Hustler X One
Hustler X One
Operator’s Manual
Hesston, Kansas
67062
604909 REV D
REV D 604909
Table of Contents
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
This manual applies to the following Hustler equipment lines: Directions used in this manual, for example RIGHT or LEFT,
refer to directions when in operator position and facing forward,
Hustler® X-One® unless otherwise stated.
Photographs and illustrations used were current at the time of
To the New Owner printing, but subsequent production changes may cause your
machine to vary slightly in detail. Hustler® Turf Equipment
The purpose of this manual is to assist owners and operators reserves the right to redesign and change the machine as deemed
in maintaining and operating your Hustler® mower. Please read necessary, without notification. If a change has been made to
it carefully; information and instructions furnished can help you your machine which is not reflected in this operator’s manual, or
achieve years of dependable performance. the parts manual, see your Hustler® Dealer for current
A separate Engine Owner’s Manual is included with your information and parts.
owner’s packet which contains additional engine information
that will not be repeated in this manual. It is the owner’s Warranty Registration
responsibility to make certain that the operators and mechanics
read and understand the engine owner’s manual before Your Hustler® Dealer must register the unit on-line within ten
attempting to operate or repair the engine. (10) days following date of purchase to validate your warranty
The decals are designed to give the operator brief information protection. As the new equipment owner, you should confirm
needed in the daily operation and service of the machine. These that your Hustler® Dealer has registered your mower with
decals are not intended to be used in place of this manual but Hustler® Turf Equipment.
instead are to be used as an extension of this manual. These Be sure to register the mower plus each attachment that
decals should not be removed or obliterated. Replace these displays a model and serial identification number plate with
decals if they become unreadable. Hustler® Turf Equipment.
It is the owner’s responsibility to make certain that the IMPORTANT: Any unauthorized modification, alteration,
operators and mechanics read and understand this manual and or use of non-approved attachments voids the warranty and
all decals before operating this machine. It is also the owner’s releases Hustler® Turf Equipment from any liability arising from
responsibility to make certain that the operators and mechanics subsequent use of this equipment. Do not use or operate any
are qualified and physically able individuals, properly trained in attachment not approved by Hustler® Turf Equipment.
the operation of this equipment. All operators and mechanics
Model and Serial Number
must become familiar with the safe operation of the equipment,
operator controls and decals. Mower model and serial numbers are found on the serial
IMPORTANT: The owner/user can prevent and is responsi- identification plate, located on the frame directly below and to
ble for accidents or injuries occurring to themselves, other peo- the left of the operator’s platform.
ple or property. These numbers are required when the unit is registered with
Never let children or untrained people operate or service the Hustler® Turf Equipment. They will also assure you of the
equipment. Local regulations may restrict the age of the correct service parts when replacement becomes necessary.
operator.
For more detailed maintenance and adjustment information Parts and Service
refer to the proper General Service Manual for your machine.
Refer to the “Product Literature” section of this manual for Use original Hustler® replacement parts only. These parts are
information on how to attain these manuals. available through your local Hustler® Dealer. To obtain prompt,
efficient service, always provide the following information
Using This Manual when ordering parts:
1. Correct part description.
General operation, adjustment and maintenance guidance is 2. Correct part number.
outlined for both the experienced and novice Hustler® user. 3. Correct model number.
Operating conditions vary considerably and cannot all be 4. Correct serial number.
addressed individually. Through experience, however, operators All warranty repair and service must be handled through an
should find no difficulty in developing good operating skills authorized Hustler® Dealer. Arrangements should be made
suitable to most conditions. through your local service center.
The Engine Owner’s Manual provides information regarding the U.S. Environmental Protection Agency (EPA)
and the California Emission Control Regulation of emission systems, maintenance and warranty.
Keep Engine Owner’s Manual with your unit. Should the Engine Owner’s Manual become damaged or
illegible, replace immediately. Replacements may be ordered per the information found in the Product
Information section of the owner’s manual.
Federal law and California State law prohibit the following acts or the causing thereof:
1. The removal or rendering inoperative by any person other than for purposes of maintenance,
repair, replacement, of any device or element of design incorporated into any equipment for the
purposes of emissions control prior to or after its sales or delivery to the ultimate purchaser or
while it is in use, or
2. The use of the equipment after such device or element of design has been removed or rendered
inoperative by any person.
WARNING WARNING
– denotes a hazard or unsafe practice which COULD Specific safety warning decals are located on the equip-
result in severe personal injury or death. ment near the immediate areas of potential hazards. These
decals should not be removed or obliterated. Replace
This manual uses two other words to highlight information. them if they become non-readable.
IMPORTANT calls attention to special mechanical information
and NOTE emphasizes general information worthy of special The following illustrations show the various safety decals that
attention. are located on the mower. A brief explanation, for those
All operators and mechanics should read this manual, and be requiring one, is shown to help the operator understand the
instructed about safe operating and maintenance procedures. If meanings of these decals.
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 • Read Operator’s Manual and Safety Warning Decals before
attempting to operate this machine.
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 S
EL
0 F U V OI D
E1
the proper use and should read the manuals completely and
N
WA M A X O F
HI G H ER T H A
RR A NT Y
IN F UEL
If pump belt fails, steering control will be lost. Refer to owner’s manual for
inspection and replacement intervals and refer to above paragraph for
emergency procedures.
600899
Hot surface!
• If you lose steering control while operating the machine, place Part Number 779280
the steering control levers in the park brake position immedi-
ately. Inspect the machine and involve your dealer to resolve
the problem before continuing to operate.
• If pump belt fails, steering control will be lost. Refer to owner’s
manual for inspection and replacement intervals and refer to
above paragraph for emergency procedures.
601058
601815
• Avoid skin con- • Do not overfill battery. • Do not allow open flame near the
tact with battery • Electrolyte may overflow and damage battery when charging.
acid paint, wiring or structure. When clean- • Hydrogen gas forms inside the
ing the battery, use soap and water. Be battery. This gas is both toxic and
careful not to get soap and water into flammable and may cause an
the battery. Use soda mixed in water explosion if exposed to flame.
to clean corrosion off the terminals. Always remove the negative
• Always wear eye protection when ground first and replace it last.
checking the battery, acid can cause
serious injury to skin and eyes. If con-
tact occurs, flush area with clean
water and call physician immediately.
Acid will also damage clothing.
601968
WARNING: Read Operator’s Manual and decals before attempting to operate this machine.
• Never operate machine on a slope with the ROPS folded down (lowered position).
• There is no roll over protection when the ROPS is in the lowered position.
• Lower the ROPS only when absolutely necessary. Drive slowly and carefully. Raise the
ROPS as soon as clearance permits.
• Read and follow slopes operation instructions and warnings.
• Do not wear seat belt when the ROPS is in the lowered position.
WARNING: Ejection!
WARNING: Ejection!
H
M
L
I
D E F
L
H
J A
M
C
603916
D (10o)
C (5o)
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.
Safe Operating Practices Do not operate the equipment while wearing sandals, ten-
nis shoes, sneakers, shorts or any type of loose fitting
This product is capable of amputating hands and feet and clothing. Do not use a towel as a headband or neck wrap
throwing objects. Always follow all safety instructions to avoid and do not hang a towel from the waist. Long hair, loose
serious injury or death. clothing or jewelry may get tangled in moving parts.
Always wear long pants, safety glasses, ear protection
Safe Operation and safety shoes with slip-resistant soles when operating
this mower.
Evaluate the terrain to determine what accessories and Always be aware of what is behind the mower before
attachments are needed to properly and safely perform backing up. Never mow in reverse. Always look down
the job. Only use accessories and attachments approved and behind before and while backing up.
by the manufacturer. Never push forward suddenly on your steering control
Never leave a running mower unattended. Always stop levers while the mower is in rearward motion because
on level ground, disengage the deck clutch, place the mower may tip backwards.
steering control levers in the park brake position, stop the Never pull back suddenly on your steering control levers
engine, and remove the ignition key before leaving the while the mower is in forward motion.
operator’s seat for any reason. Wait for the engine and all If mowing in reverse is unavoidable, push forward slowly
moving parts to come to a complete stop before leaving on the steering control levers and avoid sudden move-
the mower for any reason including emptying the catcher ment. Rapid movement of the steering control levers in
or unclogging the chute. either direction could result in a reaction of the mower
Do not change the engine governor setting or over speed that can cause serious injury.
the engine. Operating the engine at excessive speed may Never operate a poorly maintained mower.
increase the hazard of personal injury. Never attempt high speed maneuvering, especially in
Always remain seated while operating the mower. crowded or congested areas.
Always keep safety shields and covers in place, except Never allow persons to operate this mower without
for servicing. proper instruction or allow children to operate the mower.
Always maintain a safe distance from people and pets Allow only responsible adults who are familiar with
when mowing. Always stop mower if someone enters the these instructions to operate this mower.
area. Never put hands or feet under any part of the mower
Always operate mower in daylight or with adequate while it is running.
working lights. Never carry passengers.
Follow daily and weekly checklists, making sure hoses Never direct discharged material toward anyone. Avoid
are tightly secured and bolts are tightened. discharging material against a wall or obstruction. Mate-
Always observe traffic laws while driving mower from rial may ricochet back toward the operator. Always dis-
one location to another. Watch for traffic when operating engage the mower blades and wait for them to stop
near or crossing roadways. before crossing gravel drives, walks or roads.
Always be alert for hazards such as rocks, metal objects Never operate the machine with the floor plate pulley
and other debris which may be thrown or entangled by cover removed.
mower blades. Watch out for holes or deep depressions. Always keep clear of the mower blades and attachments
Never operate the mower when there is a risk for light- during their operation.
ning. Do not use any unauthorized attachment or modify the
Inspect area to be mowed for hazards such as rocks, mower.
metal objects and other debris which may be thrown or Turn off the mower blades when not mowing.
entangled by mower blades. Remove these objects before Slow down before turning.
mowing. Stop the engine before removing the grass catcher or
Always inspect mower for damage after striking a foreign unclogging the discharge chute. Never clear the discharge
object. If damage is found, repair mower immediately. Be chute with the engine running. Turn off the engine and be
sure to stop on level ground, disengage the deck clutch, sure the blades have stopped before cleaning. Use a stick
set the park brake, stop the engine, and remove the igni- to clear a plugged discharge area. Never use your hand!
tion switch key when leaving the operator’s seat to Do not operate the mower if you are fatigued, sick or
inspect damage. while under the influence of alcohol or drugs, if you are
Always wear adequate ear protection, such as earplugs, pregnant or under 18 years old.
when operating this equipment as prolonged exposure to Poor posture or operating the mower for extended periods
uncomfortable or loud noises can cause impairment or of time may lead to fatigue or injury, resulting in loss of
loss of hearing. Do not wear radios or music headphones mower control. Occasionally, stop the mower and get off
while operating the machinery. Safe operation requires the seat to stretch and relax.
your full attention.
G H I
WARNING
The parking brake may not hold the mower if parked on a
slope. Block or chock the machine when parked on a
slope.
Deck lift pedal
B. Deck lift pedal (Figure 3-5) — the deck lift pedal is used
to raise or lower the deck. Push on the pedal to raise the
deck and then place the deck height locking pin into the
desired cutting height hole.
Push the deck lift pedal to raise the deck when going over
obstructions.
Figure 3-5
WARNING
Figure 3-4
The safety interlock system should always function per
steps 4 and 5. If it does not function properly, it should be
corrected immediately. Do not operate machine without a
properly functioning seat safety switch.
DANGER
When moving in the rearward direction push forward
gently on steering control levers and avoid sudden move-
ment. Any sudden movement could cause the front of the
mower to come off of the ground resulting in possible
loss of control, causing serious injury or death.
WARNING
Always be aware of what is behind the machine before FORWARD TRAVEL
backing up. Do not mow in reverse unless absolutely nec-
essary. Always look down and behind before and while
backing up. N N
IMPORTANT: Rapid movement of steering control levers
is not recommended as damage to the hydraulic system compo-
nents may occur.
To increase speed, increase steering control lever’s distance
from neutral. The farther forward steering control levers are ZERO RADIUS TURN
from neutral, the faster the mower will travel forward. The
farther back steering control levers are from neutral, the faster
the mower will go in reverse. N N
FORWARD TRAVEL
RIGHT TURN
N N
REVERSE TRAVEL
RIGHT TURN
N N
REVERSE TRAVEL
N N
N = NEUTRAL POSITION
Direction of arrows indicate direction of mower
movement
Figure 3-9
DANGER
Prior to operating the mower the operator should be thor-
oughly familiar with the proper use and operation of the
equipment, should read the manual completely and thor-
oughly, and should have attempted slow moving maneu-
vers to become familiar with the operation of the
equipment before attempting normal speed operation. An
inexperienced operator should not mow on slopes or on
uneven terrain.
WARNING
co eve
Le ro
Step 1
nt r
l
ft l
WARNING
ut
ra
l
al
n
L
er
WARNING
Step 3
Sharp depressions or raised obstacles (such as gutters or
curbs) should not be directly approached at high speed in
an attempt to “jump” them as the operator could be
thrown from the equipment. Approach at a slow speed
and angle one drive wheel at the obstruction. Continue at
an angle until the wheel clears and then pivot the opposite
wheel around.
When turning on soft wet turf, keep both wheels rolling either
Neutral forward or backward. Pivoting on one stopped wheel can
Right control lever Left control lever damage turf. This is especially important when mowing.
Mower performance is at maximum when the throttle is set at
full rpm. This gives maximum power to the drive wheels and
Figure 3-10 deck when needed. Use the control levers to control ground
speed rather than engine rpm.
Keep blades sharp. Many professional mowing companies
WARNING
Make sure that the area around and under the deck is clear
and that there are no bystanders in the immediate area
before proceeding.
Pin
To check the deck clutch switch:
1. Start the engine and engage the deck clutch.
2. With the deck clutch switch up (clutch engaged) and the
engine running, listen to confirm that the mower blades Cutting height holes
are rotating.
3. Now, push the deck clutch switch down (clutch
disengaged), and with the engine running, listen to
Figure 3-13
confirm that the blades have stopped rotating.
4. If the mower blades continue to rotate with the deck Air Flow Baffles
clutch switch down, discontinue operation immediately
and contact your Hustler® Dealer. The decks are equipped with front adjustable air flow baffles.
Clutch life will be maximized if these procedures are These baffles can be adjusted up or down, depending upon the
followed. mowing conditions, to provide the best quality of cut. Figure 3-
1. Engage the clutch only when the throttle is set at 14 & Figure 3-15
approximately 2/3 throttle and there is no load on the Setting Conditions
blades. After clutch engagement, advance the engine
throttle to full rpm. A Dry, sparse grass. Particularly useful when mowing
Bottom set of holes at a height of cut of 3” (76.2mm) or higher. This set-
Engaging the deck clutch at high engine rpm or when ting provides the maximum vacuum and minimal
under heavy load (in tall grass, for example) can cause blowout.
belts and/or electric clutch to slip, resulting in premature B Manicured lawns. Provides the best vacuum for the
2nd set of holes best cut when removing weekly/bi-weekly growth.
wear or possible damage.
2. Disengage the clutch only when the throttle is set at less C Tall and stemmy grasses. The higher inner wall al-
3rd set of holes lows grasses to snap back up before contacting the
than 1/2 throttle. blades to produce a cleaner cut.
Never disengage the clutch with the engine running at
D Very tall and stemmy grasses. Allows the maximum
high rpm. Setting the throttle to less than 1/2 throttle Top set of holes height for grass to recoil before cutting. Well suited
when disengaging the clutch will help extend clutch life. for utility cutting of overgrown grass.
Warranty will not be allowed for deck clutches that fail due NOTE: The air flow baffles are preset at the factory in the
to improper engagement and disengagement practices. “B” setting.
The air flow baffles for the 48” and 54” decks come with two
Deck Cutting Height Adjustment
sets of holes per baffle. The baffle mounting hardware must be
Deck cutting height is adjustable in 1/4” (6.4mm) increments. removed and the baffle moved up or down and the hardware re-
installed in the correct set of holes and tightened. Figure 3-14
The holes in the height adjusting bar are spaced at 1/2”
The 60” decks come with three sets of mounting hardware for
(12.7mm) intervals. By turning the height adjusting stop around,
each air flow baffle. The middle set of hardware does not need
1/4” (6.4mm) increments can be attained due to the 1/4”
to be removed when changing the baffle setting. This is a slot
(6.4mm) plate that is part of the stop. Figure 3-13
and the hardware only needs to be loosened enough to allow the
EXAMPLE: When the height adjusting stop is placed in the
baffle to slide. The other hardware on the ends of the baffles will
A
B
D
Anti-scalp
wheel
Adjusting
holes
Figure 3-16
When adjusting the rear anti-scalp wheels, the wheel should
Baffles
be in the same axle mount hole as the front anti-scalp wheels.
Figure 3-14
Slot B A
Lower
C
adjusting hole
Rear center
anti-scalp roller
Figure 3-17
Baffles
Side anti-scalp rollers
Figure 3-15
Anti-Scalp Wheels
Anti-scalp wheels are standard on Hustler® X-ONE® units.
These anti-scalp wheels are designed to minimize scalping
when mowing on rough uneven terrain. Figure 3-16
Optional rear anti-scalp rollers are available.
The 48” and 54” decks use one rear anti-scalp roller. The 60”
decks can be used with either one center anti-scalp roller, two
side anti-scalp rollers or three rear anti-scalp rollers. Figure 3-17
There are two height adjustment settings for the anti-scalp Center anti-scalp
wheels/rollers. The upper hole positions the wheels/rollers 1” roller location
(25.4mm) below the cutting blades and the lower hole positions
them 2” (50.8mm) below the cutting blades. Figure 3-18
When the mowing height is set at 1” (25.4mm) to 3”
(76.2mm) the anti-scalp wheels/rollers should be in the upper Figure 3-18
position.
When the mowing height is set at 3-1/4” (82.6mm) to 5”
(127mm) the anti-scalp wheels/rollers should be in the lower
Safe Servicing Practices Never run the engine in an enclosed area unless exhaust
is vented to the outside. Exhaust gases contain carbon
This product is capable of amputating hands and feet and monoxide which is an odorless and deadly poison.
throwing objects. Always follow all safety instructions to avoid Never attempt to make any adjustments or repairs to the
serious injury or death. mower drive system, mower deck or any attachment
while the mower engine is running or deck clutch is
Service Precautions engaged. Repairs or maintenance requiring engine power
should be performed by trained maintenance personnel
Unless specifically required, DO NOT have engine run- only.
ning when servicing or making adjustments to mower. Never work under the machine or attachment unless it is
Park the machine on level ground. Place steering control safely supported with jack stands. Make certain machine
levers in the park brake position, disengage deck clutch, is secure when it is raised and placed on the jack stands.
lower deck, remove ignition switch key and disconnect The jack stands should not allow the machine to move
negative battery cable before doing any maintenance. when the engine is running and the drive wheels are
Wait for all movement to stop before adjusting, cleaning rotating. Use only certified jack stands. Use only appro-
or repairing. Repairs or maintenance requiring engine priate jack stands, with a minimum weight rating of 2000
power should be performed by trained maintenance per- pounds (907 kg) to block the unit up. Use in pairs only.
sonnel only. To prevent carbon monoxide poisoning, be Follow the instructions supplied with the vehicle stands.
sure proper ventilation is available when engine must be Exercise caution when releasing spring tension from any
operated in an enclosed area. Read and observe safety of the belt idlers or when working with any of the deck
warnings in front of manual. lift components.
Before working on or under the deck, make certain Do not touch hot parts of machine.
engine cannot be accidentally started. Shut engine off, Keep nuts and bolts tight, especially the blade attachment
remove ignition switch key and disconnect negative bat- bolts. Keep equipment in good working condition.
tery cable for maximum safety. Repairs or maintenance Never tamper with safety devices. Check their proper
requiring engine power should be performed by trained operation regularly.
maintenance personnel only. Stop the engine before removing the grass catcher or
Except when changing or checking the belt, always keep unclogging the discharge chute. Never clear the discharge
belt covers on mower deck for safety as well as for clean- chute with the engine running. Turn off the engine and be
liness. sure the blades have stopped before cleaning. Use a stick
Use a stick or similar instrument to clean under the to clear a plugged discharge area. Never use your hand!
mower making sure that no part of the body, especially Grass collection system components are subject to wear,
arms and hands are under the mower. damage and deterioration, which could expose moving
Keep your machine clean and remove any deposits of parts or allow objects to be thrown. Frequently check
trash and clippings, which can cause engine fires and components and replace with manufacturer’s recom-
hydraulic overheating as well as excessive belt wear. mended parts, when necessary.
Clean up oil or fuel spillage. Allow machine to cool Exercise caution when working under the deck as the
before storing. mower blades are extremely sharp. Wrap the blade(s) or
Clean flammable material from machine. Prevent wear gloves and use extra caution when servicing them.
fires by keeping the engine compartment, top of the Use only genuine Hustler® replacement parts to ensure
deck, exhaust area, battery, fuel line, fuel tank and that original standards are maintained.
operator’s station clean of accumulated trash, grass
clippings, and other debris. Always clean up spilled Service Introduction
fuel and oil.
Always wear adequate eye protection when servicing the Regular maintenance is the best prevention for costly
hydraulic system and battery, or when grinding mower downtime or expensive, premature repair. The following pages
blades and removing accumulated debris. contain suggested maintenance information and schedules
Use extra caution when handling gasoline and other which the operator should follow on a routine basis. For more
fuels. They are flammable and vapors are explosive. detailed information order the correct Parts Manual and General
Never attempt to start the engine when there is a strong Service Manual for your unit. Refer to the Product Literature
odor of gasoline fumes present. Locate and correct the section of this manual.
cause. Remain alert for unusual noises, which could signal a
Never remove the fuel cap or refuel the mower while problem. Visually inspect the machine for any abnormal wear or
engine is running or while engine is hot; never refuel near damage. A good time to detect potential problems is while
an open flame or near devices which can create a spark. performing scheduled maintenance service. Correcting the
Refuel outdoors. Never refuel or drain the fuel from the problem as quickly as possible is the best insurance.
machine indoors. Clear away heavy build-up of grease, oil and dirt, especially
Electrical System
The electrical system is a 12 volt, negative ground.
REV D 4-2 604909
Remember, dirt is the primary enemy of any hydraulic system.
Figure 4-2
WARNING
Shorts caused by battery terminals or metal tools touch- WARNING
ing metal mower components can cause sparks. Sparks
can cause a battery gas explosion which will result in per- Hydraulic fluid escaping under pressure may have
sonal injury. sufficient force to penetrate skin and cause serious
• Prevent the battery terminals from touching any injury. Foreign fluid injected into the skin must be
metal mower parts when removing or installing the surgically removed within a few hours by a doctor,
battery. familiar with this form of injury, or gangrene may
• Do not allow metal tools to short between the bat- result.
tery terminals and metal mower parts.
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,
WARNING use a piece of cardboard or wood — never use your
hands. Relieve all pressure in the system before dis-
Incorrect battery cable routing could cause damage to the connecting or working on hydraulic lines. To relieve
mower and battery cables. This can cause sparks which pressure, lower all attachments and shut off engine.
can cause a battery gas explosion which will result in per-
sonal injury. Check oil level in hydraulic system after every 50 hours of
• Always disconnect the negative (black) battery operation or weekly, whichever occurs first. Check more often if
cable(s) before disconnecting the positive (red) system appears to be leaking or otherwise malfunctioning.
cable(s). Figure 4-2
• Always connect the positive (red) battery cable(s) Fluid level should be 1” (25.4mm) from top of reservoir. Use
before connecting the negative (black) cable(s). only SAE 20W50 SL/SM service motor oil for the Hustler® X-
ONE.
Master in-line fuse NOTE: The reservoir will require approximately 5.75 U.S.
The Hustler® X-ONE® mowers have a master in-line fuse in quarts (5.4 liter) of SAE 20W50 SL/SM service motor oil when
the electrical system. This is the main fuse to protect the replacing the oil after an oil and filter change. Do not overfill
complete electrical system. It is located at the right front of the the reservoir.
engine close to the starter. Figure 4-1 Change the hydraulic system filter element and oil after first
50 hours of mower operation, then replace filter and oil in
reservoir every 500 hours thereafter.
IMPORTANT: It is necessary to drain the system oil from
Master fuse the hydraulic reservoir, using the reservoir drain plug, before
housing
removing the hydraulic filter. Replace the drain plug before add-
ing system oil.
The Hustler® X-ONE system filter is located inside the
hydraulic reservoir on the left side of the tank. Use a Hustler®
approved filter element only. When changing the filter use a
5/8” socket for the Hustler® X-ONE. The threads are right hand.
Figure 4-2
Fuel and Evaporative Emissions Control
System
Starter The fuel and evaporative emissions control system for this
mower is EPA compliant. Use only Hustler® approved
replacement parts.
Your evaporative emission control system may include parts
Figure 4-1 such as: fuel tanks, fuel lines, fuel line fittings, fuel caps, carbon
canisters, canister mounting brackets, carburetor purge port
Hydraulic System connection, filters, vapor hoses, clamps, control valves, control
solenoids, electronic controls, vacuum control diaphragms,
IMPORTANT: Never use hydraulic or automatic transmis- purge valves, liquid/vapor separator and other associated
sion fluid in this system; use only motor oil as specified. components.
Modifying or Tampering with the evaporative emissions
control system or the fuel system is prohibited. Federal law
and California State law prohibit the following acts or the
Closed
position
Right fuel tank
Figure 4-4
Engine Air Filter
Perform engine air filter maintenance per the Maintenance
Schedule shown elsewhere in this manual.
Figure 4-3 A specially designed dry filter is standard equipment on these
mowers and supplies clean combustion air to the engine. Figure
Engine Oil and Filter 4-5
These mowers are equipped with a safety filter. The filter
element slides over the safety filter. Figure 4-6
The safety element does not require servicing unless it
WARNING becomes contaminated with dirt or moisture.
Recommended service procedure
If the engine has been running and is up to operating tem-
1. Release clamps and remove element. Clean the canister
perature, allow the engine to cool before changing the oil.
with a damp cloth.
Engine and engine oil will be very hot, so be very careful
2. Before installing a new element, inspect it by placing a
when changing oil and wear the appropriate protective
bright light inside and rotating the element slowly,
gear to avoid being burned or exposed to engine oil.
looking for any holes or tears in the paper. Also check
Check engine oil daily and after every 4 hours of operation. gaskets for cuts or tears. Do not attempt to use a damaged
Machine must be setting level when checking oil. Refer to element which will allow abrasive particles to enter the
engine manual and maintenance schedule for oil engine.
recommendation and capacities. 3. Reinstall the dust cap. Make sure it seals all the way
around the air cleaner body, then tighten the clamps.
Fuel evaporation
system filter
Indicator
Figure 4-9
with a sharp knife.
WARNING
If the pump belt fails, loss of control will occur especially
Figure 4-7 when operating on a slope. If you lose steering control
while operating the machine, place the steering con-
trol levers in the park brake position immediately.
Fuel evaporation Inspect the machine and involve your Hustler® Dealer
system filter to resolve the problem before continuing to operate.
Inspect the belt pulley grooves and flanges for wear. A new
belt, or one in good condition, should never run against the
bottom of the groove. Replace the pulley when this is the case,
otherwise the belt will lose power and slip excessively.
Carbon Never pry a belt to get it on a pulley as this will cut or damage
canister the fibers of the belt covering.
Keep oil and grease away from belts, and never use belt
dressings. Any of these will destroy the belt composition in a
very short time.
Hydraulic Mower Blade Maintenance
reservoir
Fuel evaporation Check the mower blades daily, they are the key to power
system filter
efficiency and well groomed turf. Keep the blades sharp. A dull
blade will tear rather than cut the grass, leaving a brown ragged
Figure 4-8 top on the grass within a few hours. A dull blade also requires
more power from the engine.
Belts Replace any blade which is bent, cracked or broken.
WARNING
Always wear adequate eye protection when grinding Do not sharpen to original pattern (below). It is
mower blades. easier to get a straight cutting edge following
the resharpening pattern shown above.
Mower Blade Removal
Use a 15/16” wrench to remove the 5/8” cap screw holding
the blade to the spindle shaft from underneath. NOTE: A blade
holding tool (part number 381442) is available from Hustler®
Turf Equipment. It is designed to prevent the blades from
rotating when they are being removed or installed on the
spindle. Contact your Hustler® dealer for more information.
Original edge
Sharpen the blades on a grinder following pattern as shown
(Figure 4-10). Touch-up sharpening can be done with a file
Check the blades for balance following grinding. A
commercial balancing tool is available through most hardware
supply stores, or balancing can be done by placing the blade on
an inverted line punch or 5/8” bolt. Blade should not lean or tilt. Figure 4-10
Spin the blade slowly, blade should not wobble. If blade is out
Warped Blade (Replace)
of balance, true it up before reinstalling.
Lay the blade on a flat surface and check for distortion
Cutting
(Figure 4-11 & Figure 4-12). Replace any distorted blade. plane
Do not re-use spindle bolts which have stripped, worn or
undercut threads. Torque bolts on spindles to 118 foot-pounds
(160.0 N-m) when reinstalling blades. Straight Blade
Properly compressed cup washers maintain the correct
compression load on the blades. Replace the cup washers if they Comparison of Warped and Straight Blades
are cracked or flattened. Figure 4-11
IMPORTANT: The blade sail (curved part) must be point-
ing upward toward the inside of the deck to ensure proper cut- Cutting edge
ting.
IMPORTANT: When mounting blades, rotate them after
installation to ensure blade tips do not touch each other or sides Twisted Blade Edge
of the mower. (replace)
Cutting Plane Cutting edge
WARNING
Straight Blade Edge
Failure to correctly torque the bolt may result in the loss
of the blade which can cause serious injury. End view of blades, comparing
twisted and straightened blades
Figure 4-12
Seat (Option 1)
This 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 4-13
Figure 4-15
Forward/rearward
travel lever
Lumbar control
Figure 4-13
Seat (Option 2)
This seat can be adjusted four different ways to obtain the
most comfortable position:
1. Back angle (Figure 4-15)
2. Forward and rearward travel (Figure 4-14)
3. Weight (Figure 4-14)
4. Lumbar (Figure 4-16)
Figure 4-16
Cap screws
Lower
control
lever
Figure 4-17
NOTES:
1. Initial oil change is after 5 hours of operation. Thereafter, change oil after every 40 hours operation. Change more often under dusty or dirty conditions and dur-
ing hot weather periods.
2. Torque initially and after first 2 hours of operation.
3. Perform initial hydraulic oil and filter change after 50 hours (one week) of operation.
4. Change engine oil filter per the engine manufacturer’s recommendations. Refer to Engine Owner’s Manual for recommendations and other maintenance items.
5. Service more often under dusty or dirty conditions. Use caution when servicing to prevent dust contamination in the engine. Do not clean filter element. Replace
with a new one.
6. Pump drive belt only - Inspect every 100 hours and replace if worn or cracking is noticed. Otherwise, replace every 400 hours or 2 years whichever comes
first.
7. Check fuel system for any crack or leaks including, but not limit to, fuel line hoses, fuel valve, vent line hoses, vent valve, vapor valve, carbon canister, and
grommets. Repair as needed.
8. More often under dusty or dirty conditions and during hot weather.
9. Inspect ROPS after the first 20 hours of operation and then after every 500 hours of operation or yearly whichever comes first.
12 11
13 2 5
8 7
11 9 1. Engine Oil Fill & Dipstick
2. Fuel Filter
3. Engine Air Cleaner
6 4. Engine Oil Drain Plug
5. Battery
6. Fuel Tanks
7. Hydraulic Oil Reservoir
3 8. Hydraulic Oil Filter
9. Front Wheel Bearing Zerks (2)
10. Engine Oil Filter
11. Deck Height Pivot Zerks (4)
12. Park Brake Switch
13. Drive Tires
14. Pump Idler Zerk (1)
15. Pump Belt
10 16. Deck Pusher Arm Zerks (2)
1 17. Deck Belt
18. Spindle Housing Zerk (3)
19. Blades
4
11 20. Fuel Evaporation System Filter
12 9 21. Carbon Canister
6 13 11
Figure 4-18
Figure 4-19 Figure 4-20 Figure 4-21
20
15
21
14 20
20
Carbon canister equipped machines
19
16
18
17
19
18
18
16 19
Figure 4-23
1. Engine Oil Fill & Dipstick
2. Fuel Filter
19 3. Engine Air Cleaner
4. Engine Oil Drain Plug
16 5. Battery
18 6. Fuel Tanks
7. Hydraulic Oil Reservoir
8. Hydraulic Oil Filter
19 9. Front Wheel Bearing Zerks (2)
17
10. Engine Oil Filter
11. Deck Height Pivot Zerks (4)
12. Park Brake Switch
13. Drive Tires
18 14. Pump Idler Zerk (1)
15. Pump Belt
16. Deck Pusher Arm Zerks (2)
17. Deck Belt
18 18. Spindle Housing Zerk (3)
16
19. Blades
20. Fuel Evaporation System Filter
60” Rear Discharge 19
21. Carbon Canister
deck shown
17
Figure 4-24
19
16 18
17 19
18
19
16 18
The majority of operating problems that occur with a system can be traced to improper adjustments or delayed service. A
consistently applied preventative maintenance program, as outlined in the Maintenance section of this manual, will prevent many
problems. The following chart is designed to help you locate a problem by suggesting probable causes and the recommended
solutions.
PROBABLE SUGGESTED
PROBABLE SUGGESTED SYMPTOMS
SYMPTOMS CAUSES REMEDIES
CAUSES REMEDIES
Mower jerky when starting Steering control linkage Adjust linkage
Starting motor does not Steering control levers not Place steering control or operates in one direc- needs adjustment
crank in park brake position or levers in park brake posi- tion only
switch not adjusted tion or re-adjust switch Pump or wheel motors Contact your dealer
faulty
Deck clutch switch Disengage clutch switch
engaged Tow valves not closed com- Close tow valves
pletely
Weak or dead battery Recharge or replace
Hydraulic system oper- Low hydraulic oil level Fill reservoir
Electrical connections are Check the electrical con- ates hot (oil in reservoir
corroded or loose nections smells rancid) Hydraulic pump faulty Contact your dealer
For additional causes See engine manual Mower creeps when Steering linkage needs Adjust linkage
steering control levers are adjustment
The engine will not start, No fuel or line plugged Fill tank or replace line (See in neutral
starts hard or fails to keep Fuel System section for
running more details) Mower circles or veers in Steering linkage needs Adjust linkage
one direction adjustment
Fuel valve is turned off Open the fuel valve
Wheel motors faulty Contact your dealer
There is incorrect fuel in the Drain the tank and replace
fuel system the fuel with the proper type Tires improperly inflated Adjust air pressure to 8 - 12
psi (55 - 83 KPa)
There is dirt in the fuel filter Replace the fuel filter
Hydraulic pump faulty Contact your dealer
Dirt, water or stale fuel in Contact your dealer
the fuel system Mower creeps when park- Steering linkage out of Adjust steering linkage
ing brake engaged adjustment
The choke is not on Move the choke lever to
ON Brakes need adjustment Adjust parking brakes
Numerous See engine manual There is abnormal vibra- The engine mounting bolts Tighten the engine mount-
tion are loose ing bolts
Engine: Numerous See engine manual
Runs with continuous mis- The engine pulley, idler pul- Tighten the appropriate pul-
firing or engine runs ley or blade pulley is loose ley
unevenly or erratically
The engine pulley is dam- Contact your dealer
Loss of power or system Restrictions in air cleaner Service air cleaner aged
will not operate in either
direction Hydraulic line blockage See your dealer The cutting blade(s) is/are Install new cutting blade(s)
bent or unbalanced
Internal interference or See your dealer
leakage in wheel motor A blade mounting bolt is Tighten the blade mounting
loose bolt
Insufficient hydraulic oil Check level in reservoir
supply Spindle bearing is worn or Replace or tighten spindle
Have dealer check hydrau- loose bearing
lic pump
A blade spindle is bent Contact your dealer
Poor compression See your dealer
Blades do not rotate The deck drive belt is worn, Install a new deck drive belt
Steering linkage needs Adjust linkage loose or broken
adjustment
The deck drive belt is off Install the deck drive belt
Tow valve open Close tow valve the pulley and check for a reason
The traction drive belt is Install a new traction drive Electric clutch is not engag- Check and/or replace 10
worn, loose or broken belt ing amp fuse.
Contact your dealer
Air in system Check filter and fittings
Uneven cutting height The blade(s) are not sharp Sharpen the blades
When storing the unit at the end of the mowing season, the film of oil over any exposed metal surfaces of the engine
mower, engine, and battery should have the following items that are subject to corrosion.
serviced before storage. 8. Clean dirt and chaff from the cylinders and fins, blower
If the mower has been stored for an extended period of time, housing and muffler.
follow the new season preparation steps before beginning 9. Check the oil filler cap and fuel tank caps to make certain
operation. they are securely in place.
10. Refer to the engine manual for more information.
General mower preparation for storage
1. Remove all grass, dirt, and trash from mower and cutting Preparation of battery for storage
units. When the machine is to be unused for long periods, it is best
IMPORTANT: Wash the machine with a mild detergent to disconnect the battery and remove it from the unit. At this
and water. Do not pressure wash the machine. Avoid time perform the following battery maintenance:
excessive use of water, especially near the control panel 1. Remove the battery from machine.
and engine. 2. Clean the battery, terminals, and cable connectors.
Clean mower and deck and touch up all scrapes with 3. Charge the battery, if necessary.
touch-up paint. 4. Store the battery in a cool, dry place (do not expose to
2. Replace air filter element. freezing temperatures).
3. Check thoroughly for any worn or damaged parts that 5. Always keep the battery fully charged. Especially
need replacing and order them from your dealer. important to prevent battery damage when the
4. Thoroughly lubricate machine, according to the temperature is below 32°F (0°C).
Maintenance section. New season preparation
5. Block mower up so weight is off tires. Check tire
pressure and inflate to proper operating pressure. Before starting the mower following post season storage, the
NOTE: Do not deflate tires. following service is required:
6. Perform separate engine and battery preparation as listed 1. Clean mower, removing trash and dirt accumulation.
below. 2. Check engine oil and hydraulic oil levels.
7. Store mower in a clean, dry place. 3. Fill fuel tanks with fresh fuel. Run machine at half speed
for 5 minutes, checking operation of steering control
Preparation of engine for storage lever. Stop engine and check for oil leaks, loose fittings
When the engine is to be unused for long periods, proceed as and so forth.
follows:
1. Run the engine for a minimum of 15 minutes.
2. Drain the oil from the crankcase while the engine is still WARNING
warm.
3. Refill with fresh oil of the proper viscosity.
4. Drain the fuel tank and run the engine until it stops from At start of new season always check that fresh oil has
lack of fuel. Gasoline evaporates if left in the carburetor been added to machine. If oil is drained at season’s end
for long periods, forming gum and varnish deposits in the and not replaced, engine damage will result.
carburetor. These deposits will cause engine flooding and 4. Tighten any bolts that have loosened and make sure all
loss the previous 100 hours. hair pins, cotter pins and clevis pins are in place.
5. Remove the spark plugs and pour a tablespoon of engine 5. Install all safety shields and review safety precautions
oil into each spark plug hole. Install plugs, but do not listed in this manual.
reconnect plug leads. 6. Check and inflate tires to 8-12 psi (55-83 KPa).
6. Crank the engine with the starter at least a dozen 7. Install fully charged battery and attach the battery cables.
revolutions to distribute oil over the cylinder walls and 8. Refer to engine manual for more information.
valve mechanism.
7. Clean the exterior surface of the engine. Spread a light
If you would like to view or print a copy of the Hustler® X-ONE® product manuals (Operator’s Manual, Parts Manual, or General
Service Manual) go online to www.hustlerturf.com.
Contact your local Hustler® dealer if you require another engine owner’s manual.
Engine air filter ........................................................4-5 Safety start interlock system ................................. 3-5
Fuel and Evaporative Emissions Control System 4-3 Service precautions ............................................... 4-1
General mower preparation for storage ................6-1 Steering control lever adjustment ......................... 4-9
Moving mower with stalled engine .........................3-6 Using a Ramp ......................................................... 3-2