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HUSTLER X-ONEi General Service Manual Download Page 3

117604

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REV A

Table of Contents

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-1

Service Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-1

Maintenance Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-1

Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-1

Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-1

Safe Servicing Practices  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-1

Pre-Operation Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-1

Operation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-2

Operate Machine Safely. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-2

General Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . .  3-2

Maintenance Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-2

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-1

Standard Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-1

Special Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-1

Power Unit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-1

Steering Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-1

Park brake adjustment   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-4

Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-5

Hydraulic Pump Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . .  5-5

Hydraulic system  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-6

Warner Clutch Re-gap Adjustment Procedures . . . . . . . . . . . . .  5-6

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-8

Engine Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-1

General Engine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . .  6-1

Engine Oil and Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-1

Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-1

Fuel evaporation system filter  . . . . . . . . . . . . . . . . . . . . . . . . . .  6-2

Fuel & evaporative system line routings. . . . . . . . . . . . . . . . . . .  6-2

Deck Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-1

Deck Leveling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-1

Summary of Contents for X-ONEi

Page 1: ...117604 REV A Hustler X ONE i General Service Manual 200 S Ridge Road Hesston Kansas 67062 2097...

Page 2: ...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...

Page 3: ...nce Precautions 3 2 Torque 4 1 Standard Torques 4 1 Special Torques 4 1 Power Unit Maintenance 5 1 Steering Adjustments 5 1 Park brake adjustment 5 4 Belts 5 5 Hydraulic Pump Belt Adjustment 5 5 Hydra...

Page 4: ...REV A toc 2 117604 Blades 7 2 Belts 7 4 Deck Belt Adjustment 7 4 Electrical 8 1 Troubleshooting 10 1...

Page 5: ...d up of grease oil and dirt especially in the engine and under the seat platform areas minute dust particles are abrasive to close tolerance engine and hydraulic assemblies Daily inspect mower for gra...

Page 6: ...REV A 2 2 117604...

Page 7: ...pets 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 a...

Page 8: ...ine must be operated in an enclosed area 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 t...

Page 9: ...te 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...

Page 10: ...REV A 3 4 117604...

Page 11: ...this fastener SIZE FT LBS NM SIZE FT LBS NM 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...

Page 12: ...REV A 4 2 117604...

Page 13: ...ds and rotate the rod to lengthen the steering control linkage until the wheel s come to a stop Figure 5 3 7 Repeat for the opposite side if necessary 8 If wheel s are rotating in reverse then loosen...

Page 14: ...fore the pump bottoms out Lock in place when the adjustment is correct by re tightening the jam nut Do this for each side To adjust the stops for driving straight when steering control levers are agai...

Page 15: ...l position 6 Tighten the nut on the steering damper s front ball stud NOTE The damper must not bottom out when the pump lever is fully stroked in either direction 7 Reconnect the negative battery cabl...

Page 16: ...re 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 po...

Page 17: ...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...

Page 18: ...d your warranty The Hustler X ONE i system filter is located at the bottom of the integrated transmission with access to it from the front Use a Hustler approved filter element only When changing the...

Page 19: ...er the brake pole and around the aluminum spacers Figure 5 18 Check the air gap between rotor armature with feeler gage If the gap is less than 070 then follow the trouble shooting procedure outlined...

Page 20: ...and the deck should not be engaged with 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 the...

Page 21: ...you wish to use non pneumatic tires on your Hustler mower the tires must be an approved tire purchased from Hustler Turf Equipment Warranty claims will be denied on any mower equipped with unapproved...

Page 22: ...REV A 5 10 117604...

Page 23: ...the valve counterclockwise to open the valve Allow 10 minutes for engine oil to adequately drain 4 After oil is drained close the valve by twisting it clockwise 5 Clean up any spilled oil IMPORTANT Al...

Page 24: ...fore 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 t...

Page 25: ...04 6 3 REV A Figure 6 5 Figure 6 6 Fuel evaporation system filter Fuel shutoff valve Fuel tank Fuel tank Fuel line Seat support Figure 6 7 Fuel evaporation system filter Vapor line Tee Fuel tank Fuel...

Page 26: ...oad should be set as follows 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...

Page 27: ...igure 7 7 7 Loosen the two nuts on the front of height indicator so that the foot pedal is free Figure 7 3 Figure 7 7 8 Start the leveling process on the left front of the mower 9 Set the amount of th...

Page 28: ...block holding the threaded rod until there is slack in the deck lift chain Figure 7 7 25 Tighten the appropriate nut until the chain just becomes tight and carries most of the deck weight Check by mo...

Page 29: ...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 installa...

Page 30: ...elts and never use belt dressings Any of these will destroy the belt composition in a very short time Deck Belt Adjustment The spindle belt tension remains constant by means of a tension idler and spr...

Page 31: ...ame 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 8 26cm cut height 2 Route belt as shown 52 60 Deck Belt...

Page 32: ...REV A 7 6 117604...

Page 33: ...117604 8 1 REV A ELECTRICAL Electrical Schematic Kawasaki...

Page 34: ...REV A 8 2 117604...

Page 35: ...for engine service information NOTE After completing maintenance cycle 500 hours repeat cycle Maintenance Schedule Figure 9 1 Figure 9 2 Figure 9 3 Figure 9 4 SERVICE AT INTERVALS INDICATED WEEKLY OR...

Page 36: ...il Reservoir 8 Hydraulic Oil Filter 9 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...

Page 37: ...l Drain Plug 5 Battery 6 Fuel Tanks 7 Hydraulic Oil Reservoir 8 Hydraulic Oil Filter 9 Front Wheel Bearing Zerks 2 10 Engine Oil Filter 11 Deck Height Pivot Zerks 4 12 Park Brake Switch 13 Drive Tires...

Page 38: ...REV A 9 4 117604...

Page 39: ...ation Failed oil pump Contact your dealer High oil consumption Numerous Contact your dealer Mower jerky when starting or operates in one direc tion only Steering control linkage needs adjustment Adjus...

Page 40: ...REV A 10 2 117604...

Page 41: ...ons 3 2 Hydraulic pump belt adjustment 5 5 Hydraulic system 5 6 Maintenance introduction 2 1 Maintenance Locator Chart 9 2 Maintenance precautions 3 2 Maintenance schedule 9 1 Mower blade maintenance...

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