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603695CE

5-1

REV G

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.

SYMPTOMS

PROBABLE CAUSES

SUGGESTED

REMEDIES

Starting motor does not

crank

Steering control levers not

in park brake position or

switch not adjusted

Place steering control

levers in park brake posi-

tion or re-adjust switch

Deck clutch switch

engaged

Disengage clutch switch

Weak or dead battery

Recharge or replace

Electrical connections are

corroded or loose

Check the electrical con-

nections

For additional causes

See engine manual

The engine will not start,

starts hard or fails to

keep running

No fuel or line plugged

Fill tank or replace line

(See

Fuel System

section

for more details)

Fuel valve is turned off

Open the fuel valve

There is incorrect fuel in

the fuel system

Drain the tank and replace

the fuel with the proper

type

There is dirt in the fuel filter

Replace the fuel filter

Dirt, water or stale fuel in

the fuel system

Contact your dealer

Numerous

See engine manual

Engine:

Runs with continuous

misfiring or engine runs

unevenly or erratically

Numerous

See engine manual

Loss of power or system

will not operate in either

direction

Restrictions in air cleaner

Service air cleaner

Hydraulic line blockage

See your dealer

Internal interference or

leakage in wheel motor

See your dealer

Insufficient hydraulic oil

supply

Check level in reservoir

Have dealer check hydrau-

lic pump

Poor compression

See your dealer

Steering linkage needs

adjustment

Adjust linkage

Tow valve open

Close tow valve

The traction drive belt is

worn, loose or broken

Install a new traction drive

belt

Air in system

Check filter and fittings

For additional causes

See engine manual

Liquid cooled or Diesel

engines overheating:

Temperature light glows

Frequent refilling of radia-

tor required

Coolant appears rusty

Audible alarm

Leaks in system

Replace/tighten hoses and

connections

Coolant level low

Add coolant

Radiator screen clogged

Clean screen

Thermostat stickling or

inoperative

See engine manual

Heat light malfunction

Contact your dealer

Low engine oil pressure

Low oil level

Add oil

Oil diluted or too light

Change oil and check for

source of contamination

Failed oil pump

Contact your dealer

High oil consumption

Numerous

Contact your dealer

Mower jerky when start-

ing or operates in one

direction only

Steering control linkage

needs adjustment

Adjust linkage

Pump or wheel motors

faulty

Contact your dealer

Tow valves not closed

completely

Close tow valves

Hydraulic system oper-

ates hot (oil in reservoir

smells rancid)

Low hydraulic oil level

Fill reservoir

Hydraulic pump faulty

Contact your dealer

Hydraulic oil heat

exchanger clogged

Clean oil heat exchanger

core

Mower creeps when

steering control levers are

in neutral

Steering linkage needs

adjustment

Adjust linkage

Mower circles or veers in

one direction

Steering linkage needs

adjustment

Adjust linkage

Wheel motors faulty

Contact your dealer

Tires improperly inflated

Adjust air pressure to 55 -

83 KPa

Hydraulic pump faulty

Contact your dealer

Mower creeps when park-

ing brake engaged

Steering linkage out of

adjustment

Adjust steering linkage

Brakes need adjustment

Adjust parking brakes

There is abnormal vibra-

tion

The engine mounting bolts

are loose

Tighten the engine mount-

ing bolts

The engine pulley, idler pul-

ley or blade pulley is loose

Tighten the appropriate

pulley

The engine pulley is dam-

aged

Contact your dealer

The cutting blade(s) is/are

bent or unbalanced

Install new cutting blade(s)

A blade mounting bolt is

loose

Tighten the blade mount-

ing bolt

Spindle bearing is worn or

loose

Replace or tighten spindle

bearing

A blade spindle is bent

Contact your dealer

Blades do not rotate

The deck drive belt is worn,

loose or broken

Install a new deck drive

belt

The deck drive belt is off

the pulley

Install the deck drive belt

and check for a reason

Electric clutch is not

engaging

Check and/or replace 10

amp fuse.

Contact your dealer

SYMPTOMS

PROBABLE CAUSES

SUGGESTED

REMEDIES

Содержание 931279CE

Страница 1: ...603695CE REV G CZ DA DE EN ES FR IT NL PT SV Hustler Z Diesel Operator s Manual 200 South Ridge Road Hesston Kansas 67062 ...

Страница 2: ...ent Authorized Representative Southern Machinery LTD Downings South Prosperous NAAS Co Kildare IRL Telephone 353 45 86 0031 www southernmachinery ie Email gtutty eircom net Excel Industries Inc Manufacturer of Hustler Turf Equipment 200 South Ridge Road Hesston Kansas 67062 Telephone 620 327 4911 FAX 620 327 2828 ...

Страница 3: ...trol Panel 3 1 Controls 3 2 Safety Start Interlock System 3 3 Engine Starting 3 3 Stopping the Engine 3 4 Moving the Mower With Stalled Engine 3 4 ROPS Roll Over Protective Structure 3 4 Mower Operation 3 6 Deck Cutting Height Adjustment 3 10 Air Flow Baffles 3 10 Anti Scalp Wheels 3 11 Maintenance Adjustments 4 1 Safe Servicing Practices 4 1 Service Introduction 4 1 Torque Values 4 1 Tires 4 1 Fl...

Страница 4: ...R IT NL PT SV Belts 4 6 Mower Blades 4 6 Mower Blade Options 4 8 Seat Adjustment 4 8 Steering Control Lever Adjustment 4 9 Maintenance Locator Chart 4 13 Maintenance Record 4 16 Troubleshooting 5 1 Storage 6 1 Technical Specifications 7 1 ...

Страница 5: ...ice technician This manual contains general operation information as well as basic adjustment and maintenance information Since operating conditions vary considerably all conditions cannot be addressed individually Through training and expe rience operators should develop safe operating practices suitable to most conditions Directions used in this manual for example RIGHT or LEFT refer to directio...

Страница 6: ...tion when ordering parts 1 Correct part description 2 Correct part number 3 Correct model number 4 Correct serial number All arrangements for warranty repair and service must be handled through an authorized Hustler Dealer Product Literature If you would like to view or print a copy of this manual go online to www hustlerturf com Contact your local Hustler Dealer if you require another engine owne...

Страница 7: ...his equipment Safe Operating Practices This product is capable of amputating hands and feet and throwing objects Always follow all safety instructions to avoid serious injury or death Never allow persons to operate this mower without proper instruction or allow children to operate the mower Allow only responsible adults who are familiar with these instructions to operate this mower Safe Operation ...

Страница 8: ...aised posi tion except when the entire grass catcher attachment or mulching system is being used Always keep clear of the mower blades and attach ments during their operation Never put hands or feet under any part of the mower while it is running Stop the engine before removing the grass catcher or unclogging the discharge chute Never clear the dis charge chute with the engine running Turn off the...

Страница 9: ... 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 This will reduce the risk of the mower suddenly rolling over causing serious injury or death Use a walk behind push mower or hand held trimmer on slopes and near drop offs retaining walls drainage ditches embankments and water to...

Страница 10: ...er carry children even with the blades off They may fall off and be seriously injured or interfere with safe mower operation Children who have been given rides in the past may suddenly appear in the mowing area for another ride and be run over or backed over by the mower Never allow children to operate the mower Never allow children or others in or on towed equip ment Use care when approaching bli...

Страница 11: ...area away from sparks and flames Unplug charger before connect ing or disconnecting from battery Wear protective cloth ing and use insulated tools Avoid skin and clothing contact with battery acid Always wear eye protection when checking the battery Acid can cause serious injury to skin and eyes If contact occurs flush area with clean water and call a physician immediately Acid will also damage cl...

Страница 12: ... of vapors Long term exposure to vapors can cause serious injury and illness Keep diesel fuel away from eyes and skin Keep face away from nozzle and fuel tank or fuel container opening If diesel fuel is spilled on clothing change cloth ing immediately Safety and Instructions Decals The decals are designed to give the operator and mechanic brief daily operational and service information Use these d...

Страница 13: ...ce to pen etrate skin and cause serious injury Foreign fluid injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result Before applying pressure to hydraulic system make sure all connections are tight and all hoses and lines are in good condition Relieve all pressure in the system before disconnecting or working on hydr...

Страница 14: ...WARNING Read Operator s Manual and decals before attempting to operate this machine WARNING This structure s protective capability may be impaired by structural damage overturn or alteration If any of these conditions occur this structure must be replaced DANGER Battery Hazards Part Number 601815 Do not overfill battery Electrolyte may overflow and damage paint wiring or structure When cleaning th...

Страница 15: ...Always stop machine if someone enters the area WARNING Roll over Slow down before turning Do not operate on slopes greater than 15 degrees Keep all movement on slopes slow and gradual Never make sudden changes in speed and direction Do not operate on slopes above a retaining wall or drop off WARNING Ejection Do not operate on slopes greater than 15 degrees Keep all movement slow and gradual when g...

Страница 16: ...osition I GLO plug J If warning light comes on check charging system K Engine start position L If warning light comes on engine coolant at unsafe temperature M Read Operator s Manual before attempting to operate this machine N Wear ear protection eye protection and safety shoes when operating this equipment O Clutch engage P Clutch disengage 603758 Part Number 603758 A B P O D K L J H I G C M E F ...

Страница 17: ...perature M Read Operator s Manual before attempting to operate this machine N Wear ear protection eye protection and safety shoes when operating this equipment O Clutch engage P Clutch disengage 606412 Part Number 606412 B P D K L H E F J A O C G I N M Check engine oil Part Number 601377 Part Number 602041 WARNING Hot surface Keep a safe distance from the machine 602041 Top of Deck Clutch Switch S...

Страница 18: ... models Hustler Z Diesel 931295CE Hustler Z Diesel 931717CE Hustler Z Diesel 938191CE Hustler Z Diesel 938217CE Part Number 776310 This model is certified and is in compliance with European Directive 2006 42 EC Part Number 602562 Any maintenance operation that requires the removal of safety covers must be performed by a trained service technician 776310 REV B The information shown on this decal is...

Страница 19: ...d the paper along the slope guide lines C D or E 4 Align the closest slope guide line with the ground slope This will give you a close estimation of the ground slope to be mowed Slope Guide Lines Line B D 10o C 5o E 15o Line A Slope Guide Use this diagram when determining the degree of slope to be mowed 603695CE 2 13 REV G CZ DA DE EN ES FR IT NL PT SV ...

Страница 20: ...REV G 2 14 603695CE CZ DA DE EN ES FR IT NL PT SV ...

Страница 21: ...n the ignition switch is turned to the Pre Heat Run position and held It shows that power is going to the glo plugs F Alternator warning light Figure 3 1 Figure 3 2 this light comes on when the ignition switch is placed in the RUN position and stays it until the engine is run ning and the battery is being charges If the light comes on during operation shut the engine off imme diately locate and co...

Страница 22: ...troller 25 amp blade type This fuse can be found behind the access cover located behind the seat Controls A Steering control levers Figure 3 5 Figure 3 6 these levers control the mower s speed direction stopping and park brake J Throttle control Figure 3 3 K 15 amp fuse L 25 amp fuse Figure 3 4 J K L The parking brake may not hold the mower if parked on a slope Block or chock the machine when park...

Страница 23: ...ne fails to stop when the deck clutch switch is up or one or both of the steering control levers is in the up out of neutral position and the operator is off the seat then check the function of the seat switch Replace the seat switch if it is not operating properly is not opening or closing and if the cause can not be determined If you cannot locate the problem contact your Hustler Dealer Engine S...

Страница 24: ...ck system section 7 Allow the engine to idle a few minutes before advanc ing the throttle and or engaging the deck clutch Stopping the Engine Use the following procedure to shut the engine off 1 Place the steering control levers in the park brake posi tion 2 Throttle the engine back to low idle then disengage the deck clutch Refer to the Mower Deck Operation sec tion for more details 3 Let the eng...

Страница 25: ...ha or other chemical cleaning agents as these will weaken the webbing For the same rea son do not bleach or dye the webbing Replace the seat belt if worn or damaged Possible Damage to ROPS If the unit has rolled over or the ROPS has been in some other type of accident such as hitting an overhead object during transport replace the ROPS to retain the best protec tion A ROPS B Hair pin C Clevis pin ...

Страница 26: ...earward an equal distance Figure 3 11 To turn left move the right steering control lever farther forward from neutral than the left steering control lever To turn right move the left steering control lever farther forward from neutral than the right steering control lever Figure 3 11 Zero radius turn move one steering control lever forward and the other steering control lever back of neutral This ...

Страница 27: ...re 3 12 IMPORTANT Damage to the hydraulic system compo nents may occur with rapid movement of the steering con trols To increase speed increase the steering control lever s dis tance from neutral The farther forward the steering control levers are from neutral the faster the mower will travel for ward The farther back the steering control levers are from neutral the faster the mower will go in rev...

Страница 28: ...l l e v e r N e u t r a l Neutral Left control lever Right control lever An inexperienced operator should not mow on slopes or on uneven terrain Before attempting normal speed operation an inex perienced operator should be thoroughly familiar with the proper use and operation of the equipment read the manual completely and thoroughly have attempted slow moving maneuvers If you lose steering contro...

Страница 29: ...e grass is slightly taller than normal or if it contains a high degree of moisture Then mow it again with the cutting height set lower If the machine s forward motion must be stopped while mowing a clump of grass clippings may drop onto your lawn To avoid this move onto a previously cut area with the blades engaged Never work with blades while the engine is running or deck clutch switch is engaged...

Страница 30: ...agement and disengagement practices Deck Cutting Height Adjustment Deck cutting height is adjustable in 6 4mm increments The holes in the height adjusting bar are spaced at 12 7mm intervals By turning the height adjusting stop around 6 4mm increments can be attained due to the 6 4mm plate that is part of the stop Figure 3 15 EXAMPLE When the height adjusting stop is placed in the 76 2mm hole with ...

Страница 31: ...the cutting blades and the lower hole posi tions them 50 8 mm below the cutting blades Figure 3 18 Figure 3 19 When the mowing height is set at 25 4 mm to 76 2 mm the anti scalp wheels rollers should be in the upper position When the mowing height is set at 82 6 mm to 127 mm the anti scalp wheels rollers should be in the lower position Setting Conditions A Bottom set of holes Dry sparse grass Part...

Страница 32: ...ould be in the same axle mount hole as the front anti scalp wheels A Anti scalp wheel B Adjusting holes Figure 3 18 B A Roller shown in upper adjusting hole A Lower adjusting hole B Rear center anti scalp roller Figure 3 19 A Side anti scalp rollers B Center anti scalp roller location Figure 3 20 A B B A ...

Страница 33: ...he steering control levers in the park brake position and pivot the arm rests upward before lifting the seat platform to prevent arm rest damage Some repairs require the assistance of a trained service mechanic and should not be attempted by unskilled person nel Consult your Hustler service center when assistance is needed Torque Values Torque values are given below N m Wheel lug nuts 95 Blade spi...

Страница 34: ... oil after an oil and filter change Do not overfill the reservoir Initial system oil and filter change must be after the first 50 hours of mower operation Then replace the filter and oil in the reservoir annually or every 500 hours whichever comes first Figure 4 3 IMPORTANT It is necessary to drain the system oil from the hydraulic reservoir using the reservoir drain plug before removing the hydra...

Страница 35: ...lowly Fuel Shut off Valve The Hustler Z Diesel mower is equipped with a fuel shut off valve located to the right rear of the seat Rotate the valve to the middle position to allow fuel to flow from the right fuel tank to the fuel pump The right position prevents fuel flow to the fuel pump The left position allows fuel to flow from the left fuel tank to the fuel pump Close this valve to prevent fuel...

Страница 36: ... on the under neath side of the engine Figure 4 7 Engine Air Filter Perform engine air filter maintenance per the Maintenance Schedule shown elsewhere in this manual A specially designed dry filter is standard equipment on these mowers and supplies clean combustion air to the engine Figure 4 8 These mowers are equipped with a safety filter The filter element slides over the safety filter Figure 4 ...

Страница 37: ... 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 The warranty for air filters expires upon cleaning or servicing in any manner because the condition of the filter after servicing is completely out of the filter manufacturer s control ...

Страница 38: ...ricating oil levels with quality and viscosity recommenda tions bolt torques etc The engine warranty is backed by the engine manufacturer Special attention should be paid to applicable data which will not be duplicated here Belts Inspect belts frequently for wear and serviceability Replace a belt that shows signs of severe cuts tears separation weather checking cracking burns caused by slipping Sl...

Страница 39: ...or balance Blade balanc ing can be done by placing the blade on an inverted line punch or 5 8 bolt A commercial balancing tool is also avail able through most hardware supply stores The blade should not lean or tilt When spinning the blade slowly it should not wobble Balance the blade before rein stalling Lay the blade on a flat surface and check for distortion Replace any distorted blade Figure 4...

Страница 40: ...chnician There are two seat options available for these mowers The following are the adjustments for each of these seats Seat Option 1 This seat can be adjusted five different ways to obtain the most comfortable position 1 Back angle Figure 4 15 2 Forward and rearward travel Figure 4 15 3 Weight Figure 4 15 End view of blades comparing twisted and straightened blades A Twisted blade edge replace b...

Страница 41: ...le Figure 4 18 2 Forward and rearward travel Figure 4 17 3 Weight Figure 4 17 4 Lumbar Figure 4 19 5 Armrest Figure 4 20 A Weight adjusting con trol B Forward rearward travel lever C Isolator D Back angle control Figure 4 15 A Armrest control Figure 4 16 A D B C A A Weight adjusting con trol B Forward rearward travel lever Figure 4 17 A Back angle control Figure 4 18 A Lumbar control Figure 4 19 A...

Страница 42: ...or rearward loosen the cap screws that attach the upper control lever to the lower lever Then pivot the upper control lever Tighten the cap screws Figure 4 22 To lower and raise the control levers remove the cap screws 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 Figure 4 22 The steering control levers sh...

Страница 43: ...h use Visually inspect unit for loose hardware and or damaged parts Prior to each use Visually inspect tires Prior to each use Check oil level engine 1 4 Prior to each use or every 4 hours Clean oil heat exchanger 8 Prior to each use or every 4 hours Check radiator screen 11 Prior to each use or every 4 hours Clean air intake screen 11 Prior to each use or every 4 hours Check fuel level Prior to e...

Страница 44: ...ystem for any cracks or leaks including but not limited to fuel line hoses fuel valve vent line hoses vent valve vapor valve carbon canister and grommets Replace as needed 8 More often under dusty or dirty conditions and during hot weather 9 Inspect ROPS after the first 20 hours of operation and then after every 500 hours of operation or yearly whichever comes first 10 Refer to engine owner s manu...

Страница 45: ...voir 8 Hydraulic Oil Filter 9 Gauge Wheel Bearing Zerks 2 10 Engine Oil Filter 11 Deck Height Pivot Zerks 4 12 Park Brake Switch 13 Drive Tire 14 Pump Idler Zerk 1 15 Pump Belt 16 Deck Drive Belt 17 Engine Coolant Fill 18 Engine Oil Fill 19 Hydraulic Oil Heat Exchanger 20 Deck Pusher Arm Zerks 2 21 Deck Belt 1 or 2 22 Spindle Housing Zerks 3 23 Blades 3 Figure 4 25 7 9 11 11 12 6 1 3 9 11 11 12 6 ...

Страница 46: ...ain Plug 5 Battery 6 Fuel Tanks 7 Hydraulic Oil Reservoir 8 Hydraulic Oil Filter 9 Gauge Wheel Bearing Zerks 2 10 Engine Oil Filter 11 Deck Height Pivot Zerks 4 12 Park Brake Switch 13 Drive Tire 14 Pump Idler Zerk 1 15 Pump Belt 16 Deck Drive Belt 17 Engine Coolant Fill 18 Engine Oil Fill 19 Hydraulic Oil Heat Exchanger 20 Deck Pusher Arm Zerks 2 21 Deck Belt 1 or 2 22 Spindle Housing Zerks 3 23 ...

Страница 47: ...n Plug 5 Battery 6 Fuel Tanks 7 Hydraulic Oil Reservoir 8 Hydraulic Oil Filter 9 Gauge Wheel Bearing Zerks 2 10 Engine Oil Filter 11 Deck Height Pivot Zerks 4 12 Park Brake Switch 13 Drive Tire 14 Pump Idler Zerk 1 15 Pump Belt 16 Deck Drive Belt 17 Engine Coolant Fill 18 Engine Oil Fill 19 Hydraulic Oil Heat Exchanger 20 Deck Pusher Arm Zerks 2 21 Deck Belt 1 or 2 22 Spindle Housing Zerks 3 23 Bl...

Страница 48: ...r Hour Meter Reading Date Maintenance Service Performed Dealer Hour Meter Reading Date Maintenance Service Performed Dealer Hour Meter Reading Date Maintenance Service Performed Dealer Hour Meter Reading Date Maintenance Service Performed Dealer Hour Meter Reading Date Maintenance Service Performed Dealer Hour Meter Reading REV G 4 16 603695CE CZ DA DE EN ES FR IT NL PT SV Maintenance Record Perfo...

Страница 49: ...rheating Temperature light glows Frequent refilling of radia tor required Coolant appears rusty Audible alarm Leaks in system Replace tighten hoses and connections Coolant level low Add coolant Radiator screen clogged Clean screen Thermostat stickling or inoperative See engine manual Heat light malfunction Contact your dealer Low engine oil pressure Low oil level Add oil Oil diluted or too light C...

Страница 50: ...tion of the General Service Manual An anti scalp wheel is not set correctly Adjust the height of the anti scalp wheel The underside of the deck is dirty Clean the underside of the deck Tires improperly inflated Adjust air pressure to 55 83 KPa A blade spindle is bent Contact your dealer Flex Forks are installed After initial break in period level the deck per the Deck Leveling section of the Gener...

Страница 51: ...l filler cap and fuel cap to make certain they are securely in place 7 Refer to the engine owner s manual for more informa tion Preparation of battery for storage When the machine is to be unused for long periods it is best to disconnect the battery and remove it from the unit At this time perform the following battery maintenance 1 Remove the battery from machine NOTE Always dis connect the negat...

Страница 52: ... 6 2 603695CE CZ DA DE EN ES FR IT NL PT SV At start of new season always check that fresh oil has been added to machine If oil is drained at sea son s end and not replaced engine damage will result WARNING ...

Страница 53: ...he RMS acceleration in m s measured in 24 seconds is less than 2 5 m s The RMS acceleration in m s measured in 24 seconds is less than 2 5 m s The RMS acceleration in m s measured in 24 seconds is less than 2 6 m s The RMS acceleration in m s measured in 24 seconds is less than 2 5 m s Test was performed on a static stationary machine Guaranteed Sound Power Level Operator Ear Engine RPM Vibration ...

Страница 54: ...REV G 7 2 603695CE CZ DA DE EN ES FR IT NL PT SV ...

Страница 55: ...e Record 4 16 Maintenance Schedule 4 11 Master In Line Fuse 4 2 Model and Serial Number 1 1 Moving the Mower With Stalled Engine 3 4 Mower Blade Maintenance 4 6 Mower Blade Maintenance Precautions 2 5 Mower Blade Options 4 8 Mower Blade Replacement 4 7 Mower Blades 4 6 Mower Operation 3 4 New Season Preparation 6 1 Operating Suggestions 3 8 Operation 2 2 Parts and Service 1 2 Personal Safety 2 1 P...

Страница 56: ...REV G I 2 603695CE CZ DA DE EN ES FR IT NL PT SV INDEX PAGE PAGE ...

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