OPERATOR S MANUAL & PARTS DRAWINGS HUSTLER FLEX DECK. PO Box 7000 Hesston, Kansas /19/

Transcription

1 OPERATOR S MANUAL & PARTS DRAWINGS HUSTLER 0 FLEX DECK PO Box 000 Hesston, Kansas 0-0 0// 0.00

2 TABLE OF CONTENTS INTRODUCTION PAGE To the New Owner... Warranty Registration... Model and Serial Number... Parts and Service... Using Your Manual... SAFETY PAGE Safety Decals... General Safety Procedures... Training Required... Personal Protective Equipment Requirements... Operating Safely... Preventing Accidents... Keep Riders Off...0 Truck Or Trailer Transport...0 Maintenance...0 Hydraulic Safety... Flex Deck Safety Procedures... Cutting Unit Safety... GENERAL OPERATION PAGE Daily Inspection... Attaching... Detaching... Rear Counterbalance Weights... Mowing and Operating Procedure... Transport of Mower... Cutting Height Adjustment... Mower Front Wheel Path Adjustment... Anti-Scalp Roller Adjustment... Mulching Kit (Optional Accessory)... SERVICE PAGE Cleaning and General Maintenance... Deck Flip-Up Procedure (Service Position)... Mower Blade Inspection/Replacement... Mower Blade Sharpening... Drive Belt Inspection/Replacement... Drive Belt Tensioning Adjustments... Tire Pressure... Storage... Deck Leveling Procedure...0 Lubrication Locations... Gearbox... Maintenance Schedule... Maintenance Checklist... Dimensions...

3 TABLE OF CONTENTS PARTS PAGE Decks & Connector Links... Carrier Frame...0 Hitch Arms & Hitch Frame Shields... Drive Shaft & Gearbox... Deck Belts... Spindles... Carrier & Side Deck Shields...0 Front Anti-Scalp Rollers... Rear Rollers... Discharge Defl ectors & Rear Belting... Deck Wing Lift Arms... Deck Wing Lift Arm Hydraulics...0 Mulch Kit... WARRANTY PAGE

4 INTRODUCTION This manual applies to the following Hustler equipment lines: Hustler Flex Deck To the New Owner The purpose of this manual is to assist owners and operators in maintaining and operating the Hustler Flex Deck. Please read it carefully; information and instructions furnished can help you achieve years of dependable performance. It is divided into sections for convenient reference of the appropriate section. Keep this manual with the machine at all times. The manual should remain with the machine even if it is sold. If this manual becomes damaged or unreadable, it should be replaced immediately. Contact your Hustler dealer for a replacement. When using a Hustler attachment, be sure to read and follow the safety and operating instructions of both the power unit and the attachment being used to ensure the safest operation possible. It is the owner s responsibility to make certain that the operators and mechanics read and understand this manual and all decals before operating this machine. It is also the owner s responsibility to make certain that the operators and mechanics are qualifi ed and physically able individuals, properly trained in the operation of this equipment. All operators and mechanics must become familiar with the safe operation of the equipment, operator controls, and safety signs. The owner/user can prevent and is responsible for accidents or injuries occurring to themselves, other people, or property. Warranty Registration The completed Warranty Registration and Delivery form must be sent to Hustler Turf Equipment within ten (0) days of delivery to validate your warranty protection. As the new equipment owner, you are expected to see that the form is completed and forwarded to Hustler Turf Equipment at time of delivery. The warranty registration form can also be accomplished electronically by the Hustler dealer to validate the warranty. This form must be on fi le for validation before any warranty claim applications can be processed by Hustler Turf Equipment. Be sure to register the power unit plus each attachment that displays a model and serial identifi cation number plate with Hustler Turf Equipment. IMPORTANT: Any unauthorized modifi cation, alteration, or use of non-approved attachments voids the warranty and releases Hustler Turf Equipment from any liability arising from subsequent use of this equipment. Do not use or operate any attachment not approved by Hustler Turf Equipment. Model and Serial Number Model and serial numbers are found on the serial identifi cation plate, located on the left carrier arm. These numbers are required on the Warranty Registration form. They will also assure you of the correct service parts when replacement becomes necessary. Please fi ll in the following information for future reference. Date of Purchase: Dealer Name: Dealer Phone #: Dealer Fax #: Dealer Address: Model Number: Serial Number: Parts and Service Use original Hustler replacement parts only. These parts are available through your local Hustler dealer. To obtain prompt, effi cient service, always provide the following information when ordering parts.. Correct part description.. Correct model number.. Correct serial number. All warranty repair and service must be handled through an authorized Hustler dealer. Arrangements should be made through your local service center. Introduction -

5 Using Your Manual INTRODUCTION General operation, adjustment, and maintenance guidance is outlined for both the experienced and novice Hustler user. Operating conditions vary considerably and cannot all be addressed individually. Through experience, however, operators should find no difficulty in developing good operating skills suitable to most conditions. Directions used in this manual, for example RIGHT or LEFT, refer to directions when seated on power unit facing forward, unless stated otherwise. Photographs and illustrations used were current at the time of printing, but subsequent production changes may cause your machine to vary slightly in detail. Hustler Turf Equipment reserves the right to redesign and change the machine as deemed necessary, without notification. If a change has been made to your machine which is not reflected in this owner s manual, see you Hustler dealer for current information and parts. Throughout this manual, you will encounter special messages and symbols that identify potential safety concerns to help you as well as others avoid personal injury or damage to the equipment. SYMBOL DEFINITIONS This safety alert symbol is used to call attention to a message intended to provide a reasonable degree of PERSONAL SAFETY for operators and other persons during the normal operation and servicing of this equipment. Obey all safety messages that follow this symbol to avoid possible injury or death. There are three signal words that describe the level of safety concern: Danger, Warning, and Caution. Safety should always be the # priority when working on or operating equipment. Accidents are more likely to occur when proper operating procedures are not followed or inexperienced operators are involved. SIGNAL WORD DEFINITIONS Denotes immediate hazards which WILL result in severe personal injury or death. Denotes a hazard or unsafe practice which COULD result in severe personal injury or death. This manual may also use two other word to highlight information. IMPORTANT calls attention to special mechanical information and NOTE: emphasizes general information worthy of special attention. Introduction -

6 Safety Decals SAFETY The following safety decals must be maintained on your Hustler fl ex deck. Keep all safety decals legible. Remove all grease, dirt, and debris from safety decals and instructional labels. If any decals are faded, illegible, or missing, contact your dealer promptly for replacements. When new components are installed, be sure that current safety decals are affi xed to the replacement components. Carrier Arms F A B PTO Shaft Caster Wheels A A A Anti-scalp Rollers Shields F C E D E Belting A Rear Roller Safety -

7 SAFETY A WARNING: Thrown objects DANGER: Rotating blades, pulleys, & belts B WARNING: Rotating driveshaft! C Always maintain a safe distance from people and pets when mowing. Always stop machine if someone enters the area. Keep hands, feet, and clothing away. Keep shields or covers in place while machine is in operation. WARNING: Read Owner s Manual before attempting to operate or service this machine. D Keep hands, feet, and clothing clear of this area. Keep a safe distance from the machine. Keep shields or covers in place while machine is in operation. E Wear ear protection, eye protection, and safety shoes when operating this equipment. F WARNING: Fluid under pressure! Avoid hydraulic fluid escaping under pressure. Hydraulic fluid escaping under pressure can penetrate skin. Hydraulic fluid escaping under pressure may have sufficient force to penetrate 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 the 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 hydraulic lines. To find a leak under pressure, use a piece of cardboard or wood - never use your hands. To relieve all pressure in the system, lower attachment and turn engine off. WARNING: Thrown objects Never operate the mower deck with rear deflectors damaged, altered, removed, or in raised position. WARNING: Pinch points. Keep hands and feet clear. Moving parts can crush or cut. Decal Description Part Number Quantity A Warning, Deck Safety B Warning, Rotating Drive shaft 0.00 C Warning, Read Owner s Manual 0.00 D Warning, Fluid Under Pressure 0.00 E Warning, Thrown Objects F Warning, Pinch Point 0.00 Safety -

8 SAFETY General Safety Procedures for Machine, Attachments, & Accessories Training Required All operators and mechanics should read this manual, and be instructed about safe operating and maintenance procedures. If the operators or mechanics cannot read and understand English, it is the owner s responsibility to explain this material to them. Incorrect usage of this machine may result in severe injury. Personnel operating and maintaining it should be trained in proper use and should read the manuals completely and thoroughly before attempting to set up, operate, adjust, or service this machine. It is the owner s responsibility to make certain that the operators and mechanics read and understand this manual and all decals before operating this machine. It is also the owner s responsibility to make certain that the operators and mechanics are qualified and physically able individuals, properly trained in the operation of this equipment. All operators and mechanics must become familiar with the safe operation of the equipment, operator controls, and safety signs. Never allow children or untrained people to operate or service the equipment. Local regulations may restrict the age of the operator. The owner/user can prevent and is responsible for accidents or injuries occurring to themselves, other people, or property. The owner should also ensure the operator/mechanic know that they are responsible for their own safety as well as the safety of other persons within the vicinity. Remember, the operator is responsible for accidents or hazards occurring to other people or their property. Learn and understand the use of all controls. Know how to stop the machine and all attachments quickly in the event of an emergency. Personal Protective Equipment Requirements It is the responsibility of the owner to be sure that the operators use the proper personal protective equipment while operating the machine. Required personal protective equipment includes, but is not limited to, the following list. Wear a certifi ed ear protection device to prevent loss of hearing. Prevent eye injury by wearing safety glasses while operating the machine. Closed toe shoes must be worn at all times. Long pants must be worn at all times. When operating in dusty conditions, it is recommended that a dust mask be worn. Operating Safely Inspect machine before operation. Repair or replace any damaged, worn, or missing parts. Be sure guards and shields are in proper working condition and are secured in place. Make all necessary adjustments before operating machine. Follow daily and weekly checklists, making sure hoses are tightly secured and bolts tightened. Alterations or modifi cations to this machine can reduce safety and could cause damage to the machine. Do not alter safety devices or operate with shields or covers removed. Before each use, verify that all controls function properly and inspect all safety devices. Do not operate if controls or safety devices are not in proper working condition. Check parking brake function before operating. Repair or adjust parking brake if necessary. Observe and follow all safety decals. All controls are to be operated from the operator s seat only. Always wear a seat belt if the machine has a roll cage/bar installed. Ensure the attachment or accessory is locked or fastened securely to the power unit before operating. Ensure that all bystanders are clear of the power unit and attachment before operating. Stop machine if someone enters your work area. Never turn the PTO switch on unless the PTO shaft is securely connected to a power driven attachment. Safety -

9 SAFETY General Safety Procedures for Machine, Attachments, & Accessories Operating Safely (continued) Always be alert to what is happening around you, but do not lose focus on the task you are performing. Always look in the direction the machine is moving. Look behind and down before backing up to be sure of a clear path. Never operate a poorly maintained machine. Always inspect machine for damage after striking a foreign object. If damage is found, repair machine immediately. Be sure to stop on level ground, place park brake lever in the brake engaged position, place the PTO lever in the OFF position, lower attachment, and remove ignition switch key before leaving operator s seat to inspect damage. Stop operation immediately at any sign of equipment failure. An unusual noise can be a warning of equipment failure or a sign that maintenance is required. Make all necessary repairs before operating machine again. If equipped with a high/low range feature, never shift between high and low range while on a slope. Always move the machine to level ground and place the selector lever in park before shifting range. Do not leave machine unattended while it is running. Always park the machine on level ground. Always shut off engine when connecting attachment drive shaft to the power unit. Never leave the operator s seat without lowering the attachment to the ground, setting the parking brake, shutting off the engine, and removing the ignition key. Make sure all moving parts have come to a complete stop before dismounting. Never leave equipment unattended without lowering the attachment to the ground, setting the parking brake, shutting off the engine, and removing the ignition key. Always operate in daylight or with adequate working lights. Never direct the discharge of any attachment in the direction of people, buildings, animals, vehicles, or other objects of value. Never discharge material against a wall or obstruction. Material may ricochet back towards the operator. Use extra caution when approaching blind corners, shrubs, trees, or other objects that may obscure vision. Always disengage the blades and wait for them to stop before crossing gravel drives, walks, or roads. Do not run the engine in a building without adequate ventilation. Do not touch the engine or the muffl er while the engine is running or immediately after stopping the engine. These areas may be hot enough to cause a burn. Do not change the engine governor settings or over-speed the engine. Operating engine at excessive speed may increase the hazard of personal injury. To reduce the hazard of fi re, keep the battery compartment, engine, and muffl er areas free of grass, leaves, and excessive grease. Never put hands or feet under any part of the machine while it is running. Preventing Accidents Inspect area to be mowed for hazards such as rocks, metal objects, and other debris which may be thrown or entangled by the mower blades. Remove these objects before mowing. Watch out for holes or deep depressions. Always maintain a safe distance from people and pets when mowing. Always stop machine if someone enters the area. Know the work area well before operation. Do not operate where traction or stability is questionable. Reduce speed when you are operating over rough ground. Equipment can cause serious injury and/or death when improperly used. Before operating, know and understand the operation and safety of the power unit and the attachment being used. Safety -

10 SAFETY General Safety Procedures for Machine, Attachments, & Accessories Do not operate machine if you are not in good physical and mental health, if you will be distracted by personal devices, or are under the infl uence of any substance which might impair decision, dexterity, or judgment. Children are attracted to machine activity. Be aware of children and do not allow them in the working area. Turn off the machine if a child enters the work area. Turn off blades when not mowing. Always keep clear of the mower blades and attachments during their operation. Never raise the mower deck with the blades engaged to avoid small obstacles, drive over curbs, and so forth. Disengage PTO before raising the deck. Follow the manufacturer s recommendation for wheel weights or rear counterbalance weights. Keep Riders Off Only allow the operator on the power unit. Keep riders off. Never allow riders on any attachment or accessory. Truck Or Trailer Transport Use care when loading or unloading machine onto a truck or trailer. Never attempt to back machine onto transport trailer with mower deck or attachment in the raised position. The parking brake is not suffi cient to lock the machine during transport. Always secure the power unit and/or attachment to the transporting vehicle. Shut off fuel supply to power unit during transport on truck or trailer. Maintenance Keep all safety decals legible. Remove all grease dirt, and debris from safety decals and instructional labels. If any decals are faded, illegible, or missing, contact your dealer promptly for replacements. When new components are installed, be sure that current safety decals are affi xed to the replacement components. If any component requires replacement, use only original Hustler replacement parts. Unless specifi cally required, DO NOT have engine running when servicing or making adjustments to unit. Park machine on level ground. Place park brake lever in the brake engaged position, place the PTO lever in the OFF position, lower deck, remove ignition key, and disconnect negative battery cable before doing any maintenance. Wait for all movement to stop before adjusting, cleaning, or repairing. Repairs or maintenance requiring engine power should be performed by trained maintenance personnel only. To prevent carbon monoxide poisoning, be sure proper ventilation is available when engine must be operated in an enclosed area. Read and observe safety warnings in front of manual. Keep all bolts, nuts, screws, and other fasteners properly tightened. If the power unit, attachment, or accessory requires repairs or adjustments not instructed in the operator s or parts manual, the power unit, attachment, or accessory must be taken to an authorized Hustler dealer for service. Except when changing or checking belts, always keep belt covers on mower deck for safety, as well as cleanliness. Never perform maintenance on the power unit and/or attachment if someone is sitting in the operator s seat. Always wear adequate eye protection when servicing the hydraulic system and battery or when grinding mower blades and removing accumulated debris. Check all fuel lines for tightness and wear on a regular basis. Tighten or repair them as needed. To reduce the hazard of fi re, keep the battery compartment, engine, and muffl er areas free of grass, leaves, and excessive grease. Do not touch the engine or the muffl er while the engine is running or immediately after stopping the Safety - 0

11 SAFETY General Safety Procedures for Machine, Attachments, & Accessories engine. These areas may be hot enough to cause a burn. Do not change the engine governor settings or over-speed the engine. Operating engine at excessive speed may increase the hazard of personal injury. An obstruction or blockage in a drive system or moving/rotating parts may cause a buildup of stored energy. When the obstruction or blockage is removed, the drive system or moving/rotating parts may move suddenly. Do not attempt to remove an obstruction or blockage with your hands. Keep hands, feet, and clothing away from all power-driven parts. Dispose of all fluids in accordance with local laws. Hydraulic Safety Make sure all hydraulic connections are tight and all hydraulic hoses and tubes are in good condition. Repair any leaks and replace any damaged or deteriorated hoses or tubes before starting the machine. Hydraulic leaks can occur under high pressure. Hydraulic leaks require special care and attention. Use a piece of cardboard and a magnifying glass to locate suspected hydraulic leaks. Keep body and hands away from pinhole leaks or nozzles that eject high pressure hydraulic fl uid. Hydraulic fl uid escaping under high pressure can penetrate the skin causing serious injury. If hydraulic fl uid is injected into skin, seek immediate medical attention. Hydraulic system may contain stored energy. Before performing maintenance or repairs on the hydraulic system, remove attachments, engage parking brake, disengage weight transfer system (if equipped), shut off engine, and remove ignition key. To relieve pressure on the auxiliary hydraulic system, shut off the power unit engine and move the auxiliary control valve lever forward and backward before disconnecting the auxiliary hydraulic quick couplers. Dispose of all fluids in accordance with local laws. Safety -

12 SAFETY Flex Deck Safety Procedures Attachment hydraulic system may contain stored energy. Before performing maintenance or repairs on the hydraulic system, the attachment s auxiliary hydraulic hoses must be disconnected from the power unit. Lower the attachment to the ground, shut off power unit engine, move the auxiliary control valve lever forward and backward to relieve auxiliary hydraulic pressure, and disconnect the auxiliary hydraulic quick couplers. Cutting Unit Safety Rotating Blades: Contact with the rotating mower blades or other moving parts may cause personal injury. Keep hands and feet away. Rotation of one blade may cause another blade to rotate. Thrown Object Hazard: Do not point discharge toward people, animals, or buildings when operating. Never operate with the defl ectors removed. When not mowing, always shut off the PTO to stop the mower blades. Safety -

13 GENERAL OPERATION Daily Inspection Always set the parking brake, shut off the engine, remove the ignition key, and ensure all moving parts have stopped before checking mower deck or blade condition, or attempting any repair or adjustment.. Park power unit and flex deck mower on a level surface, with the engine shut off and all fluids cold.. Perform a visual inspection of the power unit and mower. Look for loose or missing hardware, damaged components, or signs of wear. Inspect hydraulic hoses, hydraulic fi ttings, and fuel lines to ensure tight, leak free connections.. Refer to the power unit operator s manual. Check the power unit s engine oil, hydraulic oil, cooling system, tire pressure, and fuel level. Add fl uid or service as required.. Inspect the drive belts and mower blades. Belts should be in good condition. Blades should be sharp and securely fastened. Service as required.. Test the power unit s operator safety interlock system. Attaching. Place the deck on a level, hard surface (concrete) so it can be rolled on the ground freely by hand.. Pull the power unit up close to the deck. Park the power unit in the position in which the deck should be assembled to the power unit, with approximately feet (.m) between the deck carrier arms and the front of the power unit. Fully engage the park brake, adjust the weight transfer control knob to the minimum setting (turn the knob counter-clockwise until it stops), push the tool bar lift control lever forward into the detent position, bring the throttle to low idle, shut of the engine, and remove the keys. Weight control transfer Tool bar lift control lever. bars approximately feet (. meters) long that can fit into the tool bar receivers, insert them into the tool bar receivers and push them down to lower the receivers. The receivers will need to be pushed down so they are pointed to 0 degrees down from horizontal. NOTE: It is necessary to push down on both sides of the tool bar equally at the same time. Before manipulating the tool bar, ensure engine has been shut off, the park brake has been engaged, and the ignition key has been removed. Push down on both sides of the tool bar If the PTO drive shaft is not installed onto the gearbox input shaft, insert the woodruff key into the keyway on the gearbox input shaft. Align the woodruff key with keyway on universal joint of the PTO shaft. Coat the gearbox input shaft with anti-seize compound and slide universal joint onto gearbox shaft. Secure PTO shaft to gearbox shaft with / cap screw, fl at washer, and nut provided. Torque to ft-lbs ( nm). / cap screw Universal joint Stop engine. Make sure PTO switch is off. Engage park brake and remove ignition key before getting off machine.. The tool bar receivers need to be lowered manually when the power unit is turned off. Using two. Clear away any obstructions between the deck and the power unit. Remove the tool bar hair pins and receiver locking pins and place to the side. Operation -

14 GENERAL OPERATION Receiver locking pin shaft cannot slip off. Carrier arm Drive shaft lock collar PTO shaft Tool bar Hair pin. Push the deck rearward toward the power unit, positioning the deck so the carrier arms are lined up and can be inserted into the receivers. Starting from one side, lift the carrier arm up into position and slide the deck rearward to get the carrier arm started into the tool bar receiver (the deck will be at a slight angle when carrier arm is inserted so the other side carrier arm can still be inserted). Push the deck rearward on this side just far enough so the carrier arm will stay in the receiver.. Proceed to the other side, carefully lift the carrier arm and work the deck rearward to slide the carrier arm into the receiver.. With both carrier arms started in the receivers, push from the front of the deck, working the deck rearward. The deck may need to be rocked from side to side while pushing rearward to get the carrier arms pushed far enough back into the receivers.. Once the deck is pushed back into position, check to make sure the receiver and carrier arm pin holes are lined up. Use a tapered punch, if necessary to bring the holes into alignment, insert the receiver locking pins through the receiver and carrier arms and install the hair pins into the bottom holes of the receiver locking pins. 0. Attach the PTO drive shaft to the transmission output PTO shaft. The collar on the end of the PTO drive shaft yoke is spring loaded and must be held back as the yoke is lined up with the splines of the transmission output PTO shaft and pushed onto the male shaft. Once the yoke has been inserted onto the shaft, the spring loaded collar should snap into place, which locks the yoke of the drive shaft to the male output shaft on the transmission. Pull back on the drive shaft to check that the yoke is locked and the drive NOTE: Never attach the PTO drive shaft to the transmission output PTO shaft without it being attached to the mower deck gearbox.. Check to make sure the center rear cover is installed and covering the u-joint. Center rear cover. Wipe hose ends clean, and connect to the power unit s hydraulic quick couplers.. Adjust the weight transfer control knob to the desired setting. Detaching. Park the power unit on a level, hard surface (concrete) so that the deck can be rolled on the ground freely by hand after it is disconnected from the power unit.. Fully engage the park brake, bring the throttle to low idle, and push the tool bar lift control lever forward until the deck is fully down. Keep feet and legs away from under the decks until all decks are fully lowered. Do not push the tool bar lift control lever forward rapidly as this will allow the deck to drop rapidly. Operation -

15 GENERAL OPERATION Push the control lever forward slowly to release hydraulic pressure gradually. Lower the right and left decks to the ground using the auxiliary control valve lever.. Shut off the engine and remove the key.. Move the auxiliary control valve lever forward and backward to relieve any pressure in the auxiliary hoses. Disconnect the hydraulic quick couplers from the power unit and place on the fl ex deck mower where the couplers will be free of contamination.. Detach the PTO drive shaft from the transmission output PTO shaft. The collar on the end of the PTO drive shaft yoke is spring loaded and must be held back to release the PTO drive shaft from the splines of the transmission output PTO shaft. Pull back on the drive shaft to release it from the transmission output PTO shaft.. Remove the tool bar hair pins and the receiver locking pins and place to the side.. Move to the front of the deck and pull on the deck, working the deck forward. The deck may need to be rocked from side to side while pulling to get the carrier arms pulled out of the receivers.. Reinsert the receiver locking pins through the holes in the tool bar arms and secure in place with the hair pins.. Once the deck is removed, the power unit can be driven away from the mower deck. Rear Counterbalance Weights Before operating this unit, it is recommended that rear counterbalance weights be attached to the rear of the power unit. The following is the recommended weight that needs to be added. Power unit without cab lbs (.0 kg) Power unit with cab lbs (. kg) Refer to the power unit owner s manual for more detailed information. Order the recommended weights from your Hustler Turf dealer. Improper operation on slopes can cause injury. Install rear counterbalance weights, when the attachment is installed, to increase stability. Use extreme care when operating on slopes. Mowing and Operating Procedure Check the area to be mown for rocks and other debris before mowing and remove them from operator s path. Perform daily inspection and verify that the cutting heights are set properly. Set the power unit s weight transfer system to the desired setting. With the engine running between,000 and,000 RPM, engage the PTO switch. Adjust the throttle to the desired engine RPM. Full throttle generally provides the best cut. Lower the mower deck to the ground and place the power unit s tool bar lift control lever in the float position by pushing it forward until the detent engages. The lever will stay in this position until intentionally removed. Push the auxiliary control valve lever forward to fully extend the mower deck s lift arm control links. Begin forward motion in the desired path of mowing. Avoid obstacles, removing debris as necessary. Mowing in a back and forth manner will create a striping pattern in the grass. The full length roller behind each cutting unit rolls the grass in the direction of travel. Lift the mower decks when the edge of the mowing area is reached. Turn the mower around and align for the next pass. Never raise the mower deck with the blades engaged to avoid small obstacles, drive over curbs, and so forth. Disengage the PTO before raising the deck. Transport of Mower Before transporting, raise the power unit tool bar and the left and right mower decks. This saves wear and tear on the mower and needless scuffing and rolling over the various surfaces between mowing jobs. Use moderate speed during transport to maintain control of the power unit and to reduce the amount of shock to the power unit and mower deck caused by uneven terrain. Never transport the mower with the PTO engaged. When transporting on slopes, reduce speed and lower the mower close to the ground to improve stability. Cutting Height Adjustment Always set the parking brake, shut off the engine, remove the ignition key, and ensure all moving parts have stopped before checking mower deck or blade condition, or attempting any repair or adjustment. The cutting height of the mower decks is controlled by the setting of the mower front wheels and the deck rear rollers.. Lift the mower decks to the service position. (Refer to the Deck Flip-up Procedure in the service section of this manual.) Operation -

16 GENERAL OPERATION. Determine the desired cutting height. Refer to the decals located on the left and right sides of the fl ex deck for the settings required to obtain the desired cutting height. Anti-Scalp Roller Adjustment There are three positions for mounting the fl ex deck anti-scalp rollers. The fi ve rollers should all be mounted at the same height.. Remove the front wheel axle bolts, and reinstall the wheels at the appropriate setting. Torque bolts to ft-lbs ( nm).. Remove the bolts holding the roller brackets to the decks ( bolt on both sides of each roller). Reinstall the bolts at the desired cutting height. Torque bolts to ft-lbs ( nm). Mower Front Wheel Path Adjustment Always set the parking brake, shut off the engine, remove the ignition key, and ensure all moving parts have stopped before checking mower deck or blade condition, or attempting any repair or adjustment. The front caster wheels on the left and right sides can be repositioned for different applications. For maximum deck overhang, move the caster wheels to the furthest inboard position. For maximum pass-to-pass consistency, and to achieve the best cut quality, move the caster wheels to the furthest outboard position. The left and right wheels may be set differently from each other as the application requires. Upon repositioning the front caster wheels, torque the mounting bolts to ft-lbs ( Nm). When cutting between / ( mm) and -/ ( mm), install the anti-scalp rollers in position for best performance. When cutting between -/ ( mm) and -/ ( mm), install the anti-scalp rollers in position for best performance. When cutting between -/ ( mm) and -/ ( mm), install the anti-scalp rollers in position for best performance. Upon repositioning the anti-scalp rollers, torque the mounting bolts to ft-lbs (0 Nm). Mulching Kit (Optional Accessory) Mulching procedures may vary greatly due to climate, type of grass, and soil conditions. It is generally best to mow frequently and in dry conditions. Leaves are usually mulched and dispersed better when some grass is cut with the leaves. Mulching often requires more power than normal mowing. When mulching wet and/or thick grass, more frequent cleaning of the underside of the deck is necessary. Blades must be sharp and in good condition for best results. Operation -

17 SERVICE Always set the parking brake, shut off engine, remove the ignition key, and ensure all moving parts have come to a complete stop before inspecting components or attempting any repair or adjustment. Ball pin & upper hole Carrier arm plate Attention If any component requires replacement, use only original Hustler replacement parts. Lower hole Cleaning and General Maintenance For best results, and to maintain the finish of the flex deck, clean or wash the mower to remove accumulated clippings, leaves, and dirt when the job is finished. Refer to the Deck Flip-up procedure below to access the underside of the deck. If washing the deck, do not spray directly into bearings or seals. After washing, it is important to run the mower so that water does not reside on seals of bearings for the drive system. When washing is complete, return the deck to the operating position and activate the PTO for 0 seconds to remove any standing water. Deck Flip-Up Procedure (Service Position) Insert the ball pins into the lower holes of the latch plates to lock the deck in the service position. Never engage the PTO control lever or operate the power unit with the deck in the service position.. To return the deck to the operating position, restart the engine and raise the tool bar to its highest position. Shut off the engine and remove the key.. Lift up on the front of the deck, remove the ball pins from the lower holes in the latch plates, and lower the front of the deck to the operating position. Never work under the machine or deck unless the carrier arms are 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 with a minimum weight rating of,000 pounds to block carrier arms up. Use in pairs only. Follow the instructions supplied with the jack stands.. Park power unit on a smooth level surface.. Raise power unit tool bar to its highest position.. Set parking brake, shut off engine, and remove the key.. Remove the ball pins from the left and right carrier arms and lift the mower deck up until the lower holes in the latch plates align with the holes in the carrier arm plates. As the deck is rotated forward, more weight will be transferred forward. Make sure the deck is held securely to prevent the front of the deck from dropping too quickly. Do not allow any part of the body, feet, or legs under the deck as it is lowered. Do not drive forward to release the deck from the service position, as this may damage the equipment or cause bodily injury.. Reinstall the ball pins in the upper holes in the latch plates.. With the operator in the seat, lower the deck to the ground. Service -

18 Mower Blade Inspection/Replacement SERVICE Never work with blades while engine is running or the PTO control lever is in the ON position. Always put PTO control lever in OFF position, engage parking brake, and turn off engine. Always check for blade damage if mower strikes a rock, branch, or other foreign object while mowing! Mower blades may be sharp. Always wear gloves when working with mower blades.. Rotate the mower deck up to the service position following the deck fl ip-up procedure.. Inspect the mower blades to ensure cutting edges are sharp. If blades are dull or damaged, they must be removed and sharpened or replaced.. Place a short piece of x wood between the end of the blade and an appropriate structural part of the underside of the deck to prevent the blade from rotating.. For the ) right hand blades, loosen the spindle bolt counterclockwise and remove the blade for sharpening or replacement.. For the ) left hand blades, loosen the spindle bolt clockwise and remove the blade for sharpening or replacement.. If the blades need sharpened, refer to the following Mower Blade Sharpening section.. Replace any blade that is bent, cracked, or broken. Never attempt to straighten a bent blade by heating, or to weld a cracked or broken blade as the blade may break and cause serious injury. Replace worn or damaged blades.. Before installing mower blades, lay blade on a fl at surface and check for distortion. Replace any distorted mower blade. Cutting Plane Twisted Blade Edge (Replace) Cutting Edge Straight Blade Edge End view of blades, comparing twisted and straight blades.. When installing a blade, the wood block must be placed on the opposite side to prevent rotation for tightening the blade bolt. 0. Do not re-use spindle bolts which have stripped, worn, or undercut threads. Torque the spindle bolts to -0 ft-lbs (0-0 Nm). Failure to correctly torque the spindle bolt may result in loss of the blade which can cause serious injury. Mower Blade Sharpening Blades should be sharpened and balanced by a professional. Maintain balance, same bevel, and length of sharpened surface. Drive Belt Inspection/Replacement Always set the parking brake, shut off the engine, remove the ignition key, and ensure all moving parts have stopped before checking mower deck or blade condition, or attempting any repair or adjustment. Warped Blade (Replace) Straight Edge Comparison of warped and straight blades. Inspecting the drive belts of the mower can prevent sudden belt failure by finding problems before the belts break. Typical wear on a drive belt may result in the conditions shown in the above diagram. If any of these conditions occur, the drive belt will require replacement. Service -

19 SERVICE Center Deck Belt (R). Detach the mower deck from the power unit.. Raise the carrier frame shield.. Release the center deck belt tensioning spring.. Remove the old center deck belt.. Install the new center deck belt. Place belt into the pulley system according to the belt diagram located on the underside of the carrier shield.. Engage the deck belt tensioning spring.. Lower the carrier frame shield and latch in place. Left Deck Belt (P). Detach the mower deck from the power unit.. Raise the carrier frame shield.. Remove the left deck shield and the left deck hinge shield.. Release the left deck belt tensioning spring and the center deck belt tensioning spring.. Remove the center deck belt from the double spindle pulley that drives the left deck belt.. Remove the left deck belt.. Install the new left deck belt. Place belt into the pulley system according to the belt diagram located on the underside of the carrier shield.. Engage the left deck belt tensioning spring.. Place the center deck belt back on the spindle pulley. 0. Engage the center deck belt tensioning spring.. Reinstall the left deck shield and the left deck hinge shield.. Lower the carrier frame shield and latch in place. Right Deck Belt (P). Detach the mower deck from the power unit.. Raise the carrier frame shield.. Remove the right deck shield and the right deck hinge shield.. Release the right deck belt tensioning spring and the center deck belt tensioning spring.. Remove the center deck belt from the double spindle pulley that drives the right deck belt.. Remove the right deck belt.. Install the new right deck belt. Place belt into the pulley system according to the belt diagram located on the underside of the carrier shield.. Engage the right deck belt tensioning spring.. Place the center deck belt back on the spindle pulley. 0. Lower the carrier frame shield and latch in place.. Engage the center deck belt tensioning spring.. Reinstall the right deck shield and the right deck hinge shield. Drive Belt Tensioning Adjustments Each drive belt of the fl ex deck mower is spring loaded to maintain proper belt tension. No adjustments are required. Tire Pressure The flex deck is equipped with flat-free, cushioning tires to provide a maintenance free, consistent cutting height. No tire pressure adjustments are required. Storage Preparing the Flex Deck Mower for Storage. Clean the mower decks and the frame.. Inspect for loose or missing hardware, damaged components, or signs of wear. Repair or replace as necessary.. Inspect hydraulic hoses and fi ttings to ensure tight, leak free connections. Repair or replace any damaged or worn components.. Inspect belts, spindles, and blades. Repair or replace any damaged or worn components. Apply grease to all grease points.. Check lubricant level in gearbox.. Depending on the position of the mower during storage, a light coating of oil on the exposed cylinder rod is recommended.. Wipe off all excess grease or oil. Removing the Flex Deck Mower from Storage Inspect, clean, and prepare the mower for use. Service -

20 SERVICE Deck Leveling Procedure Always set the parking brake, shut off the engine, remove the ignition key, and ensure all moving parts have stopped before checking mower deck or blade condition, or attempting any repair or adjustment. Mower blades may be sharp. Always wear gloves when working with mower blades. Front to Rear Deck Leveling. Place the mower on a hard surface that is clean and level.. Set the cutting height to a high setting to allow access to the mower blades. All points must be at the same cutting height.. If the deck is equipped with pneumatic tires, ensure that all the tires are inflated to the same pressure. Center Deck. Turn the mower blades so the blade tips are at the rear of the deck and measure the distance between the blade tip and the surface the deck is setting on.. Rotate the mower blades so the same tip is at the front of the deck and measure again. The blade tip should be level to / (. mm) low at the front.. If the distance is greater than / (. mm), the center deck must be leveled. To begin adjustments, loosen the ) / bolts that fasten the front of the center deck to the carrier frame.. Raise or lower the front of the deck until the front of the deck has been leveled relative to the rear of the deck for both the left and right sides of the deck.. Retighten the ) / bolts. Torque to ft-lbs (0 Nm). Left Deck. Verify that the rear roller is level with the surface that the deck is setting on. If the roller is not level (if either the right or left end of the roller is raised off the ground), the front and rear connecting links require adjustment. a. If the outboard side of the roller is raised off the measuring surface, the links must be shortened. Loosen the jam nuts, unbolt the rod ends from the center deck, and turn the rod ends in two turns. Reattach rod ends to center deck. Repeat until the rear roller is level with the measuring surface, reattach rod ends to the center deck, and tighten the jam nuts. b. If the inboard side of the roller is raised off the measuring surface, the links must be lengthened. Loosen the jam nuts, unbolt the rod ends from the center deck, and turn the rod ends out two turns. Reattach rod ends to center deck. Repeat until the rear roller is level with the measuring surface, reattach rod ends to the center deck, and tighten the jam nuts. 0. Turn the mower blades so the blade tips are at the rear of the deck and measure the distance between the blade tip and the surface the deck is setting on.. Rotate the mower blades so the same tip is at the front of the deck and measure again. The blade tip should be level to / (. mm) low at the front.. If the distance is greater than / (. mm), the deck must be leveled. To begin adjustments, loosen the ) / bolts that fasten the front yoke anchor plate to the front of the center deck.. For the inboard blade, raise or lower the front yoke anchor plate until the inboard blade is level to / (. mm) low at the front.. Retighten the ) / bolts. Torque to ft-lbs ( Nm).. For the outboard blade, Loosen the / bolt that holds the tire swivel frame to the deck.. Add / USS fl at washers beneath the caster wheel frame to raise the outboard front of the deck. Remove existing washers to lower the outboard front of the deck.. When the deck is level, torque the / bolt to ft-lbs (0 Nm). Service - 0

21 Right Deck. Verify that the rear roller is level with the surface that the deck is setting on. If the roller is not level (if either the right or left end of the roller is raised off the ground), the front and rear connecting links require adjustment. a. If the outboard side of the roller is raised off the measuring surface, the links must be lengthened. Loosen the jam nuts, unbolt the rod ends from the center deck, and turn the rod ends out two turns. Reattach rod ends to center deck. Repeat until the rear roller is level with the measuring surface, reattach rod ends to the center deck, and tighten the jam nuts. b. If the inboard side of the roller is raised off the measuring surface, the links must be shortened. Loosen the jam nuts, unbolt the rod ends from the center deck, and turn the rod ends in two turns. Reattach rod ends to center deck. Repeat until the rear roller is level with the measuring surface, reattach rod ends to the center deck, and tighten the jam nuts.. Turn the mower blades so the blade tips are at the rear of the deck and measure the distance between the blade tip and the surface the deck is setting on. 0. Rotate the mower blades so the same tip is at the front of the deck and measure again. The blade tip should be level to / (. mm) low at the front.. If the distance is greater than / (. mm), the deck must be leveled. To begin adjustments, loosen the ) / bolts that fasten the front yoke anchor plate to the front of the right deck.. For the inboard blade, raise or lower the front yoke anchor plate until the inboard blade is level to / (. mm) low at the front.. Retighten the ) / bolts. Torque to ft-lbs ( Nm).. For the outboard blade, Loosen the / bolt that holds the tire swivel frame to the deck.. Add / USS fl at washers beneath the caster wheel frame to raise the outboard front of the deck. Remove existing washers to lower the outboard front of the deck.. When the deck is level, torque the / bolt to ft-lbs (0 Nm). SERVICE Service -

22 SERVICE Lubrication Locations Always set the parking brake, shut off the engine, remove the ignition key, and ensure all moving parts have stopped before checking mower deck or blade condition, or attempting any repair or adjustment. Lubrication is required at the following locations. Refer to the maintenance schedule for service intervals. Some shields and covers removed for clarity. Item Description # of Locations A Drive Shaft B Hitch Arm Pivot C Cylinder End D Spindle E Caster Wheel Pivot F Yoke Pivot G Rear Roller Bearing H Wheel Axle Bearing Top View of Deck E E E H H E H F D D F D H A D C A Rear View of Deck F F G G G Service -

23 SERVICE Front View of Deck F F B Gearbox Check gearbox lubricant daily by looking at the sight gauge located on side of gearbox. It should appear half full. Add ISO VG oil (Hustler P/N 0) as necessary. To fi ll, remove the vent plug located on top front of gearbox and add oil until the sight ball fl oats off the bottom. Vent plug Sight Gauge Service -

24 Maintenance Schedule Maintenance Schedule Item # of Locations # of Pumps AS NEEDED Daily At 0 Hours At 00 Hours At 0 Hours At 00 Hours At 0 Hours At 00 Hours SERVICE At 0 Hours At 00 Hours At 0 Hours At 00 Hours Grease & Lubrication: See Lubrication Section At 0 Hours At 00 Hours At 0 Hours At 00 Hours At 0 Hours At 00 Hours At 0 Hours At 00 Hours At 0 Hours At 000 Hours Months Drive Shaft A Hitch Arm Pivot B ^ Cylinder End C ^ Spindle D Caster Wheel Pivot E Yoke Pivot F ^ Rear Roller Bearing ** G ** Wheel Axle Bearing ** H ^ ** Check Gearbox Oil Level Change Gearbox Oil. Replace w/ ISO VG oil. Inspect for Loose, Missing, or Worn Components. Inspect Belts, Pulleys, Blades, and Blade Retaining Bolts. Inspect Hitch Pivot Bolts. Torque to 0 ft lbs (0 Nm). Inspect Anti-scalp Roller Axle Bolts. Torque to ft lbs (0 Nm). Inspect Rear Roller Axle Bolts. Torque to ft lbs ( Nm). Inspect Caster Wheel Axle Bolts and Rear Roller Bracket Bolts. Torque to ft lbs ( Nm). Inspect Safety Decals. ** Operation in severe conditions may require more frequent service intervals. ^ Grease Until Fresh Grease is visible Inspection Service -