Hustler 1500 Riding Greens Mower Operator s Manual

Transcription

1 Hustler 1500 Riding Greens Mower Operator s Manual P.O. Box 7000 Hesston, Kansas _0811

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3 Table of Contents General Information Safety Precautions Operation Maintenance & Adjustment Storage Product Literature _0811 toc-1

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5 GENERAL INFORMATION This manual applies to the following Hustler equipment lines: Hustler 1500 Riding Greens Mower To the new owner The purpose of this manual is to instruct the operator on how to safely operate and maintain the Hustler 1500 Riding Greens Mower. Please read it carefully; information and instructions furnished can help you achieve years of dependable performance. A separate Engine Owner s Manual is included with your owner s packet which contains additional engine information that will not be repeated in this manual. It is the owner s responsibility to make certain that the operators and mechanics read and understand the engine owner s manual before attempting to operate or repair the engine. Additionally, a separate General Service Manual is included with your owner's packet, which contains necessary information explaining how to properly make adjustments, care for, and maintain the Hustler 1500 Riding Greens Mower. The decals are designed to give the operator brief information needed in the daily operation and service of the mower. These decals are not intended to be used in place of this manual but instead are to be used as an extension of this manual. These decals should not be removed or obliterated. Replace these decals if they become unreadable. 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 mower. It is also the owner s responsibility to make certain that all 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. IMPORTANT: The owner/user can prevent and is responsible for accidents or injuries occurring to themselves, other people or property. Never let children or untrained people operate or service the equipment. Local regulations may restrict the age of the operator. IMPORTANT: For more detailed maintenance and adjustment information refer to the General Service Manual included in the owner s packet. Using this manual 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 in operator position and facing forward, unless otherwise stated. Photographs and illustrations used were current at the time of printing, but subsequent production changes may cause your mower to vary slightly in detail. Hustler Turf Equipment reserves the right to redesign and change the mower as deemed necessary, without notification. If a change has been made to your mower which is not reflected in this operator s manual, or the parts manual, see your Hustler dealer for current information and parts. Warranty registration Your Hustler Dealer must register the unit on-line within ten (10) days following date of purchase to validate your warranty protection. As the new equipment owner, you should confirm that your Hustler Dealer has registered your mower with Hustler Turf Equipment. Be sure to register the mower plus each attachment that displays a model and serial identification number plate with Hustler Turf Equipment. IMPORTANT: Any unauthorized modification, 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 Mower model and serial numbers are found on the serial identification plate, located on the frame directly below and to the right of the seat. These numbers are required when the unit is registered with Hustler Turf Equipment. They will also assure you of the correct service parts when replacement becomes necessary. Parts and service Use original Hustler replacement parts only. These parts are available through your local Hustler dealer. To obtain prompt, efficient service, always provide the following information when ordering parts: 1. Correct part description. 2. Correct part number. 3. Correct model number. 4. 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 _

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7 SAFETY PRECAUTIONS 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. DANGER denotes immediate hazards which WILL result in severe personal injury or death. WARNING denotes a hazard or unsafe practice which COULD result in severe personal injury or death. This manual uses two other words to highlight information. IMPORTANT calls attention to special mechanical information and NOTE emphasizes general information worthy of special attention. 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. Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means DANGER or WARNING - personal safety instructions. Failure to comply with the instructions may result in personal injury or death. Incorrect usage of this mower may result in severe injury. Personnel operating and maintaining it should be trained in the proper use and should read the manuals completely and Safety and Instruction Decals thoroughly before attempting to set-up, operate, adjust, or service this mower. The decals are designed to give the operator brief information needed in the daily operation and service of the mower. These decals are not intended to be used in place of this manual but instead are to be used as an extension of this manual. These decals should not be removed or obliterated. Replace these decals if they become unreadable. It is the owner s responsibility to make certain that operators and mechanics read and understand this manual and all decals before operating this mower. It is also the owner s responsibility to make certain that all 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 let children or untrained people 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 that 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. Specific safety warning decals are located on the equipment near the immediate areas of potential hazards. These decals should not be removed or obliterated. Replace them if they become non-readable. The following illustrations show the various safety decals that are located on the mower. A brief explanation, for those requiring one, is shown to help the operator understand the meanings of these decals. FUEL VOIDS WARRANTY MAX OF 10% E10 FUEL IGHER THAN IN ETHANOL H Read Operator s Manual and Safety Warning Decals before attempting to operate this machine. Do not smoke while refueling. Do not remove the fuel tank cap or fill tank with engine running or while the engine is hot. Allow engine to cool before storing machine inside a building. Store away from open flame or spark if there is fuel in tank. Clean up any fuel spills. Do not refuel while in enclosed trailer or other enclosed areas. Maximum of 10% ethanol in fuel. Higher than E10 fuel voids warranty _

8 Part Number Hydraulic Oil Decal WARNING: Hot surface! Avoid skin contact with hot surface BIODEGRADABLE HYDRAULIC OIL SPECIFICATION Use Terresolve Envirologic 168 Oil ONLY! Attention! Read Operator s Manual Pull choke cable forward (out) to choke, push rearward (in) to shut off choke. Part Number Choke Control Decal Attention! Read Operator s Manual Part Number Hydraulic Oil Decal WARNING: Hot surface! Avoid skin contact with hot surface HYDRAULIC OIL SPECIFICATION Use Mineral Based ISO 68 Oil ONLY! Part Number Steering Column Adjustment Decal 1. Release steering column adjusting lever. 2. Pivot steering column to desired setting. 3. Lock steering column adjusting lever Disengage park brake lever Attention! Read Operator s Manual Attention! Read Operator s Manual Part Number Cutting Unit Safety Decal DANGER: Cutting reel knife! Cutting hazard! Engage park brake lever Park Brake Control Decal Part Number Part Number Depress pedal to set park brake when park brake lever is in locked position Traction Drive Pedal Decal Fast Traction drive forward Slow Neutral Slow Attention! Read Operator s Manual Attention! Read Operator s Manual Keep shields and guards in place at all times Read General Service Manual Stop engine & mower reel before servicing this mower Traction drive rearward Fast Seat Platform Release Decal Lock Release Pull out on seat platform release Part Number handle and pivot seat platform. Jacking point or jackstand location Part Number Hot Surface Decal Part Number Jack Point Decal WARNING: Hot surface! Keep a safe distance from the machine _0811

9 Part Number Raise Cutting Units Cutting Unit Raise/Lower Decal Lower Cutting Units Attention! Read Operator s Manual Part Number Engine Cover Decal Part Number Attention! Read Operator s Manual Hydraulic Oil Pressure Decal WARNING: Hot surface! WARNING: Fluid under pressure! Engine cover must be in place at all times when in operation 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 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 system, lower attachment and turn engine off _

10 Battery Decal Attention! Read Operator s Manual DANGER: Battery Hazards! Part Number Avoid skin contact with battery acid Do not overfill battery. Electrolyte may overflow and damage paint, wiring or structure. When cleaning the battery, use soap and water into the battery. Be careful not to get soap and water into the battery. Use soda mixed in water to clean corrosion off the terminals. 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 physician immediately. Acid will also damage clothing. Do not allow open flame near the battery when charging. Hydrogen gas forms inside the battery. This gas is both toxic and flammable and may cause an explosion if exposed to flame. Always remove the negative ground first and replace it last. Part Number 6017 ROPS Decal 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. WARNING: Roll over! Avoid crushing, use seat belt. Do not jump if machine tips. Never operate the mower without the ROPS. Always wear your seat belt when operating this mower. Do not remove ROPS WARNING: Ejection! Always pull from the tractor hitch. Do not attach chains or ropes to the ROPS for pulling purposes, as the machine can tip backwards _0811

11 Part Number Instrument Panel Decal C Q J O R L E F G H P I D M N K A B A. Fast (engine speed) B. Slow (engine speed) C. Backlap circuit active light (optional) D. Warning light high hydraulic oil temperature E. Ignition switch insert key F. OFF G. ON H. Engine start position I. Wear ear protection, eye protection and safety shoes when operating this equipment. J. Mow switch ( I is ON, O is OFF) K. Before starting the engine: Read Owner s Manual Disengage cutting reels Engage park brake L. Warning light low engine oil pressure M. Transport speed position (reels cannot rotate) N. Mow speed position O. Three wheel drive switch (optional) P. Light switch (optional) Q. Mow circuit active light R. Read Operator s Manual _

12 Part Number 6021 Operating Safety Decal WARNING: Rollover! Mow a safe distance (minimum of 10 feet) away from drop-off, 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. WARNING: Ejection! Lower cutting units when driving down slopes. Never push down suddenly on reverse or brake pedal while the mower is in forward motion because mower may tip forward causing loss of control. Slow down before turning. Wear seat belt WARNING: Back over! Always be aware of what is behind the mower before backing up. Do not backup in reverse unless absolutely necessary. Always look down and behind before and while backing up. Do not carry passengers Always stop mower if someone enters the area. WARNING: Rollover! Do not operate on slopes greater than 15 degrees. WARNING: Ejection! Never drive the mower at high speeds without the cutting units mounted to the power unit. Never push down suddenly on reverse or brake pedal while the mower is in forward motion because mower may tip forward causing loss of control. Wear seat belt WARNING: Ejection! Keep all movement on slopes slow and gradual. Never make sudden changes in speed or direction. Do not operate on slopes greater than 15 degrees. WARNING: Rollover! WARNING: Loss of traction/control on slopes! Do not mow on slopes above a retaining wall or drop-off. Shut off cutting reels. Back slowly down the slope when loss of traction occurs _0811

13 Slope Guide Use this diagram when determining the degree of slope to be mowed. E (15 o ) Slope Guide Lines D (10 o ) C (5 o ) Line B Line A 1. Hold this sheet of paper in front of you. Make sure that Line A is horizontal. 2. Align Line B with a vertical surface such as pole, tree or building. 3. Fold 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 _

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15 OPERATION 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. Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by the manufacturer. Never leave a running mower unattended. Park the mower on level ground. Set park brake, place mow switch in the OFF position, lower cutting units, stop the engine, and remove ignition switch key. Wait for engine and all moving parts to come to a complete stop before leaving operator s seat for any reason. Do not change the engine governor setting or overspeed the engine. Operating the engine at excessive speed may increase the hazard of personal injury. Always remain seated while operating mower. Always keep safety shields and covers in place, except for servicing. Always maintain a safe distance from people and pets when mowing. Always stop mower if someone enters the area. Always operate mower in daylight or with adequate working lights. Follow daily and weekly checklists, making sure hoses are tightly secured and bolts are tightened. Always observe traffic laws while driving mower from one location to another. Watch for traffic when operating near or crossing roadways. When operating on public roads make sure to use safety lights (flashing lights, rotating beacon, etc) in conjunction with slow moving vehicle symbols on the mower, according to local regulations. Always be alert for hazards such as rocks, metal objects and other debris which may be thrown or entangled by reel knives. Watch out for holes or deep depressions. Inspect area to be mowed for hazards such as rocks, metal objects and other debris which may be thrown or entangled by reel knives. Remove these objects before mowing. Always inspect mower for damage after striking a foreign object. If damage is found, repair mower immediately. Be sure to stop on level ground, set park brake, place mower switch in the OFF position, lower cutting units, stop the engine, and remove ignition switch key before leaving operator s seat to inspect damage. Always wear adequate ear protection, such as earplugs, when operating this equipment as prolonged exposure to uncomfortable or loud noises can cause impairment or loss of hearing. Do not wear radios or music headphones while operating the machinery. Safe operation requires your full attention. Do not operate the equipment while wearing sandals, tennis shoes, sneakers, shorts or any type of loose fitting clothing. Do not use a towel as a headband or neck wrap and do not hang towel from the waist. Long hair, loose clothing or jewelry may get tangled in moving parts. Always wear long pants, safety glasses, ear protection and safety shoes when operating this mower. Always be aware of what is behind the mower before backing up. Never mow in reverse. Always stop cutting units and look down and behind before and while backing up. Grass baskets must be properly installed on each cutting unit when in operation for maximum safety. Grass baskets must be properly installed on each cutting unit when mower is in operation to prevent the rear cutting unit discharging clippings towards the operator. Before emptying the grass baskets, park the mower on level ground. Set the park brake, turn the mow switch to the "OFF" position, lower cutting units, and turn off the engine. Wait for engine and all moving parts to come to a complete stop before leaving the operator's seat. Never push down suddenly on brake pedal while the mower is in forward motion because mower may tip forward causing loss of control. Never operate a poorly maintained mower. Never attempt high speed maneuvering, especially in crowded or congested areas. Never allow persons to operate this mower without proper instruction or allow children to operate mower. Allow only responsible adults who are familiar with these instructions to operate this mower. Never put hands or feet under any part of the mower while it is running. Never carry passengers. Never direct discharged material toward anyone. Avoid discharging material against a wall or obstruction. Material may ricochet back towards the operator. Always disengage the reel knives and wait for them to stop before crossing gravel drives, walks or roads. Always keep clear of the reel knives and cutting units during their operation. Do not use any unauthorized attachment or modify the mower. The mow switch should be in the OFF position and the cutting units raised during operation of the unit when not mowing. Slow down before turning. Stop the engine before removing the grass baskets. On multi-cylinder/multi-reel mowers, take care as rotating one cylinder/reel can cause other cylinders/reels to rotate. Use a scraper or brush to clean cutting unit and remove grass and debris. Never use your hands - the reel and bedknives are very sharp and can cause serious injuries! If it is required to clean under the cutting units, be sure they are safely supported from the ground when doing so. Never put hands, feet or any other body parts under cutting units if they are not safely supported from the ground _

16 Do not operate the mower if you are fatigued, sick or while under the influence of alcohol or drugs, if your are pregnant or under 18 years old. Exercise caution when loading or unloading the mower onto a trailer or truck. Always wear safety goggles or safety glasses with side shields when operating the mower. Data indicates that operators, age 60 years and above, are involved in a large percentage of riding mower-related injuries. These operators should evaluate their ability to operate the mower safely enough to protect themselves and others from serious injury. Follow the manufacturer s recommendation for wheel weights or counterweights. Clean flammable material from mower. Prevent fires by keeping engine compartment, cutting units, exhaust area, battery, fuel line, fuel tank and operator s station clean of accumulated trash, grass clippings, and other debris. Always clean up spilled fuel and oil. Never cover the mower with a tarp or cover of some type until the engine and muffler have cooled. Park the mower on level ground. Set park brake, place mow switch in the OFF position, lower cutting units, stop the engine, remove ignition switch key and wait for engine and all moving parts to come to a complete stop before removing grass wound around the reel knives. Always buckle seat belt before starting mower. Using a ramp Use extreme caution when loading and unloading a unit onto a truck or trailer with a ramp. Use only a single, full width ramp; do not use individual ramps for each wheel of the unit. Having a full width ramp provides a surface for the mower frame to contact if the unit starts to tip backwards. It also reduces the risk of a wheel going off and the mower tipping over. Do not exceed a 15 degree angle between the ramp and the ground or between the ramp and the trailer or truck. When on a ramp avoid sudden acceleration Slope Operation Slopes are a major factor in loss-of-control and tip-over accidents, which can result in severe injury or death. All slopes require extra caution. If you cannot drive forward up the slope or if you feel uneasy on it; do not mow it. REMINDER: Only operate on slopes of 15 degrees or less. Use extreme caution when operating on slopes. Be extremely careful changing directions on a slope. Slow down. Do not operate where the mower could slip or tip. Turn slowly Turn on the most level part of the slope If it becomes necessary to turn downhill, turn slowly and gradually, if possible. Watch for holes, ruts, bumps, rocks or other hidden objects. Uneven terrain could overturn the mower. Tall grass can hide obstacles. Remove obstacles such as rocks, tree limbs, etc. Keep all movement on slopes slow and gradual. Do not make sudden changes in speed or direction. Avoid starting and stopping on a slope. If tires lose traction, disengage the cutting units and proceed slowly straight down the slope. As long as it is safe to do sound the base of the slope will result in a safe exit and is unobstructed. Mow a safe distance (minimum of 10 feet) away from 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 avoid mower rollover and serious injury or death. Do not mow on wet grass. Slippery conditions reduce traction which could cause sliding and loss of control. Do not tow on slopes. The weight of the towed equipment may cause loss of traction and loss of control. Do not try to stabilize the mower by putting your foot on the ground. If the mower s tires lose traction when operating on slopes, place park brake lever in the brake engaged position, place mow switch in the OFF position, lower cutting units, stop the engine, remove ignition switch key, and get help. Never make sudden starts, stops, turns, or reverse direction, especially when maneuvering on slopes. Never stop suddenly while driving down slopes. This action may result in a reaction of the mower that can cause serious physical injury. The Hustler mower is capable of operating horizontally (traverse) on moderately steep slopes. When operating on slopes up to 15 degrees, be aware of any conditions that may cause the mower drive tires to lose traction resulting in a possible loss of control of the mower. An operator should not operate on a slope until he is thoroughly familiar with the equipment. Do not operate on slopes greater than 15 degrees. Refer to the Slope Guide when determining the degree of slope to be mowed. It is strongly recommended that the operator drive the mower off of the slope, using extreme caution, if any sign of loss of traction is detected. Wait until the condition that caused the problem is resolved before attempting to operate on the slope again. Terrain conditions can affect traction resulting in possible loss of control of the mower. Some of the conditions to be aware of are: 1. Wet terrain 2. Depressions in the ground; i.e. holes, ruts, washouts 3. Mounds of dirt 4. Soil type; i.e. sand, loose dirt, gravel, clay 5. Grass type, density, and height 6. Extremely dry conditions of grass 7. Tire pressure _0811

17 The attachments mounted to the mower will also affect the way it handles on a slope. Be aware that each attachment s characteristics vary. Another consideration to safe mowing on slopes is to be aware of what is located at the bottom of the slope. Extreme caution should be used when there is a hazard located at the bottom of the slope. Some examples are: 1. Water; i.e. lake, river 2. Cliffs, retaining walls 3. Roads, highways 4. Buildings 5. Rocks These are just a few examples of situations when caution must be used when operating on a slope. There are many other possibilities too numerous to mention. Just remember to always exercise extreme caution when operating on any slope. The ROPS will minimize chance of injury or death from rollover. Seat belt must be fastened while operating a mower equipped with ROPS. Failure to use seat belt will result in serious injury in the event of a roll over. Children Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the mower and the mowing activity. Never assume that children will remain where you last saw them. Never leave mower unattended with ignition key in switch, especially with children present. Children or bystanders may be injured if they move or attempt to operate the mower while it is unattended. Place park brake lever in the brake engaged position, place mower switch in the OFF position, lower cutting units, stop the engine, and remove ignition switch key Keep children out of the mowing area and under the watchful care of a responsible adult other than the operator. Be alert and turn the mower off if children enter the area. Before and while backing, look behind and down for small children. Never carry children, even with the cutting units 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 equipment. Use care when approaching blind corners, shrubs, trees, the end of a fence or other objects that may obscure vision _

18 Instrument Panel and Controls A F J K E H C L I A. Choke B. Throttle C. Mow switch D. Mow/Transport speed lever E. Mow circuit active light F. Lift/lower lever G. Ignition switch H. Hour meter I. Hydraulic oil temperature warning light J. Engine oil pressure light K. Backlap circuit active light (optional) L. Three wheel drive switch (optional) M. Headlight switch (optional) Figure 3-1 A. Choke control (Figure 3-1) a cable is linked to manually operate the engine choke. When the knob is pushed in (toward the rear of the tractor), the choke is in the "OFF" (run) position. When the knob is pulled out (forward) the choke is in the "ON" (start) position. Once the engine is started and warmed up, the choke must be shut "OFF". B. Throttle control (Figure 3-1) a cable is linked to the engine throttle for controlling engine speed. Move lever forward to increase engine rpm, move lever rearward to decrease engine rpm. C. Mow switch (Figure 3-1) This switch must be turned to the "ON" (I) position to enable the mow circuit. This switch works in series with a microswitch actuated by the mow speed lever (D), so when the mow switch is on and the mow speed lever is in the mow position, the mow circuit is "ACTIVE". In this condition, when the lift/ lower lever is pushed to lower the cutting units, the cutting units will automatically lower to the ground and the reels will rotate in the mowing direction. When the lift/lower lever is pulled back, the cutting units will lift to transport height and the cutting units will turn off. When the mow switch is switched "OFF" (O), the mow circuit is disabled. D. Mow/transport speed lever (Figure 3-1) This lever allows the operator to select between mow speed and transport speed. As the decal indicates, the mower is in transport speed when the lever is in the forward position, and mow speed when the lever is in the rearward D G M B position. A cable is connected to this lever which actuates a pedal stop (adjustable) to limit the speed of the tractor for mow speed. Additionally, a microswitch is closed when in mow speed to work in conjunction with the mow switch (C) to enable the mow circuit so it is active. E. Mow circuit active light (Figure 3-1) This light will come on when the mow switch is in the "ON" (I) position, and when the mow/transport speed lever (D) is shifted rearward to the mow speed position. This light should remain off if either or both of these controls are not in this condition. F. Lift/lower lever (Figure 3-1) This lever controls the lifting and lowering of the cutting units. It is pushed forward to lower the cutting units and pulled rearward to raise the cutting units. In the condition when the mow circuit is active (the mow circuit active light (E) is "ON"), to lower the cutting units, the lever needs to be pushed momentarily fully forward and then released, the cutting units will fully lower to the ground and will start to rotate. When the lever is momentarily pulled fully back and released, the cutting units will lift to the transport (highest) position and the cutting units will shut off. In the condition when the mow circuit is not active (mow circuit active light (E) is "OFF") and when the optional backlap circuit is not active, the lift/lower lever becomes fully manual in operation, meaning that the cutting units will only lower when the lever is pushed and held in the lower position, and will cease to lower when the lever is released. Likewise when lifting the cutting units, they will only lift as long as the lever is held in the lift position. G. Ignition switch (Figure 3-1) a three position switch: OFF, RUN, and START. With key inserted, rotate it clockwise to START position; release key when engine starts, and switch will automatically return to the RUN position. H. Electronic hour meter (Figure 3-1) registers 1/10 hour increments up to,. total hours. Connected to the ignition switch, the meter records the accumulative time while the ignition key is switched to the RUN position. I. Hydraulic oil temperature warning light (Figure 3-1) this light will come on if the hydraulic oil becomes too hot. J. Engine oil pressure warning light (Figure 3-1) this light comes on when the ignition switch is placed in the RUN position and stays lit until the engine is running and a safe oil pressure is developed. If light comes on during operation, shut engine off as soon as it is safe to do so, then locate and correct the problem. K. Location for optional backlap circuit active light (Figure 3-1) If a backlap kit is installed, an indicator light will be installed here. Refer to the backlap kit instructions for details and information. L. Location for optional three wheel drive switch (Figure 3-1) If a three wheel drive kit is installed, a rocker switch will be installed here. Refer to the three wheel drive kit instructions for details and information. M. Location for optional headlight switch (Figure 3-1) _0811

19 If a headlight kit is installed, a rocker switch will be installed here. Refer to the headlight kit instructions for details and information. N. Traction drive pedal (Figure 3-2) The ground speed and direction of travel is controlled by this pedal. Depress the front of the pedal to go forward. To go backward, depress the back of the pedal. The more the pedal is depressed the faster the mower will move in that direction. NOTE: This pedal must be in neutral (not depressed) to start the engine. NOTE: The operator s heel should rest on the floorboard and not on the lower part of the pedal. This will reduce operator fatigue. Q WARNING The parking brake may not hold the mower if parked on a slope. Block or chock the machine when parked on a slope. O. Brake pedal (Figure 3-2) Depress the brake pedal to stop the unit. P. Park brake lever (Figure 3-2) This lever works as a lock to hold the brake pedal in the engaged position and provide a constant brake engagement when pushed rearward in the locked position. To set the park brake, move the park brake lever rearward, then press down on the brake pedal firmly to engage the brakes. It will be easily noticed that the park brake is on when the brake pedal stays engaged and does not return to normal position. To release the park brake, simply push down on the brake pedal with your right foot and hold. Then with the left foot, release the park brake lever by pushing it forward into the unlocked position. Always remember to set the park brake whenever you leave the seat of the mower. Figure 3-3 Steering column N O P Figure 3-2 Q. Steering column adjusting lever (Figure 3-3) To pivot the steering column (Figure 3-4) to a comfortable Figure 3-4 operating position, rotate the steering column adjusting lever rearward. Then, rotate the steering column until it is at the desired location. Rotate the steering column adjusting lever completely forward to lock the steering column in place. R. Seat adjustment lever (Figure 3-5) The seat can be adjusted forward and rearward by sliding the seat release handle and moving the seat until a comfortable operating position is attained. Figure 3-5 S. Seat platform latch lever (Figure 3-5) The seat platform can be raised to allow access to the area under the platform. To release the seat platform, pull out on the seat platform latch lever and pivot the seat platform up and forward _

20 T. Backlapping switch (optional) (Figure 3-6) This switch is turned "ON" (I) to enable the backlap circuit. This switch is turned "OFF" (O) to disable the backlap circuit. As explained in the function of the Lift/Lower Lever, when the backlap circuit is active and the lift/ lower lever is pushed forward, the cutting units will lower to the ground and the reels will begin to spin in the backlapping direction. To stop the reels from rotating, the backlap switch can be switched "OFF", or the lift/lower lever can be pulled back in the rearward direction which will lift the reels to the transport position and stop the reels. Refer to the backlap kit instructions and General Service Manual for more information on the complete backlap system function. Inspection before operation Before operating the mower check and inspect the following areas on the mower. Refer to the Maintenance Schedule, located in this manual, for complete maintenance information. 1. Engine oil Check the engine oil level per the engine s operator s manual. If necessary, add oil using only engine oil that meets the engine manufacturer s specifications. 2. Hydraulic oil Check the mower s hydraulic system oil per the Hydraulic system section of this manual. Add oil if necessary. 3. Hydraulic oil cooler (if mower is equipped with one) S R Figure 3-5 Figure 3-6 T Check the hydraulic oil cooler and screen and clean any debris from the cooling fins and the cooler screen. 4. Fuel tank Check the fuel level in the fuel tank and fill with the proper fuel that is shown in the engine operator s manual. Refer to the Fuel system section of this manual for detailed fuel tank filling and fuel handling safety information. 5. Tire pressure Check the tire pressure. It should be 8-12 psi (55-83 KPa). 6. Reel-to-Bedknife contact Always check the reel-tobedknife contact. Light contact must occur across the full length of the reel and bedknife. Refer to the General Service Manual for more details. 7. Safety interlock system Check this system prior to starting the mower. Refer to the Safety interlock system section of this manual for detailed information. Safety interlock system The mower is equipped with a safety interlock system. Check the mower s safety interlock system daily, prior to operation. This system is very important for the safety of this mower. It should be repaired immediately if it malfunctions. This system incorporates a seat switch to sense the presence of an operator, and will STOP the engine if the operator is unseated while the mower is in operation. Safety interlock system testing and inspection procedure: 1. The mower must be parked on level ground clear of any obstructions and bystanders and the mower shall NOT be allowed to roll when instructed to release the parking brake. The operator must be seated in the seat when performing this procedure unless otherwise noted. 2. Set the park brake. 3. Be sure the traction drive pedal is in the neutral position and the operator's foot is not resting on it, the lift/lower lever is upright and disengaged from the lifting or lowering positions, and the mow switch (and backlap switch if equipped) is "OFF". 4. Start the engine and allow it to warm up to operating temperature. 5. The traction drive pedal must remain in the Neutral position for steps 6 thru With the mow switch "OFF" (and backlap switch "OFF", if equipped) slowly raise off the seat. The engine should continue to run in this condition. Never leave the mower unattended when it is running. 7. With the operator seated in the seat, disengage the park brake. Slowly raise off the seat. The engine should stop. 8. Set the park brake and restart the engine. Turn on the mow switch. Shift the mow/transport speed lever rearward to the mow position. The mow circuit active light should glow. Slowly raise off the seat. The engine should continue to run. While raised off the seat, momentarily push the lift/lower lever forward and release the lever. The reels should lower to the ground, but the reels should not begin rotating when out of the seat. Sit back down in the seat. Push the lift/lower lever forward momentarily again and release. The reels _0811

21 should begin to rotate.. Remain seated. Shut off the engine. Check to make sure the park brake is set. With the mow switch "ON" and the mow/transport speed lever pulled back into the mow speed position (the mow circuit active light should glow), try to start the engine. The engine should not start. Steps 10 and 11 should be completed if the mower is equipped with the backlap kit: 10. With the engine off, set the park brake, and place the mow switch in the OFF position. Release the seat latch, lift the seat and place the backlap switch in the "ON" position. Turn the ignition switch to the "RUN" position. The backlap circuit active light should glow. Stand to the right side, making sure you are clear of the mower, and turn the ignition switch to the START position. The engine should not start. 11. Turn the key switch off. Turn the backlap switch OFF. Start the engine. Set the throttle to 1/3 of the way up. Turn the backlap switch to the ON position. The backlap circuit active light should glow. Standing at the side of the mower, clear of the cutting units, locate the lift/lower lever and momentarily push it forward to lower the cutting units and release it. The reels should lower to the ground and start rotating in the backlapping direction. Pull the lift/lower lever rearward and release it. The cutting units should raise to transport height and the reels should stop rotating. Turn the backlap switch to the "OFF" position. Turn the ignition switch to the "OFF" position. Lower the seat so it latches. IMPORTANT: For any of the above conditions, if any malfunctions are found in the operation of the safety interlock system, the mower must not be used and the problem must be fixed immediately by a qualified technician before further use. If the engine fails to stop as described above when the operator is out of the seat, this is an indication that the seat switch circuit is faulty and must be fixed by a qualified technician. This mower must not be used until any problems are fixed and the steps above are repeated and passed! 12. This step is to test the traction drive pedal neutral switch function. The backlap switch must be in the OFF position. The operator must be seated with the seat belt securely fastened. The mow switch must be in the OFF position. Set the park brake. NOTE: In this step the operator should expect the mower to move forward and be ready for this movement and aware of the situation. Start the engine and push the throttle forward to 1/3 full. Lightly press the traction drive pedal in the forward direction. Again, the mower may creep forward a small amount. As you press down and move the traction drive pedal in the forward direction, the engine should stop. If the engine fails to stop, release your foot from the pedal and allow it to come back to neutral. Shut off the engine. The neutral safety circuit is not functioning correctly and must be fixed by a qualified technician. Do not operate the mower until the problem is fixed! Engine starting WARNING The safety interlock system should always function per these procedures. If it does not function properly, it should be corrected immediately. Do not operate machine without properly functioning safety interlock system. The mower s safety interlock system is designed to protect the operator and others from accidental injury due to unintentional engine starting. The engine starting motor will not engage until: 1. Traction drive pedal is in the neutral position. 2. Brake pedal is depressed or park brake is set. 3. Mow switch is in the disengaged OFF position. 4. Backlapping switch (if equipped) is in the OFF position. WARNING The safety interlock system must not be disconnected or bypassed. Doing so could cause the machine to operate unexpectedly resulting in personal injury. The following steps are the correct procedures for starting the engine. If difficulty is encountered, contact the Hustler Dealer in your area. 1. Before starting mower each day, perform daily preinspection. (See Inspection before operation section) 2. Make sure the park brake is set, the HST pedal is in the neutral position, and the mow switch is OFF (and the backlap switch is OFF if mower is so equipped). Only start the engine from the operator s position. 3. Use the choke when engine is cold, or if warm engine fails to start within 5 seconds of cranking. Avoid flooding and operate engine without choking as soon as possible. 4. Set throttle at approximately 1/2 open position. 5. Insert key in ignition switch and rotate full clockwise to engage starting motor. Release key when engine starts. IMPORTANT: The engine starter should not be operated for periods longer than 30 seconds at a time. An interval of at least two minutes should be allowed between such cranking periods to protect the starter from overheating and burn-out. 6. Perform test to make sure safety interlock system is operating properly. Refer to Safety Interlock System section. 7. As soon as engine begins to run, check to make certain the engine oil pressure warning light turns off and stays off. If the oil pressure warning light continues to glow, shut the engine off immediately and have the problem checked and fixed by a qualified technician. 8. Allow the engine to idle a few minutes before advancing the throttle and/or operating the mower _

22 Stopping the engine Use the following procedure to shut off the engine after operating the equipment. 1. Set park brake and make sure mow switch is in the "OFF" position and that the mow circuit active light is OFF (backlap switch should be "OFF" and backlap circuit active light should be OFF as well, if equipped). 2. Pull throttle lever back to idle position and allow engine to run at idle for a couple of minutes. 3. Lower the cutting units. 4. Turn engine off at ignition key by rotating counterclockwise. Remove the key from the key switch before leaving the mower. Moving mower with stalled engine If it becomes necessary to move the mower when the engine is inoperative, the hydraulic traction drive pump is equipped with a bypass valve. Before moving the mower, set the park brake and make sure the mower will not roll. Locate the bypass valve on the hydraulic traction drive pump (Figure 3-7) and turn it counterclockwise 1/2 to 1 turn to switch it into bypass mode. The park brake must be released in order to move the machine. Do not tow the machine. Move it by hand or use a winch to load on a trailer for transporting. When winching the mower onto a trailer attach the winch line to the pull point located on the back wheel mount weldment. Figure 3-8 When transporting on another vehicle, the mower must be secured. IMPORTANT: Always make certain the bypass valve is returned to its operating position before running the mower following repairs. Figure 3-8 belt. ROPS when used with seat belt is effective in reducing injuries during overturn accidents. Overturning the mower without a ROPS can result in serious injury or death. Figure 3- ROPS Pull point Bypass valve Figure 3-7 ROPS (Roll Over Protective Structure) A Roll Over Protective Structure (ROPS) and seat belt is provided with the equipment. Do not remove the ROPS and seat Figure 3- NOTE: Inspect the ROPS after the first 20 hours of operation. Following the initial inspection, check the ROPS after every 500 hours of operation or every six months, whichever comes first _0811

23 1. Check the torque of the ROPS mounting bolts. Tighten the bolts to the correct torques as shown below if necessary. Figure Inspect the operator s seat and the mounting parts for the seat belt. Tighten the bolts to the correct torque as shown below if necessary and replace parts that show wear or damage. 3. Check the seat latch to make sure it is secured and functioning properly. Adjust or repair it as necessary. WARNING Never operate the mower with the seat latch un-installed and improperly secured. The seat platform must be securely latched to prevent seat from moving/tilting in the event of mower tipping or rollover. Torque values are given below: Ft-lbs. Nm ROPS mounting bolts Seat belt mounting hardware ROPS post Figure 3-10 WARNING Never operate the mower without the ROPS. Always wear your seat belt when operating this mower. WARNING ROPS mounting bolts Do not attach chains or ropes to the ROPS for pulling purposes, as the machine can tip backwards. Always fasten seat belt during operation of the machine (mower equipped with ROPS installed). Inspect the area prior to being mowed for proper overhead clearance (tree limbs, guy wires, doorways, etc). Do not contact any overhead object with the ROPS. Inspect the seat belt system (all seat, seat belt parts, seat pan and seat pan latch) daily prior to mowing for signs of any damage. These parts should be replaced if any parts indicate signs of: 1. cuts 2. fraying 3. extreme or unusual wear 4. significant discoloration due to UV exposure 5. dirt or stiffness 6. abrasion to the seat belt webbing 7. damage to the buckle, latch plate or hardware. 8. or any other problem If the seat belt is to be cleaned, use soap and water. Do not use carbon tetrachloride, naphtha, etc., as these will weaken the webbing. For the same reason, do not bleach or dye the webbing. Replace seat belt if worn or damaged. Possible damage to the 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), the ROPS must be replaced to retain the best protection. Following an accident, check the ROPS, the operator s seat, the seat belt, seat belt mountings and seat latch for possible damage. Before operating the machine, replace all damaged parts. IMPORTANT: Do not attempt to weld or straighten the ROPS. WARNING The ROPS structure s protective capability may be impaired by structural damage, overturn or alteration. Do not remove or alter any of the ROPS parts. Do not attempt to weld or straighten ROPS. Failure to adhere to these instructions could result in severe injury or death. If the ROPS or cab is replaced, make sure that the proper hardware is used and the recommended torque values are applied to the attaching bolts. Becoming familiar with the mower Before actually mowing, operators should practice in an open area as to become familiar with the way the mower operates. They should familiarize themselves with the raising and lowering of the cutting units. The front two cutting units raise and lower at the same time while the rear cutting unit does so slightly later. This allows the rear cutting unit to start and stop in the same location as the front units. Practicing will allow the operator to become proficient at starting and stopping each mowing pass close to the edge of the green. When an operator can routinely start and stop mowing within a foot or two of the edge of the green then he/she is ready to start mowing the greens _

24 Only one final mowing pass around the outside of the green is required when the cutting units are raised a foot or two from the edge of the green. Operating the machine in transport mode. The cutting units should be in the fully raised position while operating the mower when it is not mowing. To drive the mower in transport speed, shift the mow/ transport speed lever forward into the transport position. When operating the traction drive pedal, always use smooth, gradual movements, and do not allow your foot to slip off the traction drive pedal. If the step treads on the top of the traction drive pedal or surrounding floor pan areas start to show signs of wear, replace immediately. Always slow down before driving on sloped or rough areas and drive the mower at slow manageable speeds in these areas. When proceeding down a slope, use the brake to help slow or stop the machine when necessary. Before mowing the greens: 1. Remove any signs, markers, flag sticks, etc. that will interfere with operation and move them out of the mowing area. 2. Inspect the area to be mowed and remove any debris (sticks, stones, pine cones, etc.) that could damage the reels and/or bedknives. Mowing practices Several factors may determine the direction of the mowing pattern: 1. The direction the green was mown previously. Determine the direction that the green was mown last and proceed to mow in a different direction. Never mow in the same direction as the previous mowing to prevent the grass from laying down which makes it difficult to trap the grass between the reel blades and the bedknife. 2. Sand traps, trees, etc. that are located near the green can restrict mower turning. 3. Terrain Other things to consider when mowing greens are as follows: 1. Never stop the mower on the green with the reels turning. This will help prevent damage to the green. 2. Never stop the mower on a wet green as wheel indentions may occur. Mowing the green 1. As the mower approaches the green make sure that the mow/transport speed lever is shifted into the mow speed position, that the mow switch is in the ON position and the throttle is set to full throttle. 2. Approach the green at mowing speed. 3. Lower the cutting units just as the front grass baskets cross the leading edge of the green. 4. Proceed to mow in a straight line across the green. 5. When the front edge of the leading grass baskets clear the edge of the green, raise the cutting units. NOTE: The timing of this procedure is important so that the cutting units do not cut into the grass outside the green. However, you do not want to raise the cutting units too early as that can cause you to mow two peripheral passes around the green instead of one. 6. After the mower s rear tire has cleared the edge of the green turn the unit around and line up for the next pass. Do not start the turn before the rear tire is off the green as turf damage can occur. NOTE: To cut down on mowing time turn the mower slightly in the opposite direction of the area to be mowed next and then turn the mower back the other direction. i.e. if you want to turn right, first turn slightly left and then back to the right. This allows the mower to line up easier for the next pass. NOTE: During normal operation and where conditions permit, it is good practice to make as short a turn as possible. However, during warmer weather making wider turns may be preferred to prevent turf damage. 7. It is necessary to overlap the previous pass by approximately 2-3 inches. 8. After mowing the green using straight passes, make one final cut around the perimeter of the green. Always mow the outer edge of the green in the opposite direction than it was mowed the last time.. After the green has been completely mowed, stop the mower on a flat, suitable location off the green, set the park brake, idle down the engine, shut off the mow switch, and then turn off the engine. Replace the flag. Emptying the grass baskets It is recommended practice to empty the grass baskets after cutting every green. The more often the grass baskets are emptied and not allowed to accumulate large amounts of grass, the more consistent your cut quality will be. 1. Stop the mower on flat ground in an appropriate location off the field of play. Turn off the mow switch, lower the cutting units, set the park brake, and turn off the engine. 2. Remove each grass basket and dispose of the grass clippings appropriately. 3. Replace the grass baskets back on the basket hangers of each cutting unit and make sure they are properly seated. Cleaning the mower and cutting units after each use It is necessary after each mowing to thoroughly wash the mower and cutting units to remove grass and debris build up. The following are general guidelines for cleaning the equipment. 1. Lower the cutting units. 2. Park the mower in an appropriate location, set the parking brake, turn off engine, and remove ignition key. Allow the mower to cool down for several minutes before beginning to wash it. WARNING Clear area of bystanders. Wear eye protection. 3. When cleaning the unit never use compressed air that has a higher pressure than 30 psi (210kPa). 4. Use compressed air to clean the following areas. Do not use water when cleaning these areas. A. Engine compartment B. Under the operator s seat platform _0811

25 C. Any place that electrical components are located. Water in electrical components may create electrical problems. 5. Use high volume, low pressure water to clean the rest of the machine. Start with the front cutting units and work towards the rear of the mower. Wash each grass basket out thoroughly. Do not use high pressure to wash the mower. IMPORTANT: Do not use high pressure water on the mower. High pressure washing can cause water to blow by seals and enter into bearings and other components which will cause damage. 6. Grease the mower and cutting units after washing to purge any moisture in the system. Use only enough grease to prevent the bearings from drying out. Wipe off excess grease. If grease is allowed to build up, it may drop onto the grass, which may cause grass damage. Refer to the Maintenance Locator Chart at the end of this manual for lubrication points. Inspecting the mower after each use Inspect the mower for any fluid leaks, loose hardware, broken or damaged parts, and worn parts. Check the cutting units for proper adjustment and sharpness _

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27 MAINTENANCE & ADJUSTMENT Safe Servicing Practices This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death. Service Unless specifically required, DO NOT have engine running when servicing or making adjustments to mower. Park the mower on level ground. Set park brake, place mow switch in the OFF position, lower cutting units, stop the engine, and remove ignition switch key. Wait for engine and all moving parts to come to a complete stop before leaving operator s seat for any reason. 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. Before working on or under the cutting units, make certain engine cannot be accidentally started. Shut engine off, remove ignition switch key and disconnect negative battery cable for maximum safety. Wait for engine and all moving parts to come to a complete stop before leaving operator s seat for any reason. Repairs or maintenance requiring engine power should be performed by trained maintenance personnel only. Always keep covers on cutting units for safety as well as cleanliness. Do not operate mower with engine cover removed. Use a scraper or brush to clean cutting unit and remove grass and debris. Never use your hands - the reel and bedknives are very sharp and can cause serious injuries! If it is required to clean under the cutting units, be sure they are safely supported from the ground when doing so. Never put hands, feet or any other body parts under cutting units if they are not safely supported from the ground. Keep your mower clean and remove any deposits of trash and clippings, which can cause engine fires and hydraulic overheating. Clean up oil or fuel spillage. Allow mower to cool before storing. Clean flammable material from mower. Prevent fires by keeping engine compartment, cutting units, exhaust area, battery, fuel line, fuel tank and operator s station clean of accumulated trash, grass clippings, and other debris. Always clean up spilled fuel and oil. Always wear adequate eye protection when servicing the hydraulic system and battery, or when grinding reel knives and removing accumulated debris. Use extra caution when handling gasoline and other fuels. They are flammable and vapors are explosive. Never attempt to start engine when there is a strong odor of gasoline fumes present. Locate and correct cause. Do not remove the fuel tank cap or fill fuel tank with engine running or while the engine is hot. Never refuel near an open flame or near devices which can create a spark. Refuel outdoors. Never refuel or drain the fuel from the mower indoors. Never run the engine in an enclosed area unless exhaust is vented to the outside. Exhaust gases contain carbon monoxide which is odorless and deadly poison. Never attempt to make any adjustments or repairs to the mower drive system, cutting unit or any attachment while the mower engine is running or mow switch is engaged. Repairs or maintenance requiring engine power should be performed by trained maintenance personnel only. Never work under the mower or attachment unless it is safely supported. Make certain mower is secure when it is raised and placed on jack stands. Jack stands should only be positioned where jack point decals are shown. The jack stands should not allow the mower to move when the engine is running and the drive wheels are rotating. Use only certified jack stands. Use only appropriate jack stands, with a minimum weight rating of 2000 pounds (07 kg) to block the unit up. Use in pairs only. Follow the instructions supplied with the vehicle stands. Do not touch hot parts of mower. Keep nuts and bolts tight. Keep equipment in good working condition. Never tamper with safety devices. Check their proper operation before each use. Stop the engine before removing the grass baskets. Grass collection system components are subject to wear, damage and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check components and replace with manufacturer s recommended parts, when necessary. Exercise caution when working with the cutting units as the reel knives and bedknives are extremely sharp. Wear gloves and use extra caution when servicing them. On multi-cylinder/multi-reel mowers, take care as rotating one cylinder/reel can cause other cylinders/reels to rotate. Use caution when performing maintenance or adjusting the mower to prevent entrapment of fingers between moving blades and fixed parts of the mower. Use only genuine Hustler replacement parts to ensure that original standards are maintained. Introduction Regular maintenance is the best prevention for costly downtime or expensive, premature repair. The following pages _

28 contain suggested maintenance information and schedules which the operator should follow on a routine basis. For more detailed information refer to the Parts Manual and General Service Manual. Refer to the Product Literature section of this manual or contact your Hustler Dealer to obtain additional copies of these manuals. Remain alert for unusual noises, they could be signaling a problem. Visually inspect the machine for any abnormal wear or damage. A good time to detect potential problems is while performing scheduled maintenance service. Correcting the problem as quickly as possible is the best insurance. Clear away heavy build-up of grease, oil and dirt, especially in the engine and under the seat platform areas; minute dust particle are abrasive to close-tolerance engine and hydraulic assemblies. Also, be sure to clean up any excess grease, at grease points, to prevent grease from dropping onto the turf, which can result in turf damage. Inspect mower daily for grass clippings and wire and string tangles. The cutting units will collect a build-up of grass clippings and dirt, especially when grass is wet or has high moisture content. This build-up will harden, restricting reel and air movement and will probably show a poorer quality of cutting. Therefore it should be removed routinely. Some repairs require the assistance of a trained service mechanic and should not be attempted by unskilled personnel. Consult your Hustler service center when assistance is needed. Torque values Torque values are given below: Ft-lbs. Nm Wheel (lug) nuts Wheel motor nut Lug nuts only - It is recommended that these be checked after the first 2 hours of operation, initially, every 50 hours and following removal for repair or replacement. For all other torques refer to the mower s General Service Manual for standard torque chart. For engine torque values, see engine owner s manual. Tires It is important that the tires have the same amount of air pressure. The recommended pressure is 8-12 psi (55-83 KPa). Solid fill tires are not recommended for Hustler turf equipment. On any machine, with solid filled tires, the warranty claim will be denied. Lubrication WARNING Particular attention must be given to tightening the drive wheel lug nuts. Failure to correctly torque these may result in the loss of a wheel, which can cause serious damage or personal injury. regularly. Use a SAE multi-purpose lithium based grease. Refer to the Maintenance Chart for grease intervals, as well as the Maintenance Locator Charts which show all grease points. NOTE: It is necessary to grease all grease points every time the mower is washed to drive out the moisture. Electrical system The electrical system is a 12V DC system with negative ground. The engine block is the common ground in this system. Recommended battery size is a garden tractor BCI size U1R with 225 or greater CCA (cold cranking amp) rating. A maintenance-free battery is recommended. Follow the battery manufacturer's maintenance, safety, storage, and charging specifications. Figure 4-1 WARNING Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. WARNING Charge batteries in an open well ventilated area, away from sparks and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothing and use insulated tools. WARNING 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 physician immediately. Acid will also damage clothing. Do not drink the battery electrolyte. Do not allow open flame near the battery when charging. Hydrogen gas forms inside the battery. This gas is both toxic and flammable and may cause an explosion if exposed to flame. Always remove the negative ground first and replace it last. Do not overfill battery. Electrolyte 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 battery. Clean the battery terminals with a solution of four parts water and one part baking soda when they become corroded. This mower has many grease points that must be lubricated _0811

29 WARNING Shorts caused by battery terminals or metal tools touching metal mower components can cause sparks. Sparks can cause a battery gas explosion which will result in personal injury. Prevent the battery terminals from touching any metal mower parts when removing or installing the battery. Do not allow metal tools to short between the battery terminals and metal mower parts. WARNING Incorrect battery cable routing could cause damage to the mower and battery cables. This can cause sparks which can cause a battery gas explosion which will result in personal injury. Always disconnect the negative (black) battery cable(s) before disconnecting the positive (red) cable(s). Always connect the positive (red) battery cable(s) before connecting the negative (black) cable(s). The electrical system is protected by a 20 Amp master fuse located under the seat near the battery. For more electrical system information or troubleshooting, refer to the General Service Manual for this unit. Figure 4-1 Hydraulic system WARNING 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 hydraulic system, make sure all connections are tight and all hoses and lines are in good condition. To find a leak under pressure, use a piece of cardboard or wood never use your hands. Relieve all pressure in the system before disconnecting or working on hydraulic lines. To relieve pressure, lower all attachments and shut off engine. The Hustler 1500 Riding Greens Mower offers two different options for hydraulic oil - a mineral based hydraulic oil and a biodegradeable hydraulic oil. These oils are not compatible with each other! It is very important to know what model your greens mower is so that you know what hydraulic oil to use! A decal is located on the hydraulic oil reservoir near the reservoir fill neck. (Figure 4-2) If this decal becomes hard to read or is missing, it must be replaced. Figure 4-3 Battery Reservoir fill neck Master fuse Hydraulic reservoir Sight glass Figure 4-1 Figure 4-2 Recommended Hydraulic Oil The recommended hydraulic oil used in the Hustler 1500 Riding Greens Mower will depend upon which model you have. 1. Mineral based hydraulic systems: Mobil DTE 26 hydraulic oil is recommend. Use any oil that meets ISO 68 hydraulic oil specifications. An ISO 68 hydraulic oil is required to be used in this mineral based hydraulic system. 2. Biodegradeable hydraulic oil systems (hydraulic oil cooler is required): Terresolve Envirologic 168 biohydraulic oil only! This is the only hydraulic oil approved for this system - use of any other oil in this hydraulic system will void the _

30 Sight glass Figure 4-3 Decal mower s warranty! IMPORTANT: Any mower that uses biodegradable hydraulic oil must have an optional hydraulic system oil cooler installed. Figure 4-4 reservoir. The oil level is at an acceptable level when the sight glass shows a level between 1/4 and 3/4 of the height of the sight glass. Figure 4-3 NOTE: If the oil level drops lower than 1/4 of the height of the sight glass, the sight glass can show a FALSE oil level reading because oil can pool in the bottom of the sight glass, when in reality the oil level in the reservoir could be lower than the sight glass. Be careful not to overfill the hydraulic oil reservoir, as oil can overflow out of the fill cap when the unit warms up to operating temperature and the oil expands. The oil level shall not register higher than 3/4 of the height of the sight glass when the unit is cold. An oil level higher than this is considered over full and must be drained to the appropriate level! There are two hydraulic filters in this system. Both are located under the instrument panel. (Figure 4-5) Change the filter elements according to the Maintenance Schedule. NOTE: Replace both of these filter elements at the same time when doing normal maintenance. Use Hustler approved filter elements only. Hydraulic oil cooler Figure 4-4 It is recommended that you purchase replacement hydraulic oil thru your Hustler dealer. NOTE: Hustler Turf Equipment is not responsible for any damage caused by the use of non-approved hydraulic oil in this hydraulic system. NOTE: If changing from mineral based hydraulic oil to biodegradable hydraulic oil, the hydraulic system must be flushed correctly. Contact your authorized Hustler dealer for the approved flushing requirements. Any unit running biodegradable hydraulic oil must have a hydraulic oil cooler installed. Check oil level in hydraulic system after every 50 hours of operation or weekly, whichever occurs first. Check more often if system appears to be leaking or otherwise malfunctioning. NOTE: If a leak detection system is installed, see the leak detection system s manual to check oil level, as the sight glass on the hydraulic reservoir will no longer be used. To check the hydraulic fluid level, the mower must be parked on a flat, level surface. NOTE: The hydraulic oil level shall be checked when the unit is cold. The oil level can be seen in the sight glass located on the rear right-hand corner of the hydraulic Fuel system Hydraulic filter Figure 4-5 Hustler 1500 Riding Greens Mowers are EPA compliant. Use only Hustler approved replacement parts. Do not modify or tamper with the fuel system. Do not overfill the fuel tank. DANGER To avoid personal injury or property damage, use extreme care in handling fuel. Fuel is extremely flammable and the vapors are explosive. WARNING Observe usual fuel handling precautions Do not smoke while refueling. Extinguish all cigarettes, cigars, pipes and other sources of ignition _0811

31 Do not remove fuel cap or fill tank with engine running or while engine is hot. Engine cover must be in place when fueling mower. Clean up any fuel spills. If fuel is spilled, do not attempt to start the engine but move the mower away from the area of spillage and avoid creating any source of ignition until fuel vapors have dissipated. Allow engine to cool before storing mower 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 appliances. Use extreme care when handling gasoline and other fuels. They are extremely flammable and vapors are explosive. A fire or explosion from fuel can burn you and others and can damage property. Refuel outdoors. Never refuel or drain the fuel from the machine indoors. Never attempt to start engine when there is a strong odor of gasoline fumes present. Locate and correct cause. Store fuel in an approved container and keep it out of the reach of children. Never buy more than a 30 day supply of fuel. Do not fill fuel containers inside a vehicle or on a truck or trailer bed with interior carpets or plastic truck bed liners. Always place fuel containers on the ground away from your vehicle before filling. When practical, remove gas powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground. If this is not possible, then refuel such equipment on the truck or trailer using a portable container and not a fuel dispenser nozzle. If a fuel dispenser nozzle must be used, keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock-open device. Never use gasoline for cleaning parts. Read and observe safety precautions elsewhere in this manual. WARNING Gasoline is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness. Avoid prolonged breathing of vapors. Keep face away from nozzle and gas tank or fuel container opening. Keep gas away from eyes and skin. If fuel is spilled on clothing, change clothing immediately. The fuel tank is located at the rear of the unit on the left hand side above the hydraulic reservoir. Figure 4-6 Remove the fuel cap slowly. When threading the fuel cap onto the filler neck, tighten the Fuel tank cap until it begins to click, then, continue to turn it until at least three clicks are heard. IMPORTANT: Do not overfill the fuel tank. The fuel tank should be filled no higher than the bottom of the fill neck. The fuel system is designed to leave room for the fuel to expand with fuel temperature changes. Use regular unleaded gasoline with an octane rating of 87 or higher. IMPORTANT: Never use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with gasoline. Engine oil and filter Check engine oil daily. Mower must be setting level when checking oil. Refer to engine manual and maintenance schedule for oil recommendation and capacities. Change the engine oil and filter after the first 5 hours of operation, then per the engine manufacturer s recommendations after that. If the mower is being operated in extremely dirty conditions, then it is recommended oil be changed more frequently. Figure 4-7 Engine air filter Figure 4-6 WARNING Overfilling fuel tank may cause the following: Engine damage Fire hazard! WARNING Engine cover If the engine has been running and is up to operating temperature, allow the engine to cool before changing the oil. Engine and engine oil will be very hot, so be very careful when changing oil and wear the appropriate protective gear to avoid being burned or exposed to engine oil. Perform engine air filter maintenance per the engine s _

32 Carbon canister Fuel evaporation system filter Oil filter Hydraulic reservoir owner s manual. General engine maintenance Detailed instructions and recommendations for break-in and regular maintenance are specified in the Engine Owner s Manual. Please refer to this manual for engine servicing, lubricating oil levels with quality and viscosity recommendations, 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. Carbon canister Figure 4-7 The Hustler 1500 Riding Greens Mower has a carbon canister incorporated into the fuel system. Figure 4-8 This is a mandatory feature that is required on all mowers using gasoline engines that are put into operation in California. Fuel evaporation system filter Oil drain valve All Hustler 1500 Riding Greens Mowers have a fuel evaporation system filter. This filter must be checked and replaced every 500 hours or annually whichever comes first. Figure 4-8 Backlapping system (optional) The on-board backlapping system (optional kit) allows the user to adjust the reel speed to their preference when backlapping the cutting units. This is accomplished by adjusting the hydraulic valve located on the top of the hydraulic valve block. (Figure 4-) Figure 4-8 To change reel speed in backlap, first loosen the jam nut on the valve. To increase the reel speed, turn the adjusting screw clockwise to close the valve. Alternatively, to decrease reel speed, turn the adjusting screw counterclockwise to open the valve. This adjustment can be made in conjunction with the throttle lever to change engine speed to provide the user with the preferred reel speed. Once the valve is adjusted properly, tighten the jam nut. NOTE: This valve only changes reel speed in the backlapping condition, and will not affect the reel speed in the mowing condition. Adjusting screw Jam nut Figure 4- Hydraulic valve block _0811