spacer Figure 8-3 7.
  • Page 37 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. ® It is designed to prevent the blades from rotating when they A.

  • Page 38: Belts

    Do not re-use spindle bolts which have stripped, worn or Do not over tension the spring to IMPORTANT: undercut threads. Torque bolts on spindles to 118 ft-lbs compensate for a badly worn belt or pulley. (160.0 N•m) when reinstalling blades. Side Discharge Deck Failure to correctly torque the bolt may result in the loss of the blade which can cause serious...
  • Page 39 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 3.25" (82.6mm) cut height. Route belt as shown. Side Discharge Deck Belt Routing &...
  • Page 40 Rear Discharge Deck Belt Routing & Tensioning 54" & 60" decks 9.3" – 10.3" (236 – 262 mm) Figure 8-11 REV C 123940...

  • Page 41: Electrical

    ELECTRICAL Electrical Schematic – Kawasaki RED/BLK (18) IGNITION SWITCH RED (14) CLUTCH SWITCH BLK (18) ORG (18) ORG/RED (18) SEAT SWITCH ORG (18) TAN (18) NEUTRAL NEUTRAL SWITCH SWITCH ORG (18) TAN/RED (18) TAN/RED (18) OIL* PRESS ORG (18) J1-P J1-N J1-M J1-L...

  • Page 42: Electrical Schematic - Kawasaki Efi

    Electrical Schematic – Kawasaki EFI RED/BLK (18) IGNITION SWITCH RED (14) CLUTCH SWITCH BLK (18) ORG/RED (18) ORG (18) SEAT SWITCH TAN (18) ORG (18) NEUTRAL NEUTRAL SWITCH SWITCH TAN/RED (18) ORG (18) TAN/RED (18) ORG/WHT (16) PRESS ORG (18) RH FUEL J1-N J1-M...

  • Page 43: Electrical Schematic - Kohler Efi

    Electrical Schematic – Kohler EFI RED/BLK (18) IGNITION SWITCH RED (14) CLUTCH SWITCH BLK (18) ORG/RED (18) ORG (18) SEAT SWITCH TAN (18) ORG (18) NEUTRAL NEUTRAL SWITCH SWITCH ORG (18) TAN/RED (18) TAN/RED (18) PRESS ORG (18) J1-P J1-N J1-M J1-L J1-K...
  • Page 44 REV C 123940...

  • Page 45: Maintenance

    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 1. Engine Oil Fill & Dipstick 2. Fuel Filter 3. Engine Air Cleaner 4. Engine Oil Drain Valve 5. Battery 6. Fuel Tanks 7. Hydraulic Oil Reservoir 8. Hydraulic Oil Filter 9. Front Wheel Bearing Zerks (2) Units with Kawasaki Engines 10.
  • Page 48 1. Engine Oil Fill & Dipstick 2. Fuel Filter 3. Engine Air Cleaner 4. Engine Oil Drain Valve 5. Battery 6. Fuel Tanks 7. Hydraulic Oil Reservoir 8. Hydraulic Oil Filter 9. Front Wheel Bearing Zerks (2) 10. Engine Oil Filter 11.
  • Page 49 Figure 10-4 1. Engine Oil Fill & Dipstick 2. Fuel Filter 3. Engine Air Cleaner 4. Engine Oil Drain Valve 5. Battery 6. Fuel Tanks 7. Hydraulic Oil Reservoir 8. Hydraulic Oil Filter 9. Front Wheel Bearing Zerks (2) 10. Engine Oil Filter 11.
  • Page 50 REV C 10-6 123940...

  • Page 51: Troubleshooting

    TROUBLESHOOTING SUGGESTED SYMPTOMS PROBABLE CAUSES SUGGESTED REMEDIES SYMPTOMS PROBABLE CAUSES REMEDIES Mower creeps when Steering linkage needs Adjust linkage Starting motor does not Steering control levers not Place steering control steering control levers are adjustment crank in park brake position or levers in park brake in neutral switch not adjusted...
  • Page 52 REV C 11-2 123940...
  • Page 53 INDEX PAGE PAGE Avoid Acid Burns ........4-4 Maintenance Introduction .
  • Page 54 INDEX PAGE PAGE REV C 123940...

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