Hustler 106567 User Manual

Page 1
Parts Manual
106567 Rev. 7/06
•••••••
Hustler Turf Equipment
•••••
P.O. Box 7000
•••
Hesston, Kansas
67062-2097
Page 2
WARNING:
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects or other reproductive harm.
IMPORTANT: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate this engine on any fores t-covered, brush-covered, or grass-covered unimproved land. Other states or federal areas may have similar laws.
This spark ignition system complies with Canadian ICES-002.
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 pe r the information found in the Produc t Information sec tion of the
owner’s manual.
Page 3
Chapter 1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Chapter 2 Contents
Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Chapter 3 Contents
Hydraulic System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Chapter 4 Contents
Battery Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Steering and Park Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Pump Belt and Pulleys Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Chapter 5 Contents
Kawasaki Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Honda Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Kohler Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Fuel System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Instrument Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Electrical Schematic (799320) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Table of Contents

Chapter 6 Contents
Front Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Front Wheel Breakdown—747782 . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Optional Semi-Pneumatic Tire/Wheel—789537 . . . . . . . . . . . . . . . 6-5
Drive Wheel Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Anti-Rollover Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Chapter 7 Contents
66" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
66" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
60" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
60" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
54" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
54" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Spindle Assembly–796235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Chapter 8 Contents
Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Deck Belt Routing and Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Seat Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Chapter 9 Contents
Tractor Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
66" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
60" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
54" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
106567 7/06 c-1
Page 4
Chapter 10
Maintenance & Adjustments Safety Precautions . . . . . . . . . . . . .10-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-7
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-15
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1
c-2 106567 7/06
Page 5

Chapter 1

General Information

This Manual covers Hustler XR7 Z models 927723, 927731, 927749, 927756, 927772, 927798, 927806, 927814.
Frequently Ordered Parts
PART NO. DESCRIPTION
027912 Lubrizol 7 oz. Bottle 027920 Lubrizol 10 oz. Bottle 768341 Hydraulic Oil Filter 781443 Pump Drive Belt 797696 Blade, F18.50"-H-F-CW (54" Deck) 794685 Blade, F20.50"-H-F-CW (60" Deck) 798496 Blade, F22.50"-H-F-CW (66" Deck) 797928 Belt, B-Section (54" Deck) 797720 Belt, B-Section (60" Deck) 797936 Belt, B-Section (66" Deck) 068478 Fuel Filter 785261 Main Air Filter Element 785279 Safety Air Filter Element 772079 Kawasaki Engine Oil Filter 785634 Honda Engine Oil Filter 747303 Kohler Engine Oil Filter
Service Literature
PART NO. DESCRIPTION
375527 Owner’s Manual 785642 Honda 18/20/24 Engine Owner’s Manual 778423 Kawasaki 19–25 hp Engine Owner’s Manual 742684 Kohler Engine Owner’s Manual
Note: When ordering parts, you must use the part number as shown for each part, not the index number. Always give the model and serial number to your parts and service representative.
Note: Items sold in bulk such as seals and hoses are sold by the foot.
Using this manual
Illustrations used were current at the time of printing, but subsequent production changes may cause your machine to vary slightly in detail. Excel Industries, Inc. reserves the right to redesign and change the machine as deemed neces­sary, without notification. If a change has been made to your machine which is not reflected in this parts manual, see
106567 7/06 1-1
Page 6
your Hustler dealer for current information and parts.
Hardware Description Codes & Abbreviations
The following codes are used throughout this parts manual. Refer to this list when ordering parts.
ABBREVIATION DESCRIPTION
CB Carriage Bolt CE Clevis Pin CP Cotter Pin CS Cap Screw
CW Cup Washer
FDRW Fender Washer
FW Flat Washer
HX Hex Head LW Lock Washer MB Machine Bushing MS Machine Screw NT Nut SC Self Tapping Cap Screw SH Socket Head SB Shoulder Bolt SS Set Screw OD Outside Diameter
ID Inside Diameter
Standard Torques
The following chart lists the standard torque values for the threaded fasteners found in this manual. Torque all cap screws, nuts and set screws to these values unless a different torque is shown in the Notes section next to the fastener.
SIZE FT-LBS NM SIZE FT-LBS NM
.250 8.2 11.1 M3 1 1.3 .312 17 23 M4 2.2 3 .375 30 40 M5 4.5 6.1 .438 48 65 M6 7.7 10.4 .500 73 99 M8 18.5 25 .562 105 143 M10 37 50 .625 145 200 M12 64 87 .750 260 350 M14 80 108.5 .875 420 565 M16 160 215
1.00 625 850 M20 320 435 M24 555 750
NOTE:
Loctite® 592 to be used on all pipe threads. Lubricate all grease zerks.
1-2 106567 7/06
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106567 7/06 1-3
Page 8
1-4 106567 7/06
Page 9

Chapter 2 Contents

Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
106567 7/06 2-1
Page 10

Rivet Nut Installation

2
1
2
2
3
5
2
3
4
INDEX NO.
1 548032 107701 1 TRACTOR FRAME (54")
2 N/A 808493 15 3/8-16 THREAD RIVET NUT
3 N/A 600961 8 1/2-13 THREAD RIVET NUT
4 N/A 808477 2 1/4-20 THREAD RIVET NUT (KAW ONLY)
5 547950 106732 1 XR7 MMZ SEAT SUPPORT
3
SERVICE
PAR T NO.
547760 106211 1 TRACTOR FRAME (60")
547752 106039 1 TRACTOR FRAME (66")
MFG. PART
NO.
QTY. DESCRIPTION
NOTES:
1. Seat support 547950 includes rivet nuts.
2-2 106567 7/06
Page 11

Footrest Assembly

1
2
4
5
6
3
5
1
7
INDEX
NO.
1 359547 359547 2 STEP TREAD
2 395533 395533 1 FLOOR
3 305615 305615 2 PLATFORM STEP TREAD
4 086660 086660 2 NT .375-16 HX LK NY
5 767954 767954 4 FW .406 X .812 X .060 SAE HD ZN
6 781880 781880 2 RUBBER BUMPER
7 052860 052860 2 CS .375-16 X 1.250 HX G5 ZN
SERVICE
PART NO.
MFG.
PART NO.
QTY DESCRIPTION
NOTES:
1. Do not tighten, Item 2 (348276 Floor) must be able to pivot on these bolts.
106567 7/06 2-3
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2-4 106567 7/06
Page 13

Chapter 3 Contents

Hydraulic System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
106567 7/06 3-1
Page 14

Hydraulic System Installation

2
1
16
15
31
4
3
17
19
5
20
18
17
FRONT
30
18
17
10
11
6
10
14
20
29
9
28
23
11
7
21
8
22
12
24
26
25
12
11
27
13
24
3-2 106567 7/06
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Hydraulic System Installation
ITEM
NO.
1 768515 768515 2 FW .281 X .625 X .051/.080 HD ZN/YL
2 055947 055947 2 CS .250-20 X .500 HX G5 ZN
3 032771 032771 1 STRAINER
4 032763 032763 1 BREATHER CAP
5 349860 349860 1 RESERVOIR
6 034272 034272 4 NT .312-18 HX G5 ZN
7 768523 768523 4 FW .343 X .687 X .051/.080 HD ZN/YL
8 781062 781062 1 HYDRO-GEAR PUMP, BDP-10A-300
9 781047 781047 1 HYDRO-GEAR PUMP BDP-10A-400
10 041707 041707 4 NT .437-14 HX G5 ZN
11 704742 704742 8 FW .453 X .812 X .060 ZN
12 781054 781054 2 ROSS/PARKER WHEEL MOTOR, MB-15
13 705186 705186 4 CS .437-14 X 1.375 HX G5 ZN
14 768341 768341 1 FILTER ELEMENT
15 768333 768333 1 FILTER HEAD
16 781575 N/A 1 -6STR -6 90°, PUSHLOC HOSE 4.75"
17 763946 N/A 3 90°, -6 O-RING/-6 JIC FITTING
18 778985 N/A 2 -6STR -6 90°, PUSHLOC HOSE, 13.00"
19 781591 N/A 1 -6STR -6 90°, PUSHLOC HOSE, 15.00"
20 779132 N/A 2 STR-6MORB/-6JIC FITTING
21 781559 N/A 1 45°, -8MORB/-8MSL FITTING
22 781542 N/A 1 90°,-8MORB/-8MSL FITTING
23 781658 N/A 1 STR-8-MORB/HEX PLUG
24 781526 N/A 4 90°, -10MORB/-8MSL FITTING
25 781500 N/A 1 RIGHT LOOP/RP-BM HYDRO TUBE
26 781492 N/A 1 RIGHT LOOP/LP-TM HYDRO TUBE
27 781484 N/A 1 LEFT LOOP/RP-BM HYDRO TUBE
28 781476 N/A 1 LEFT LOOP/LP-TM HYDRO TUBE
29 781534 N/A 2 STR-8MORB/-8MSL FITTING
30 781518 N/A 1 -6STR -6STR PUSHLOC HOSE, 9.00"
31 763953 N/A 1 -6 O-RING/-6JIC/6JIC T FITTING
SERVICE
PART NO.
N/A 781469 1 MMZ HYDRAULIC KIT (INCLUDES 16-31)
MFG.
PART NO.
QTY DESCRIPTION
NOTES:
1. Add 3.5 oz. Lubrizol® (027912) when hydraulic oil is changed (see
Owner’s Manual).
2. Hydraulic system capacity is 5 US quarts. Fill reservoir to within 1" of top
of Item 3 (032771 Strainer)
106567 7/06 3-3
Page 16
Note:
HYDRAULIC SYSTEM CHARGING PROCEDURE
1. Set handles in the neutral position.
2. Start engine at idle.
3. Let run for a minimum of 30 seconds.
4. Stroke handles to forward position.
5. If motors do not turn in 15 seconds return handles to neutral and
repeat step 3 and 4 (one time).
6. If motors do not turn after second attempt, shut off the engine
and check for oil at the pump.
7. Increase throttle to half speed and work handles through forward
and reverse position until the motor operates smoothly throughout the entire speed range.
Seal Kit for hydraulic pump; 727756 (BDP10 Overhaul Seal Kit)
3-4 106567 7/06
Page 17

Chapter 4 Contents

Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Steering and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Pump Belt and Pulley Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
106567 7/06 4-1
Page 18

Battery Installation

TRACTOR FRAME
1
2
1
4
3
5
1
9
8
11
6
5
7
8
9
10
11
12
4-2 106567 7/06
Page 19
Battery Installation
INDEX
NO.
1 024927 024927 2 NT .250-20 HX GR.5 ZN
2 771428 771428 1 RED BATTERY CABLE BOOT
3 796219 796219 1 36" NEGATIVE BATTERY CABLE
4 744276 744276 1 POSITIVE BATTERY CABLE
5 768523 768523 3 FW .343 X .687 X .051/.080 HD ZN/YL
6 058776 058776 2 NT .312-18 HX NL ZN
7 348417 348417 1 BATTERY CLAMP STRAP
8 055939 055939 2 CS .250-20 X .750 HX G5 ZN
9 029868 029868 4 LW .250 INT-EXT TOOTH ZN
10 740696 740696 1 BATTERY
11 034272 034272 2 NT .312-18 HX G5 ZN
12 779850 779850 2 CB .312-18 X 3.00 FUL ZN
SERVICE
PART NO.
MFG.
PART NO.
QTY DESCRIPTION
NOTES:
1. When performing service on mower, disconnect battery ground cable
and do not reconnect to battery until engine is ready to be started. See Owners Manual.
106567 7/06 4-3
Page 20

Deck Lift Assembly

1
2
4
5
TRACTOR FRAME
5
6
7
10
4
3
5
12
11
4
5
13
1
5
10
10
4
6
4
1
1
5
1
8
9
10
4
8
4
14
8
4
9
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9
Page 21
Deck Lift Assembly
ITEM
NO.
1 348318 348318 1 STOP HANDLE
2 600437 600437 1 DECK HEIGHT 1/2" PIN W/A
2
{
3 783001 783001 1 DECK LIFT INDICATOR SUBASSEMBLY
4 704643 704643 8 NT .437-14 HX FLG ZN
5 781294 781294 7 CLIP E, 1.00 X .625 X .050
6 782995 782995 2 DECK LIFT SPRING SUBASSEMBLY
7 781229 781229 1 CE .750 X 2.25 X 1.75 HEADLESS
8 055749 055749 3 CS .437-14 X 1.750 HX G5 ZN
9 348391 018846 4 DECK LIFT CHAIN
10 015495 015495 4 STRAIGHT GREASE FITTING
11 034272 034272 1 NT .312-18 HX G5 ZN
12 756270 756270 1 CS .312-18 X 1.50 FUL THR GR5 ZN
13 348458 348458 1 DECK LEVELER YOKE
14 781831 781831 1 CS .437-14 X 1.750 FUL THD G5 ZN
SERVICE
PART NO.
348284 N/A 1 HEIGHT ADJUSTMENT STOP 3/8"
MFG.
PART NO.
QTY DESCRIPTION
NOTES:
1. Apply grease to zerks (see owner’s manual).
2. Verify pin diameter prior to ordering replacement part. For mowers with 3/8" diameter pins, order 348284; for mowers with 1/2" pins, order
600437. Item 3 includes 600437 (1/2" pin).
106567 7/06 4-5
Page 22

Steering and Park Brake Assembly

1
10
2
3
4
8
6
7
5
3
3
5
9
3
14
3
6
7
3
11
15
16
11
12
17
18
13
4
20
21
7
30
38
19
7
6
21
22
23
7
25
24
3
26
27
3
10
36
35
28
40
31
1
39
30
29
3
28
36
7
33
3
34
29
37
6
7
30
3
15
41
TRACTOR FRAME
32
2
4-6 106567 7/06
Page 23
Steering and Park Brake Assembly
ITEM
NO.
1 781260 N/A 2 STEERING BAR GRIP 2 348755 348755 2 STEERING BAR 3 767954 767954 48 FW .406 X .812 X .060 SAE HD ZN 4 036244 036244 10 CS .375-16 X 1.000 HX G5 ZN 5 705178 705178 6 CS .375-16 X 1.750 HX G5 ZN 6 041152 041152 8 NT .312-24 HX ZN 7 768523 768523 18 FW .343X .687 X .051/.080 HD ZN/YL 8 348946 348946 2 STEERING ARM MOUNT 9 348888 348888 1 STEERLEVER SUPPORT LH
10 055822 055822 8 CS .375-16 X .750 HX G5 ZN 11 781716 781716 4 SS .500-13 X 1.75 SH ZN 12 053199 053199 2 NT .500-13 HX JAM ZN 13 348987 348987 1 STEERING CONTROL PANEL 14 348862 348862 4 STEERLEVER BUSHING 15 086660 086660 8 NT .375-16 HX LK NY 16 781583 781583 2 BRAKE ROD ASSEMBLY 17 063198 063198 4 CS 10-24 X .750 HXFLK ZN 18 781211 781211 2 PUSH BUTTON SWITCH 19 781286 781286 2 PUMP ROD ADJUSTER ASSEMBLY 20 600221 600221 2 CENTERING DAMPER
6
21 781922 781922 4 DAMPER BALL STUD 22 704163 704163 2 CS .250-20 X 2.00 HX G5 ZN 23 768515 768515 4 FW .281 X .625 X .051/.080 HD ZN/YL 24 068551 068551 2 NT .250-20 HX NL ZN 25 367557 367557 2 PUMP ARM 26 348797 348797 2 ADJUSTABLE PIVOT 27 781153 781153 4 BUSHING 28 005116 005116 4 CS .375-16 X 1.375 HX G5 ZN 29 054502 054502 4 NT .375-16 HX GRD 5 ZN 30 034272 034272 8 NT .312-18 HX G5 ZN 31 781765 781765 2 BRAKE DRUM-HUB ASSEMBLY 32 781112 781112 1 BRAKE ASSEMBLY
3 4
33 036236 036236 4 CS .312-18 X 1.000 HX G5 ZN 34 350272 350272 2 BRAKE ARM EXTENSION 35 350330 350330 1 L.S. BRAKE PIVOT ARM
36 765339 765339 4 BUSHING 37 059832 059832 4 NT #10-24 HX NL ZN 38 782979 782979 2 CS .375-16 X 4.75 HX G5 ZN 39 065516 N/A 2 ROSS CASTLE NUT 40 350397 350397 2 BRAKE LINK TURNBUCKLE 41 064337 N/A 2 ROSS KEY
SERVICE
PART NO.
348714 348714 1 STEERLEVER SUPPORT RH
783696 783696 2 CENTERING DAMPER
781351 781351 1 BRAKE ASSEMBLY
350264 350264 1 R.S. BRAKE PIVOT ARM
MFG.
PART NO.
QTY DESCRIPTION
106567 7/06 4-7
Page 24
NOTES:
1. Torque to 350-375 ft.-lbs. Included with wheel motor.
2. Torque brake assembly mounting bolts to 100 ft.-lbs.
3. 781112 used on left wheel.
4. 781351 used on right wheel.
5. Includes Item 1 (781260 Steering Bar Grip).
6. Use 783696 on mowers with serial numbers prior to 06071499.
4-8 106567 7/06
Page 25
This page intentionally left blank.
106567 7/06 4-9
Page 26

Pump Belt and Pulleys Installation

TRACTOR FRAME
3
24
25
26
2
2
6
8
7
10
23
9
13
10
9
1
5
2
4
1
5
6
12
8
10
11
7
2
6
14
10
18
19
16
3
15
17
20
21
22
4-10 106567 7/06
Page 27
Pump Belt and Pulleys Installation
INDEX
NO.
1 779876 779876 1 ENGINE SC SINGLE PULLEY
2 212076 212076 1 KEY 1/4 SQ X 1.50 LONG
3 787366 787366 1 WARNER CLUTCH
4 783829 783829 1 FW .460 X 1.750 X .250 ZNYC
5 785659 785659 1 CS .437-20 X 2.50 HX G5 ZNYC
6 083196 083196 4 SS .312-18 X .750 SQ-HD ZN
7 768127 768127 2 KEY 5MM X 30MM RADIUS ENDS
8 325308 325308 2 PULLEY & FAN
9 008193 008193 2 NT .500-13 HX G5 ZNYC
10 767962 767962 4 FW .531 X 1.063 X .090 SAE HD ZN
11 016527 016527 2 CS .500-13 X 1.00 HX G5 ZNYC
12 366765 366765 1 CLUTCH ANCHOR ANGLE
13 784918 784918 2 RUBBER BUMPER
14 349761 349761 1 PUMP IDLER ARM
15 015495 015495 1 STRAIGHT GREASE FITTING
16 025296 025296 1 FW .760 X 1.625 X .08 ZN
17 061101 061101 1 NT .750-10 HX NL ZN
18 781856 781856 1 IDLER PULLEY
19 028118 028118 1 FW .62 X 1.00 X.134 ZN
20 794446 794446 1 CS .625-11 X 1.50 HX G5 ZN
21 781302 781302 1 IDLER SPRING
22 781443 781443 1 A-SEC PUMP IDLER BELT
23 791251 791251 1 HARNESS, CLUTCH PIGTAIL(DIODE)
24 036236 036236 1 CS .312-18X1.000 HX G5 ZNYC
25 768523 768523 1 FW .343 X .687 X .051/.080 HD ZNYC
26 034272 034272 1 NT .312-18 HX G5 ZNYC
SERVICE
PART NO.
MFG.
PART NO.
QTY DESCRIPTION
NOTES:
1. Torque to 45-48 ft-lbs.
2. Torque to 12-15 ft-lbs.
3. Apply grease at zerk (see owner’s manual).
4. Included with Honda 24 HP engine (785014).
5. Electric clutch burnishing procedure: After installing a new clutch it is
important to burnish the clutch to insure maximum deck clutch life. In an open area with no bystanders set the engine speed to half throttle. Cycle the deck clutch on for 15 seconds, and then off for 15 seconds. Repeat this operation 10 times, it will require about 5 minutes to complete.
106567 7/06 4-11
Page 28
4-12 106567 7/06
Page 29

Chapter 5 Contents

Kawasaki Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Honda Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Kohler Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Fuel System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Instrument Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Electrical Schematic (799320) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
106567 7/06 5-1
Page 30

Kawasaki Engine Installation

Y
TO ENGINE SENSOR
2
ELLOW
5
6
7
TO SPADE
2
TERMINAL
TO BULLET
2
TERMINALS
2
RED/BLK
7
10
6
11
PAR T OF ENGINE
7
6
17
16
19
20
3
22
3
23
1
18
21
9
STARTER SELENOID GROUND
2
3
NEGATIVE BATTERY CABLE
8
4
17
3
20
24
17
2
3
12
13
6
POSITIVE BATTERY CABLE
32
14
31
PURPLE
3
15
TRACTOR FRAME
2
38
37
23
25
26
3
27
3
15
28
29
3
30
PART OF COMMON WIRE HARNESS
9
33
34
36
39
35
1
5-2 106567 7/06
Page 31
Kawasaki Engine Installation
ITEM
NO.
1 777656 777656 1 KAWASAKI 23 HP ENGINE
5 6
2 058776 058776 4 NT .312-18 HXZY NL
3 768523 768523 22 FW .343 X .687 X .051/.080 HD ZN/YL
4 029876 029876 1 LW .312 INT-EXT TOOTH ZN
5 792762 792762 1 BATTERY CABLE
6 768515 768515 5 FW .281 X .625 X .051/.080 HD ZN/YL
7 024927 024927 3 NT .250-20 HX GR.5 ZN
8 799312 799312 1 WIRE HARNESS ADAPTER
9 799320 799320 1 COMMON WIRE HARNESS
10 044255 044255 1 NT #10-32 HX ZN
11 030817 030817 1 STARTER SOLENOID
12 055947 055947 2 CS .250-20 X .500 HX G5 ZN
13 792192 792192 1 STARTER RELAY GROUND WIRE
14 771428 771428 1 RED BATTERY CABLE BOOT
15 050161 050161 4 CS .312-18 X 1.75 HX G5
16 786673 786673 1 DONALDSON AIR CLEANER CAP
7
17 057661 057661 3 HOSE CLAMP
18 788943 788943 1 AIR FILTER INDICATOR
19 785741 785741 1 MOUNTING BAND
20 034272 034272 6 NT .312-18 HX G5 ZN
21 782763 782763 1 AIR CLEANER
22 366443 366443 1 REMOTE AIR CLEAN MOUNT BRACKET
23 036236 036236 6 CS .312-18 X 1.00 HX G5 ZNYC
24 786038 786038 1 REMOTE AIR FILTER HOSE
25 796524 796524 1 OIL DRAIN M20 X 2.5 VALVE
26 350371 350371 1 MUFFLER GUARD
27 349704 349704 1 ENGINE CAGE MOUNT PLATE
28 767962 767962 6 FW .531 X 1.063 X .090 SAE HD ZN
29 016527 016527 6 CS .500-13 X 1.00 HX G5 ZN
30 064006 064006 2 CS .312-18 X .625 HX G5 ZN
31 781732 781732 1 MUFFLER MANIFOLD
32 781724 781724 1 MUFFLER
33 720177 720177 2 CS M 8-1.25 X 20 10.9 HXFL ZN
34 782649 782649 1 KAW (23) EXHAUST PIPE CLAMP
35 782664 782664 4 NT M8-1.25 HX STAINLESS STEEL
36 017004 017004 4 LW .312 MED SPRING ZN
37 360693 360693 1 HEAT SHIELD
38 780841 780841 2 KAW (23) MUFFLER GASKET
39 789131 789131 1 HUSTLER Z FAN CONNECTOR CAP
SERVICE
PART NO.
782318 782318 1 KAWASAKI 25 HP ENGINE (FH721V, 3600 RMP)
MFG.
PART NO.
QTY DESCRIPTION
106567 7/06 5-3
Page 32
NOTES:
1. Includes mounting hardware.
2. Part of Item 8 (799312 Wire Harness Adapter).
3. Engine oil capacity; 2 US quarts.
4. Engine RPM to be set at 3600± 50.
5. 23 HP engine used in 927723 and 927731 only.
6. 25 HP engine used in 927772 and 927798 only.
7. Includes one (1) of Item 17 (057661 Hose Clamp).
8. When installing lower hose clamp on air cleaner hose, install as low as possible (against carburetor inlet).
9. This connector used for optional hydraulic oil cooler fan.
10. Air filter service parts:
785261 MAIN AIR FILTER ELEMENT
763318 VACUATOR VALVE
5-4 106567 7/06
Page 33
This page intentionally left blank.
106567 7/06 5-5
Page 34

Honda Engine Installation

2
YEL
2
BLK
2
3
4
5
NEGATIVE BATTERY CABLE
2
RED/BLK
3
9
PART OF COMMON WIRE HARNESS
PAR T OF ENGINE
10
1
7
8
10
12
3
ORG
3
BRN
GRA/PUR
7
6
PUR
3
POSITIVE BATTERY CABLE
3
14
11
11
13
3
15
3
16
13
3
26
27
25
17
11
2
28
29
31
36
TRACTOR FRAME
30
1
32
33
3
18
19
20
3
16
22
3
8
21
24
23
9
3
16
35
8
7
8
34
5-6 106567 7/06
Page 35
Honda Engine Installation
ITEM
NO.
1 785014 785014 1 HONDA 24HP ENGINE
6
2 058776 058776 4 NT .312-18 HXZY NL
3 768523 768523 23 FW .343 X .687 X .051/.080 HD ZN/YL
4 799320 799320 1 COMMON WIRE HARNESS
5 029876 029876 1 LW .312 INT-EXT TOOTH ZN
6 077545 N/A 1 NT M8-1.25 X 10 HX ZNYC
7 017004 N/A 5 LW .312 MED SPRING ZN
8 799304 799304 1 WIRE HARNESS ADAPTER
9 050161 050161 4 CS .312-18 X 1.75 HX G5
10 775353 775353 1 DONALDSON AIR CLEANER CAP
11 057661 057661 3 HOSE CLAMP
12 785741 785741 1 MOUNTING BAND
13 034272 034272 6 NT .312-18 HX G5 ZN
14 782763 782763 1 AIR CLEANER
15 366443 366443 1 REMOTE AIR CLEANER MOUNT BRACKET
16 036236 036236 9 CS .312-18 X 1. HX G5 ZNYC
17 785675 785675 1 REMOTE AIR FILTER HOSE
18 787689 787689 1 HONDA OIL DRAIN VALVE
19 787713 787713 1 0.50" LOW PRESSURE HOSE, 3.00" LONG
20 382168 382168 1 MUFFLER GUARD
21 377994 377994 1 MMZ ROLLER HEAT SHIELD
22 365742 365742 1 ENGINE CAGE MOUNT PLATE
23 767962 767962 6 FW .531 X 1.063 X .090 SAE HD ZN
24 016527 016527 6 CS .500-13 X 1.00 HX G5 ZNYC
25 017038 017038 2 LW .250 MED SPRING ZNYC
26 024927 024927 2 NT .250-20 HX GR.5 ZNYC
27 785477 N/A 1 HONDA 20 AMP RECTIFIER
28 768515 768515 2 FW .281 X .625 X .051/.080HD ZNYC
29 056077 056077 2 CS .250-20 X 1.00 HX G5 ZNYC
30 784843 784843 1 MUFFLER
31 720177 720177 2 CS M 8-1.25 X 20 10.9 HXFL ZN
32 785378 785378 1 1.50" MUFFLER CLAMP
33 785543 N/A 2 HONDA (20) MUFFLER GASKET
34 782664 N/A 4 NT M8-1.25 HX STAINLESS STEEL
35 784959 784959 1 MUFFLER MANIFOLD
36 789131 789131 1 HUSTLER Z FAN CONNECTION CAP
SERVICE
PART NO.
MFG.
PART NO.
QTY DESCRIPTION
NOTES:
1. Includes mounting hardware.
2. Part of Item 4 (799320 Tractor Common Wire Harness).
3. Part of 8 (799304 Wire Harness Adapter).
4. Engine oil capacity; 2 US quarts.
5. Engine RPM to be set at 3600± 50.
6. Used on 927756 only.
106567 7/06 5-7
Page 36
7. Includes one (1) of Item 14 (057661 Hose Clamp).
8. Supplied with engine.
9. When installing lower hose clamp on air cleaner hose, install as low as possible (against carburetor inlet).
10. This connector used for optional hydraulic oil cooler fan.
11. Air filter service parts:
785261 MAIN AIR FILTER ELEMENT
763318 VACUATOR VALVE
5-8 106567 7/06
Page 37
This page intentionally left blank.
106567 7/06 5-9
Page 38

Kohler Engine Installation

1
POSITIVE BATTERY CABLE
6
TRACTOR FRAME
2
3
5
PUR (P/O ENGINE)
RED/BLK
4
6
4
BLK
NEGATIVE BATTERY CABLE
2
7
8
2
9
10
4
14
8
4
12
15
8
11
12
4
13
3
4
16
17
25
24
1
23
27
28
24
26
4
4
14
6
6
20
PART OF COMMON WIRE HARNESS
29
21
2
22
18
19
4
14
5-10 106567 7/06
Page 39
Kohler Engine Installation
ITEM
NO.
1 788216 788216 1 KOHLER 27HP ENGINE
5
2 799320 799320 1 COMMON WIRE HARNESS
3 058776 058776 4 NT .312-18 HXZY NL
4 768523 768523 29 FW .343 X .687 X .051/.080 HD ZN/YL
5 029876 029876 1 LW .312 INT-EXT TOOTH ZN
6 050161 050161 4 CS .312-18 X 1.75 HX G5
7 786673 786673 1 DONALDSON AIR CLEANER CAP
8 057661 057661 3 HOSE CLAMP
9 788943 788943 AIR FILTER INDICATOR
10 782763 782763 1 AIR CLEANER
11 785741 785741 1 MOUNTING BAND
12 034272 034272 6 NT .312-18 HX G5 ZN
13 366443 366443 1 REMOTE AIR CLEANER MOUNT BRACKET
14 036236 036236 9 CS .312-18 X 1.00 HX G5 ZNYC
15 795310 795310 1 REMOTE AIR FILTER HOSE (STRAIGHT)
16 796672 796672 1 3/8-18 OIL DRAIN VALVE
17 787713 787713 1 0.50" LOW PRESSURE HOSE
18 382168 382168 1 MUFFLER GUARD
19 365742 365742 1 ENGINE CAGE MOUNT PLATE
20 377994 377994 1 MMZ ROLLER HEAT SHIELD
21 016527 016527 6 CS .500-13 X 1.00 HX G5 ZNYC
22 767962 767962 6 FW .531 X 1.063 X .090 SAE HD ZN
23 029751 029751 2 CS .375-16 X 1.00 HXFLK ZNYC
24 705137 705137 4 FW .391 X 1.250 X .060 ZNYC
25 788018 788018 1 MUFFLER
26 788026 788026 1 MUFFLER MANIFOLD
27 785378 785378 1 1.50" MUFFLER CLAMP
28 016899 016899 2 NT .375-16 HXFLK ZNYC
29 789131 789131 1 HUSTLER Z FAN CONNECTION CAP
SERVICE
PART NO.
MFG.
PAR T NO.
QTY DESCRIPTION
NOTES:
1. Includes mounting hardware.
2. Part of Item 2 (799320 Common Wire Harness).
3. Engine oil capacity; 2 US quarts.
4. Engine RPM to be set at 3600± 50.
5. Used on 927806, and 927814 only.
6. Supplied with engine.
7. Air filter service parts:
785261 MAIN AIR FILTER ELEMENT
763318 VACUATOR VALVE
106567 7/06 5-11
Page 40

Fuel System Installation

1
6
1
2
5
4
1
7
3
10
4
4
17
15
8
9
8
14
6
9
13
7
1
11
12
11
1
6
9
4
13
14
7
1
6
5-12 106567 7/06
Page 41
Fuel System Installation
ITEM
NO.
1 779306 779306 2 3.5" FUEL CAP
2 793240 793240 1 LEFT SIDE FUEL TANK
3 793232 793232 1 RIGHT SIDE FUEL TANK
4 000323 000323 6 CLIP
5 106732 N/A 1 REAR SEAT SUPPORT
6 055822 055822 12 CS .375-16 X .750 HX G5 ZN
7 712919 712919 11 FW .406 X 1.00 X .12 HRD ZN
8 036244 036244 2 CS .375-16 X 1.000 HX G5 ZN
9 767954 767954 3 FW .406 X .812 X .060 SAE HD ZN
10 045088 045088 1 HOSE CLAMP 1"
11 797084 797084 1 3-WAY NYLON FUEL VALVE
12 347989 347989 1 FUEL SHUT-OFF BRACKET
13 016527 016527 8 CS .500-13 X 1.00 HX G5 ZN
14 767962 767962 8 FW .531 X 1.063 X .090 SAE HD ZN
15 015818 015818 1 FUEL LINE 45.5"
16 015818 015818 1 FUEL LINE 26.5"
17 015818 015818 1 FUEL LINE 22.5"KAWASAKI
SERVICE
PART NO.
015818 015818 1 FUEL LINE 36”"HONDA
015818 015818 1 FUEL LINE 38"KOHLER
000331 000331 3 BLACK CABLE TIE (NOT SHOWN)
MFG.
PART NO.
QTY DESCRIPTION
1. Torque to 20 ft.-lbs.
2. Supplied with new fuel tank.
3. Fuel tank service part not shown:
PN DESCRIPTION
799197 SZ HOSE ASSY, SUCTION
NOTES:
106567 7/06 5-13
Page 42

Instrument Panel Assembly

1
2
3
4
5
6
3
4
11
8
7
10
1
7
9
12
13
14
FUSE SIZE AND LOCATION
10a
15a
15a
RIGHT SIDE FUEL TANK
13
12
5-14 106567 7/06
Page 43
Instrument Panel Assembly
ITEM
NO.
1 776476 776476 1 PTO SWITCH
2 083022 N/A 2 IGNITION KEY
2 785808 785808 1 INDAK COATED KEY
3 045898 045898 1 KEY SWITCH
4 785030 785030 1 Z CHOKE CABLE (KAWASAKI)
5 712257 712257 1 RED INDICATOR LIGHT
6 000430 000430 2 TIE STRAP
7 704932 704932 4 FW .219 X .500 X .048 ZN
8 714998 714998 2 MS #10-24 X .625 HX ZN
9 059832 059832 2 NT #10-24 HX NL ZN
10 769166 769166 1 HOUR METER
11 778365 778365 1 THROTTLE/CHOKE CABLE
12 055947 055947 3 CS .250-20 X .500 HX G5 ZN
13 768515 768515 3 FW .281 X .625 X .051 /.080 HD ZN/YL
14 106633 106633 1 INSTRUMENT PANEL
SERVICE
PART NO.
786657 786657 1 Z CHOKE CABLE (HONDA & KOHLER)
026237 N/A 6 RELAY (NOT SHOWN)
762195 N/A 1 DELAY MODULE (NOT SHOWN)
MFG.
PART NO.
QTY DESCRIPTION
NOTES:
1. Part of 799320 (Common Wire Harness)
106567 7/06 5-15
Page 44

Electrical Schematic (799320)

13
5-16 106567 7/06
Page 45

Chapter 6 Contents

Front Wheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Front Wheel Breakdown—747782. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Option Semi-Pneumatic Tire/Wheel Breakdown—789537 . . . . . . . . 6-5
Drive Wheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Anti-Rollover Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
106567 7/06 6-1
Page 46

Front Wheel Assembly

1
2
3
3
4
5
3
4
6
7
8
9
TRACTOR FRAME
1
2
3
3
4
9
2
10
5
3
4
11
6
7
9
9
1
11
1
8
6-2 106567 7/06
Page 47
Front Wheel Assembly
INDEX
NO.
1 705954 705954 2 CS .500-13 X 1.25 HX G5 ZN
2 344267 344267 2 FW .510 X 2.15 X .187 SPL ZN
3 712976 712976 2 FW .531X 1.375X.125 ZNY
4 784223 784223 4 BEARING W/O COLLAR
5 387035 387035 2 SPACER, 1.07 X 1.312 X 2.793
6 045765 045765 2 FW 1.030 X 1.500 X.134 ZN
7 349266 349266 2 FORK
8 041475 041475 2 CS .750-10 X 9.50 HX ZN
9 025296 025296 4 FW .760 X 1.625 X .08 ZN
10 061101 061101 2 NT .750-10 HX NL ZN
11 747782 747782 2 WHEEL & TIRE ASSY
SERVICE
PART NO.
789537 N/A 2 OPTIONAL SEMI-PNEUMATIC WHEEL/TIRE ASSEMBLY
MFG.
PART NO.
QTY DESCRIPTION
NOTES:
1. Apply grease to zerks.
2. Torque to 100 ft.-lbs.
3. Assemble with extended inner race toward item 5 (387035 Spacer, 1.07
x 1.312 x 2.793).
106567 7/06 6-3
Page 48
Front Wheel Breakdown—747782
1
1
2
3
4
1
ITEM
NO.
1 039677 N/A 2 WHEEL BEARING
2 747741 N/A 1 13 X 6.50 TIRE
3 747832 N/A 1 6 X 4.5 WHEEL
4 782771 N/A 1 BEARING SPACER
5 019521 N/A 1 TIRE VALVE
6 015511 N/A 1 GREASE FITTING 45 DEG 1/4
SERVICE
PART NO.
1. Inflate tire to 8-10 psi.
MFG.
PART NO.
6
5
QTY DESCRIPTION
NOTES:
6-4 106567 7/06
Page 49
Optional Semi-Pneumatic Tire/Wheel—789537
1
2
3
4
1
ITEM
NO.
1 039677 N/A 2 WHEEL BEARING
2 789537 N/A 1 TIRE/WHEEL ASSEMBLY
3 015511 N/A 1 GREASE FITTING 45 DEG 1/4
4 782771 N/A 1 BEARING SPACER
SERVICE
PART NO.
MFG.
PART NO.
QTY DESCRIPTION
NOTES:
106567 7/06 6-5
Page 50

Drive Wheel Assembly Installation

1
6
1
5
INDEX
NO.
1 784058 784058 2 WHEEL & TIRE ASSY FOR 66" (QTY PER TRACTOR)
2 781245 N/A TIRE, 12 X 12 X 24 FOR 66"
3 784066 N/A WHEEL ASSEMBLY 12 X 8.50 FOR 66"
4 019521 N/A TIRE VALVE
5 061077 061077 10 WHEEL NUT (QTY PER TRACTOR)
1 781237 781237 2 WHEEL & TIRE ASSY FOR 60" & 54" (QTY PER TRACTOR)
2 781245 N/A TIRE, 12 X 12 X 24 FOR 60" & 54"
3 781252 N/A 2 WHEEL ASSEMBLY 12 X 8.50 FOR 60" & 54"
4 019521 N/A 2 TIRE VALVE
5 061077 061077 10 WHEEL NUT (QTY PER TRACTOR)
4
SERVICE
PART NO.
1. Torque to 65-75 ft. lbs.
2. Inflate tire to 8-10 psi.
2
2
3
PART NO. QTY DESCRIPTION
NOTES:
6-6 106567 7/06
Page 51

Anti-Rollover Wheel Assembly

TRACTOR FRAME
1
1
3
3
1
4
3
2
3
INDEX
NO.
1 068239 068239 2 CS .500-13 X 4.500 HX G5 ZN
2 031997 031997 2 ANTI-SCALP WHEEL
3 767962 767962 4 FW .531 X 1.063 X .090 SAE HD ZN
4 781567 781567 2 NT .50-13 HX LK NY
SERVICE
PART NO.
MFG.
PART NO.
QTY DESCRIPTION
NOTES:
1. Do not torque, wheel must turn freely.
2
106567 7/06 6-7
Page 52
6-8 106567 7/06
Page 53

Chapter 7 Contents

66" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
66" Deck Pulley Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
60" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
60" Deck Pulley Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
54" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
54" Deck Pulley Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
SpindleAssembly - 796235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
106567 7/06 7-1
Page 54

66" Deck Assembly

2
11
6
5
9
7
8
10
12
11
1
12
9
11
4
9
14
4
12
13
15
11
10
8
14
9
7
5
4
4
1
3
7
9
8
10
7
8
11
12
9
16
10
8
16
4
7
17
4
7
7
5
16
10
8
7
18
}
20
Optional Anti-Scalp Wheels
19
7-2 106567 7/06
Page 55
66" Deck Assembly
INDEX
NO.
1 547737 103929 1 66" DECK CRATED
3
2 798694 798694 1 RUBBER CHUTE ASSEMBLY
3 052860 052860 2 CS .375-19 X 1.250 HX G5 ZN
4 767954 767954 22 FW .406 X .812 .060 SAE HD ZN
5 086660 086660 8 NT .375-16 HX LK NY
6 103010 103010 1 DISCHARGE CHUTE MOUNT BRACKET
7 781708 N/A 6 CS .500-13 X 4.25 HX G5 ZN
8 767962 N/A 12 FW .531 X 1.063 X .090 SAE HD ZN
9 031997 N/A 6 ANTI-SCALP WHEEL
10 053199 N/A 6 NT .500-13 HX JAM ZN
11 781567 781567 6 NT .50-13 HX LK NY
12 808485 808485 4 5/16-18 THREAD RIVET NUT
13 314104 314104 1 PUSHER
14 015495 015495 2 STRAIGHT GREASE FITTING
15 052860 052860 6 CS .375-16 X 1.25 HX G5
16 025395 025395 6 CB .375-16 X 1.00 STD CD
17 103713 103713 2 66, AIR FLOW FLOOR
18 N/A 808493 2 RIVET NUT, 3/8-16 THREAD
2
SERVICE
PAR T NO.
788166 788166 4 ANTI SCALP WHEEL ASSY
MFG.
PART NO.
QTY DESCRIPTION
NOTES:
1. Do not torque, Item 2 (349324 Discharge Chute) must pivot freely.
2. Includes 6 each of items 7 through 10.
3. Service part deck includes decals (see ’’66" Deck Decals” in Chapter 9
on page 9-4 for listing of decals).
4. For optional anti-scalp wheels order:
INDEX NO.
19 788166 788166 2 ANTI-SCALP WHEEL ASSEMBLY
2
20 781567 781567 2 NT .500-13 H8ZY NL
SERVICE
PAR T NO.
MFG.
PART NO.
QTY. DESCRIPTION
106567 7/06 7-3
Page 56

66" Deck Pulley Assembly

4
9
13
16
10
1
2
4
3
4
5
4
7
8
11
12
14
18
16
6
15
4
17
19
17
BELT GUIDE INDEXING
17
30
30
25
20
22
17
26
27
2
21
23
24
28
1
29
7-4 106567 7/06
Page 57
66" Deck Pulley Assembly
ITEM
NO.
1 797936 797936 1 B-SECTION BELT
2 025007 025007 1 CS .625-11 X 1.75 HX G5 ZNYC
3 347443 347443 1 DECK BELT IDLER GUIDE
4 028118 028118 5 FW .62 X 1.00X.134 ZN
5 781856 781856 1 5.00" IDLER PULLEY
6 797910 797910 6 CS .312-18 X 1.50 FLT SH ZNYC
7 600189 600189 1 RS UHMW IDLER SLIDE
8 600171 600171 1 LS UHMW IDLER SLIDE
9 373191 059961 1 SIDE MOUNT CHAIN (21 LINKS)
10 781302 781302 1 IDLER SPRING
11 350884 350884 1 DECK IDLER
12 786335 786335 1 .03 THICK UHMW
13 103721 103721 1 RS 66" XR7 PULLEY COVER
14 103739 103739 1 LS 66" XR7 PULLEY COVER
15 016972 016972 2 NT .625-11 HX G5 ZNYC
16 781385 781385 2 6.00" IDLER PULLEY,
17 792002 792002 4 5/16-18 X 3/4"MALE KNOB
18 016527 016527 3 CS .500-13 X 1.00 HX G5 ZN
19 078386 078386 3 FW .510 X 1.750 X .18 ZN
20 798975 798975 3 B-SEC 6.32 EOD PULLEY
21 705954 705954 12 CS .500-13 X 1.25 HX G5 ZNYC
22 767962 767962 12 FW .531 X 1.063 X .090 SAE HD ZN
23 768523 768523 6 FW .343 X .687 X .051/.080 HD ZN
24 058776 058776 6 NT .312-18 HXZY NL
25 212472 212472 3 KEY 1/4 SQ X 1.00 LONG
26 796235 796235 3 SPINDLE HOUSING ASSEMBLY
27 798496 798496 3 BLADE, F22.50"-H-F-CW
28 782474 782474 5 CW .631 2.250 X .187 PNT
29 029934 029934 3 CS .625-11 X 3.00 HX G5 ZNYC
30 783738 783738 2 CS .625-11 X 3.00 FULL HX G5 ZN
SERVICE
PAR T NO.
798512 N/A 3 OPTIONAL BLADE, F24.50"-H-F-CW
MFG.
PART NO.
QTY DESCRIPTION
NOTES:
1. Torque to 118 ft. lbs.
2. Torque to 67-75 ft. lbs.
3. Apply grease to zerk (see owner’s manual).
4. See ’’Deck Belt Routing and Tensioning” in Chapter 8 on page 8-4 for
belt tensioning.
5. See ’’Spindle Assembly–796235” in Chapter 7 on page 7-14 for
breakdown.
106567 7/06 7-5
Page 58

60" Deck Assembly

2
4
5
5
4
1
3
8
4
6
16
15
7
9
10
12
7
8
14
9
10
11
7
9
18
8
10
4
11
9
12
13
8
18
11
4
11
6
5
14
1
5
14
8
4
11
7
10
9
7
17
4
4
11
4
14
12
13
16
4
12
10
8
9
7
4
4
5
20
19
22
}
21
Optional Anti-Scalp
4
5
7-6 106567 7/06
Wheels
Page 59
60" Deck Assembly
INDEX NO.
1 547745 314021 1 60" DECK CRATED
3
2 798694 798694 1 RUBBER CHUTE ASSEMBLY
3 052860 052860 2 CS .375-16 X 1.25 HX G5
4 767954 767954 30 FW .406 X .812 X .060 SAE HD ZN
5 086660 086660 18 NT .375-16 HX LK NY
6 103010 103010 1 DISCHARGE CHUTE MOUNT BRACKET
7 781708 N/A 6 CS .500-13 X 4.25 HX G5 ZN
8 767962 N/A 12 FW .531 X 1.063 X .090 SAE HD ZN
9 031997 N/A 6 ANTI-SCALP WHEEL
10 053199 N/A 6 NT .500-13 HX JAM ZN
11 781567 781567 6 NT .50-13 HX LK NY
12 005116 005116 4 CS .375-16 X 1.375 HX G5 ZNYC
13 103184 103184 2 REAR ANTI-SCALP BRACKET
14 N/A 808485 4 5/16-18 THREAD RIVET NUT
15 314104 314104 1 PUSHER
16 015495 015495 2 STRAIGHT GREASE FITTING
17 036244 036244 6 CS .375-16 X 1.00 HX G5 ZNYC
18 025395 025395 6 CB .375-16 X 1.00 STD CD
19 102764 102764 2 60" AIR FLOW FLOOR
20 N/A 808493 2 RIVET NUT, 3/8-16 THREAD
2
SERVICE
PAR T NO.
788166 788166 4 ANTI SCALP WHEEL ASSY
MFG.
PART NO.
QTY. DESCRIPTION
NOTES:
1. Do not torque, Item 2 (349324 Discharge Chute) must pivot freely.
2. Includes items 7 though 10.
3. Service part deck includes decals (see ’’60" Deck Decals” in Chapter 9
on page 9-5 for listing of decals).
4. For optional anti-scalp wheels order:
INDEX NO.
21 788166 788166 2 ANTI-SCALP WHEEL ASSEMBLY
2
22 781567 781567 2 NT .500-13 H8ZY NL
SERVICE
PAR T NO.
MFG.
PART NO.
QTY. DESCRIPTION
106567 7/06 7-7
Page 60

60" Deck Pulley Assembly

4
9
10
1
2
3
6
4
5
4
17
60" DECK
13
16
28
17
17
15 4
15
4
11
23 24
16
21
12
18
7
8
2
19
20
22
17
25
26
14
BELT GUIDE INDEXING
27
28
30
1
29
7-8 106567 7/06
Page 61
60" Deck Pulley Assembly
ITEM
NO.
1 797720 797720 1 B-SECTION BELT
2 025007 025007 1 CS .625-11 X 1.75 HX G5 ZNYC
3 347443 347443 1 DECK BELT IDLER GUIDE
4 028118 028118 5 FW .62 X 1.00X.134 ZN
5 781856 781856 1 5.00" IDLER PULLEY
6 797910 797910 6 CS .312-18 X 1.50 FLT SH ZNYC
7 600189 600189 1 RS UHMW IDLER SLIDE
8 600171 600171 1 LS UHMW IDLER SLIDE
9 373191 059961 1 SIDE MOUNT CHAIN (21 LINKS)
10 781302 781302 1 IDLER SPRING
11 350884 350884 1 DECK IDLER
12 786335 786335 1 .03 THICK UHMW
13 103192 103192 1 RS 60" XR7 PULLEY COVER
14 103200 103200 1 LS 60" XR7 PULLEY COVER
15 016972 016972 3 NT .625-11 HX G5 ZNYC
16 781385 781385 3 6.00" IDLER PULLEY,
17 792002 792002 4 5/16-18 X 3/4"MALE KNOB
18 016527 016527 3 CS .500-13 X 1.00 HX G5 ZN
19 078386 078386 3 FW .510 X 1.750 X .18 ZN
20 770842 770842 3 DECK DRIVE PULLEY
21 705954 705954 12 CS .500-13 X 1.25 HX G5 ZNYC
22 767962 767962 12 FW .531 X 1.063 X .090 SAE HD ZN
23 768523 768523 6 FW .343 X .687 X .051/.080 HD ZN
24 058776 058776 6 NT .312-18 HXZY NL
25 212472 212472 3 KEY 1/4 SQ X 1.00 LONG
26 796235 796235 3 SPINDLE HOUSING ASSEMBLY
27 794685 794685 3 BLADE, F20.50" H-F-CW
28 782474 782474 6 CW .631 2.250 X .187 PNT
29 029934 029934 3 CS .625-11 X 3.00 HX G5 ZNYC
30 783738 783738 3 CS .625-11 X 3.00 FULL HX G5 ZN
SERVICE
PAR T NO.
794230 N/A 3 OPTIONAL BLADE, 20.50" GAT-F-CW
MFG.
PART NO.
QTY DESCRIPTION
NOTES:
1. Torque to 118 ft. lbs.
2. Torque to 65-75 ft. lbs.
3. Apply grease to zerk (see owner’s manual).
4. See ’’Deck Belt Routing and Tensioning” in Chapter 8 on page 8-4 for
belt tensioning.
5. See ’’Spindle Assembly–796235” in Chapter 7 on page 7-14 for
breakdown.
106567 7/06 7-9
Page 62

54" Deck Assembly

2
4
15
5
14
13
14
3
8
12
17
11
10
4
16
4
9
13
9
8
12
9
16
18
10
11
4
1
3
10
9
13
11
9
7
10
13
4
13
12
11
10
11
8
17
12
4
5
1
12
13
11
5
9
10
4
4
4
5
8
18
19
6
}
4
5
7-10 106567 7/06
Optional Anti-Scalp Wheels
21
20
Page 63
54" Deck Assembly
INDEX NO.
1 548008 103317 1 54" DECK CRATED
2 798694 798694 1 54" DISCHARGE CHUTE
3 052860 052860 8 CS .375-16 X 1.25 HX G5 ZN
4 767954 767954 30 FW .406 X .812 X .060 SAE HD ZN
5 086660 086660 18 NT .375-16 HX LK NY
6 N/A 808493 2 3/8-16 THREAD RIVET NUT
7 103010 103010 1 DISCHARGE CHUTE MOUNT BRACKET
8 N/A 808485 4 5/16-18 THREAD RIVET NUT
9 781708 N/A 6 CS .500-13 X 4.25 HX G5 ZN
10 767962 N/A 12 FW .531 X 1.063 X.090 SAE HD ZN
11 053199 N/A 6 NT .500-13 HX JAM ZN
12 781567 781567 6 NT .50-13 HX LK NY
13 031997 N/A 6 ANTI-SCALP WHEEL
14 015495 015495 2 STRAIGHT GREASE FITTING
15 314104 314104 1 PUSHER
16 005116 005116 4 CS .375-16X1.375 HX G5
17 103184 103184 2 REAR ANTI-SCALP BRACKET
18 025395 025395 6 CB .375-16X 1.00 STD CD
19 103572 103572 2 54" AIR FLOW BAFFLE
2
SERVICE
PAR T NO.
788166 788166 6 ANTI-SCALP WHEEL ASSEMBLY
MFG.
PART NO.
QTY. DESCRIPTION
NOTES:
1. Do not torque, Item 2 (798694 Discharge Chute) must pivot freely.
2. Includes items 9, 10, 11, and 13.
3. Secure Item 11 (053199 Jam Nut) to bolt with a drop of Loctite® (271
Red). Tighten Item 11 to shank of Item 9 (781708 Cs .500-13 X 4.25 Hx G5 Zn). Anti-scalp wheel must turn freely.
4. Assemble in top hole for shipping purposes.
5. Item 15 (314104 Pusher) installed as shown with zerks pointing upward,
apply grease to zerks.
6. Service part deck includes decals (see ’’66" Deck Decals” in Chapter 9
on page 9-4 for listing of decals) and item 2 (Discharge Chute).
7. For optional anti-scalp wheels order:
INDEX NO.
20 788166 788166 2 ANTI-SCALP WHEEL ASSEMBLY
2
21 781567 781567 2 NT .500-13 H8ZY NL
SERVICE
PAR T NO.
MFG.
PART NO.
QTY. DESCRIPTION
106567 7/06 7-11
Page 64

54" Deck Pulley Assembly

4
12
13
1
3
9
10
6
4
7
8
54" DECK ASSY
31
15
31
21
22
14
18
11
19
20
23
17
2
16
31
2
4
2
5
31
25
29
4
5
26
27
BELT GUIDE POSITIONING
28
25
28
7-12 106567 7/06
1
30
25
24
Page 65
54" Deck Pulley Assembly
INDEX
NO.
1 797928 797928 1 B-SECTION BELT
2 016972 016972 2 NT .625-11 HX G5 ZNYC
3 025007 025007 1 CS .625-11 X 1.50 HX G5 ZN
4 028118 028118 5 FW .62 X 1.00 X .134 ZN
5 781385 781385 2 6.00" IDLER PULLEY
6 797910 797910 6 CS .312-18X1.50FLT SH ZY
7 600189 600189 1 IDLER SLIDE UHMW RS
8 600171 600171 1 IDLER SLIDE UHMW LS
9 347443 347443 1 DECK BELT IDLER TOP GUIDE
10 781856 781856 1 5.00" IDLER PULLEY
11 350884 350884 1 DECK IDLER
12 373191 059931 1 SIDE MOUNT CHAIN 21 LINKS
13 781302 781302 1 IDLER SPRING
14 786335 786335 1 UHMW .03 THICK
15 103986 103986 1 RS 54" PULLEY COVER
16 103994 103994 1 LS 54" PULLEY COVER
17 016527 016527 3 CS .500-13 X 1.00 HX G5 ZN
18 078386 078386 3 FW .510 X 1.75 X .18 ZN
19 798967 798967 3 DECK DRIVE PULLEY
20 705954 705954 12 CS .500-13X1.25 HX G5 ZY
21 767962 767962 12 FW .531X 1.063X.090 SAE
22 212472 212472 3 KEY 1/4 SQ X 1.00 LONG
23 796235 796235 3 DECK SPINDLE ASSY
24 797696 797696 3 BLADE, F18.50"-H-F-CW
25 782474 782474 5 CW .631 X 2.250 X .187 PNT
26 768523 768523 6 FW .343X.687X.051/.080H
27 058776 058776 6 NT .312-18 HXZY NL
28 783738 783738 2 CS .625-11X3.00 FULL HX G5 ZN
29 769257 769257 1 FW .656X 1.250X.250 ZNY
30 029934 029934 3 CS .625-11 X 3.00 HX G5 ZNYC
31 792002 792002 4 5/16-18 X 3/4"MALE KNOB
SERVICE
PAR T NO.
797712 N/A 3 BLADE, 18.50"-GAT-F-CW
MFG.
PART NO.
QTY. DESCRIPTION
NOTES:
1. Torque to 118 ft. lbs.
2. Torque to 65-75 ft. lbs.
3. Apply grease to zerk.
4. See ’’Deck Belt Routing and Tensioning” in Chapter 8 on page 8-4 for
belt tensioning.
5. See ’’Spindle Assembly–796235” in Chapter 7 on page 7-14 for
breakdown.
106567 7/06 7-13
Page 66
Spindle Assembly–796235
4
5
1
1
2
3
2
1
6
INDEX
NO.
1 077123 N/A 2 BEARING W/O COLLAR
2 766204 N/A 1 BLADE SPINDLE BUSHING
3 034843 N/A 1 CAST SPINDLE HOUSING
4 012005 N/A 1 GREASE FITTING
5 072272 N/A 1 FW 1.06 X 2.00 X.134 SAE ZN
6 796227 N/A 1 SADDLELESS SPINDLE SHAFT
SERVICE
PAR T NO.
MFG.
PAR T NO.
QTY. DESCRIPTION
NOTES:
1. Install upper bearing with extended inner race up.
2. Install lower bearing with extended inner race down.
7-14 106567 7/06
Page 67

Chapter 8 Contents

Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Deck Belt Routing and Tensioning. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
106567 7/06 8-1
Page 68

Deck Installation

TRACTOR ASSEMBLY
1
4
3
2
5
DECK ASSEMBLY
5
8-2 106567 7/06
Page 69
Deck Installation
ITEM
NO.
1 055749 055749 4 CS .437-14 X 1.750 HX G5 ZN
2 061101 061101 2 NT .750-10 HX NL ZN
3 025296 025296 4 FW .760 X 1.625 X.08 ZN
4 051169 051169 2 CS .750-10 X 3.000 HX G5 ZN
5 704643 704643 8 NT .437-14 HX FLG ZN
SERVICE
PART NO.
MFG.
PART NO.
QTY DESCRIPTION
NOTES:
1. 66" Deck installation is shown, 54" and 60" Deck installations are similar.
106567 7/06 8-3
Page 70

Deck Belt Routing and Tensioning

1
DECK ASSEMBLY
8-4 106567 7/06
Page 71
NOTES:
1. Spring length after tensioning belt. Measure spring from outside of hook
to outside of hook.
2. Route belt as shown.
106567 7/06 8-5
Page 72

Seat Installation

15
17
8
5
14
3
4
5
16
1
4
3
1
2
1
8
9
6
7
10
13
4
5
5
11
12
8-6 106567 7/06
Page 73
Seat Installation
INDEX
NO.
1 793661 793661 1 MICHIGAN SEAT
2 350041 350041 1 SEAT PAN
3 000331 000331 3 BLACK CABLE TIE
4 086660 086660 3 NT .375-16 HX LK NY
5 767954 767954 7 FW .406 X .812 X .060 SAE HD ZN
6 724716 724716 1 FIBER WASHER
7 350421 350421 1 SEAT PAN STOP
8 036244 036244 3 CS .375-16 X 1.000 HX G5 ZN
9 052860 052860 2 CS .375-16 X1.250 HX G5 ZN
10 768523 768523 4 FW .343 X .687 X .051/.080 HD ZN/Y
11 034272 034272 4 NT .312-18 HX G5 ZN
12 781880 781880 2 BUMPER
13 080358 080358 1 GM .50 X 1.00 X .75 X .12 GROMMET
14 748756 748756 1 LATCH SPRING PLUNGER
15 350462 350462 1 SEAT LATCH BRACKET
16 781617 781617 3 RUBBER BUMPER
17 722199 722199 1 2" WIDE SCOTCH POLYURETHANE 5.55" LONG
SERVICES
PART NO.
MFG.
PART NO.
QTY DESCRIPTION
NOTES:
1. Must pivot freely.
2. Service parts available for Michigan Standard seat;
PART NO.
793695 SLIDE KIT
797464 L.H. ARMREST ASSMBLY
797472 R.H. ARMREST ASSMBLY
793315 SEAT SWITCH
797480 MOLDED ARMREST KIT (INCLUDES BOTH ARMRESTS)
793273 ARMREST STOP ASSY
DESCRIPTION
106567 7/06 8-7
Page 74
8-8 106567 7/06
Page 75

Chapter 9 Contents

Tractor Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
66" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
60" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
54" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
106567 7/06 9-1
Page 76

Tractor Decals

A
4
2
1
A
3
5
17
6
8
TOP OF SEAT PAN
9
10
BOTTOM OF SEAT PAN
11
12
7
9-2 106567 7/06
13
14
15
Page 77
Tractor Decals
16
INDEX
NO.
1 781427 781427 1 DECK HEIGHT INDICATOR DECAL
2 779280 779280 1 HOT & HYDRAULIC OIL DECAL
3 784702 784702 1 INSTRUMENT PANEL DECAL (SEPARATE CHOKE)
4 727008 727008 1 HYD PRESSURE DECAL
5 791830 791830 1 FUEL INDICATOR DECAL
6 782136 782136 1 Z OPERATION DECAL
7 788968 788968 1 ENGINE COMPARTMENT DECAL
8 785188 785188 1 Z ARMREST WARNING DECAL
9 782128 782128 1 Z SERVICE DECAL
10 727016 727016 1 BATTERY DECAL
11 771436 771436 1 STABILIZER DECAL
12 727172 727172 1 MADE IN USA DECAL
13 N/A 083279 1 TURF PROD SERIAL NO PLATE
14 782573 782573 1 FIRST ZERO TURN DECAL
15 793588 793588 1 HUSTLER NAME PLATE
16 786426 786426 1 HUSTLER Z ID DECAL
17 600899 600899 1 PUMP BELT WARNING DECAL
SERVICE
PAR T NO.
MFG.
PAR T NO.
QTY. DESCRIPTION
NOTES:
106567 7/06 9-3
Page 78

66" Deck Decals

8
1
9
10
7
2
3
4
8
6
5
5
6
INDEX
NO.
1 799189 799189 1 66" SIDE DISCHARGE DECK ID DECAL
2 760637 760637 1 MOWER DECK QUICK REFERENCE DECAL
3 727420 727420 1 DEFLECTOR SHIELD DECAL
4 727172 727172 1 "MADE IN U.S.A." DECAL
5 727453 727453 2 BELT & PULLEY DECAL
6 727438 727438 2 WHIRLING BLADES DECAL
7 781419 781419 1 BELT ROUTING DECAL
8 799353 799353 2 DECK XR7 ID DECAL
9 359547 359547 1 5.00 X 9.00 STEP TREAD
10 797845 797845 1 FUSION DECAL
SERVICE
PAR T NO.
MFG.
PAR T NO.
QTY. DESCRIPTION
NOTES:
9-4 106567 7/06
Page 79

60" Deck Decals

10
9
8
6
8
1
2
7
3
4
5
INDEX
NO.
1 786277 786277 1 60" SIDE DISCHARGE DECK ID DECAL
2 760637 760637 1 MOWER DECK QUICK REFERENCE DECAL
3 727420 727420 1 DEFLECTOR SHIELD DECAL
4 727172 727172 1 "MADE IN U.S.A." DECAL
5 727453 727453 2 BELT & PULLEY DECAL
6 727438 727438 2 WHIRLING BLADES DECAL
7 799395 799395 1 BELT ROUTING DECAL
8 799353 799353 2 DECK XR7 ID DECAL
9 359547 359547 1 5.00 X 9.00 STEP TREAD
10 797845 797845 1 FUSION DECAL
SERVICE
PAR T NO.
MFG.
PART NO.
QTY. DESCRIPTION
6
5
NOTES:
106567 7/06 9-5
Page 80

54" Deck Decals

10
8
1
2
3
9
7
8
5
6
5
INDEX
NO.
1 799171 799171 1 54" SIDE DISCHARGE DECK ID DECAL
2 760637 760637 1 MOWER DECK QUICK REFERENCE DECAL
3 727420 727420 1 DEFLECTOR SHIELD DECAL
4 727172 727172 1 "MADE IN U.S.A." DECAL
5 727453 727453 2 BELT & PULLEY DECAL
6 727438 727438 2 WHIRLING BLADES DECAL
7 781419 781419 1 BELT ROUTING DECAL
8 799353 799353 2 DECK XR7 ID DECAL
9 359547 359547 1 5.00 X 9.00 STEP TREAD
10 797845 797845 1 FUSION DECAL
SERVICE
PAR T NO.
MFG.
PAR T NO.
QTY. DESCRIPTION
4
6
NOTES:
9-6 106567 7/06
Page 81

Chapter 10 Contents

Maintenance & Adjustments Safety Precautions . . . . . . . . . . . . . . .10-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-7
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-15
10-1
106567_0706
Page 82
10-2
106567_0706
Page 83
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/mechanics should read this manual, or be instructed about safe operating and maintenance procedures. This is the owner’s responsibility.
Improper use or maintenance by the operator, mechanic, 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 machine may result in severe injury. Personnel operating and maintaining it should be trained in the proper use and should read the manuals completely and thoroughly before attempting to set-up, operate, adjust, or service this machine.
The Quick Reference Decals, located under the right front of the seat, the right front of the deck, and under the seat pan, are designed to give the operator/mechanic brief information needed in the daily operation and service of the machine. These decals are not intended to be used in place of this manual but instead is 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 operator/mechanic reads and understands this manual and all decals before operating this machine. It is also the owner’s responsibility to make certain that the operator/mechanic is a qualified and physically able individual, properly trained in the operation of this equipment. Local regulations may restrict the age of the operator/mechanic.
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/mechanic is responsible for accidents or hazards occurring to other people or their property.
Safe Maintenance & Adjustment Practices
This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death.
Unless specifically required, DO NOT have engine running when servicing or making adjustments to tractor. Place control levers in the park brake position, disengage deck clutch, remove ignition switch key and disconnect the negative battery cable. Repairs or maintenance requiring engine power should be performed by trained personnel only. To prevent carbon monoxide poisoning, be sure proper ventilation is available when engine must be operated in an enclosed area.
Follow daily and weekly checklists, making sure hoses are tightly secured and bolts are tightened.
Keep your machine clean and remove any deposits of trash and
clippings, which can cause engine fires and hydraulic overheating as well as excessive belt wear. Clean up oil or fuel spillage. Allow machine to cool before storing.
Clean flammable material from machine. Prevent fires by keeping engine compartment, battery, hydraulic lines, 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 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.
Never put hands or feet under any part of the machine while it is running.
Except when changing or checking belt, always keep belt covers on mower for safety as well as cleanliness.
Stop the engine before removing the grass catcher or unclogging the discharge chute. Never clear the discharge chute with the engine running. Turn off the engine and be sure the blades have stopped before cleaning. Use a stick to clear a plugged discharge area.
Never use your hand!
Exercise caution when loading or unloading the machine onto a trailer or truck.
Always wear safety goggles or safety glasses with side shields when operating the mower.
Never leave machine unattended with ignition key in switch, especially with children present.
Be alert and turn the machine off if children enter the area.
Always wear adequate eye protection when servicing the battery, hydraulic system, cooling system or when grinding mower blades and removing accumulated debris.
Use extra caution when handling gasoline and other fuels. They are flammable and vapors are explosive.
Never refuel tractor while engine is running; never refuel near an open flame or near devices which can create a spark. Refuel outdoors preferably, or in well ventilated areas.
Never attempt to start engine when there is a strong odor of gasoline fumes present. Locate and correct cause.
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 tractor drive system, mower deck or any attachment while the tractor engine is running or deck clutch is engaged. Repairs or maintenance requiring engine power should be performed by trained personnel only.
Never work under the machine or attachment unless it is safely supported with jack stands. Make certain machine is secure when it is raised and placed on the jack stands. The jack stands should not allow the machine 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 to block the unit up. Use in pairs only. Follow the instructions supplied with the vehicle stands.
Before working on or under the deck, make certain engine cannot be accidentally started. Shut engine off and remove ignition switch key for maximum safety. Repairs or maintenance requiring engine power should be performed by trained personnel only.
Use a stick or similar instrument to clean under the mower making sure that no part of the body, especially arms and hands are under mower.
Exercise caution when working under the deck as the mower blades are extremely sharp. Wearing gloves or wrapping the blade(s) is advisable when working around or with the blades.
Do not touch hot parts of machine.
Keep nuts and bolts tight, especially the blade attachment bolts. Keep equipment in good condition.
Never tamper with safety devices. Check their proper operation
SAFETY PRECAUTIONS
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10-3
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regularly.
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.
Use only genuine Hustler replacement parts to ensure that original standards are maintained
Using a ramp
Use extreme caution when loading and unloading a unit with a ramp.
Use only a single, full width ramp; do not use individual ramps for each side of the unit. Having a full width ramp provides a surface for the tractor frame to contact if the unit starts to tip backwards. It also reduces the risk of a wheel going off and the machine 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
10-4
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Safety and Instruction Decals
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 machine. A brief explanation is shown to help the operator understand the meanings of these decals.
Read Owner’s Manual and Quick Reference Decals before attempting to operate this machine.
Avoid skin 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 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. Use soda mixed in water to clean corrosion off the terminals.
Do not remove or modify stabilizer wheels or rear engine guard or injury can result.
Never operate the mower deck with side deflector removed or in raised position, except when the grass catcher attachment is being used.
Keep shields or covers in place while machine is in operation. Keep hands away from rotating pulleys and belts.
Whirling blades! Keep hands and feet away. Beware of thrown objects.
Do not smoke while refueling. Do not 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 gasoline spills. Do not refuel while in enclosed trailer or other enclosed areas
Part Number
727016
Part Number
727420
Part Number
727438
Part Number
727453
Part Number
771436
Keep engine and pump compart­ment(s) clean (especially in exhaust area) to prevent fire and provide maximum engine and hydraulic cooling.
Part Number
788968
If you loose steering control while
operating the machine, place the steering control levers in the park brake position immediately. Inspect the machine and involve your Hustler 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.
Part Number
600899
Hydraulic fluid escaping under pressure can penetrate skin. Hydraulic fluid may also cause infection in a minor cut or opening in the skin; if exposed to hydraulic fluid, see a doctor at once. 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, turn engine off and lower attachment.
Hot surface!
Part Number
727008
Part Number
779280
If you lose steering control while operating the machine, place the steering control levers in the park brake position immediately. Inspect the machine and
involve your Hustler 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.
600899
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10-6
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10-7

MAINTENANCE

MAINTENANCE LOCATOR
CHART
1a. Engine Oil Fill & Dipstick
(Kawasaki & Honda)
1b. Engine Oil Fill & Dipstick (Kohler)
2. Fuel Filter
3. Engine Air Cleaner
4. Engine Oil Drain Plug
5. Battery
6. Fuel Tanks
7. Hydraulic Oil Reservoir
8. Hydraulic Oil Filter
9. Gauge Wheel Bearing Zerks (2)
10. Engine Oil Filter
11. Deck Height Pivot Zerks (4)
12. Park Brake Switch
13. Drive Tire
14. Pump Idler Zerk (1)
15. Pump Belt
16. Hydraulic Oil Heat Exchanger
6
10
2
4
3
11
9
11
9
5
13
8
12
7
1a
6
12
11
11
Figure 10-1a
13
14
15
16
Viewed from bottom of tractor
1b
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10-8
MAINTENANCE LOCATOR
CHART
1. Deck Pusher Arm Zerks (2)
2. Deck Belt
3. Spindle Housing Zerk (3)
4. Blades
4
4
1
1
3
3
3
2
1
4
1
2
3
3
4
3
54”/66”/72” XR7 deck
60” XR7 deck
Figure 10-1b
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SERVICE AT OR 50 OR 100 500
INTERVALS INDICATED HOURS HOURS HOURS
Verify safety start interlock system Daily
Visually inspect unit for loose
hardware and/or damaged parts Daily
Visually inspect tires Daily
Check oil level, engine (1) Daily or every 4 hrs.
Clean air intake screen (5) Daily or every 4 hrs.
Check fuel level Daily
Blades - sharpen & securely fastened Daily
Discharge chute - securely in place &
in lowest position Daily
Clean engine and pump compartment Daily
Replace air cleaner paper element (5) As needed
Grease deck idler x
Grease deck pusher arms x
Grease pump idler x
Grease deck height pivots x
Grease gauge wheel bearings x
Change engine oil & filter (1) (4) x
Clean cylinder and head fins (a) x
Check battery connections x
Check tire pressure with a gauge x
Check hydraulic oil level x
Clean engine exterior (a) x
Clean and regap spark plugs (a) x
Check pump and deck belt tension
& condition (6) x
Check fuel and hydraulic lines (7) x
Check fuel valve and grommet (7) x
Tighten lug nuts on wheels (2) x
Change fuel filter x
Clean or replace hydraulic fill cap x
Change hydraulic filter and oil (3) x
Grease deck spindle housings x
Replace spark plugs x
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 during hot weather periods.
2. Torque initially and after first 2 hours of operation.
3. Perform initial hydraulic 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 line hoses, fuel valve and grommet for any cracks or leaks.
REFERENCES: a — Refer to Engine Owner’s Manual
WEEKLY MONTHLY ANNUALLY OR
NOTE: After completing maintenance cycle (500 hours), repeat cycle.
Introduction
Regular maintenance is the best prevention for costly downtime or expensive, premature repair. The following pages contain suggested maintenance information and schedules which the operator should follow on a routine basis.
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 hydraulic reservoir area; minute dust particle are abrasive to close-tolerance engine and hydraulic assemblies.
Daily inspect mower for grass clippings and wire and string tangles. The underside of the mower deck 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 blade and air movement and will probably show a poorer quality of cutting. Therefore it should be removed routinely.
To do this it will be necessary to raise and block the deck in the full up position and scrape the build-up from underneath.
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.
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Torque values
WARNING: Particular attention must be given to tightening the
drive wheel lug nuts, wheel motor nuts, and blade spindle bolts. Failure to correctly torque these items may result in the loss of a wheel or blade, which can cause serious damage or personal injury.
Torque values given below:
Ft-lbs. Nm
Wheel (lug) nuts..................................................65-75 ............88.14-101.7
Wheel motor nut .............................................350-375 ...........474.6-508.5
Blade spindle bolt top .........................................65-75 ............88.14-101.7
Blade spindle bolt bottom ......................................118.......................160.0
It is recommended that these be checked after the first 2 hours of operation, initially and every 50 hours following removal for repair or replacement.
For all other torques refer to the tractor parts manual for standard torque chart.
For engine torque values, see engine owner’s manual.
Tires
It is important for level mowing that the tires have the same amount of air pressure. The recommended pressures are:
Drive wheels...................................................................8-10 psi
Gauge wheels .................................................................8-10 psi
Solid fill tires are not recommended for Hustler turf equipment. On any machine, with solid filled tires, the warranty claim will be denied.
WARNING: Explosive separation of a tire and rim can cause serious injury or death. Do not attempt to mount a tire without the proper equipment and experience to perform the task. Always maintain the correct tire pressure and never over inflate. Never weld or heat a wheel and tire assembly as an explosion may occur. Welding can weaken or deform a wheel. When inflating tires stand to one side and not in front of or over the tire assembly. Check tires for low pressure, blemishes, damaged rims or missing lug bolts and nuts.
Hour meter
To recognize when your machine needs servicing, check the hour meter and the maintenance schedule. The hour meter shows the number of hours the engine has run and the maintenance schedule lists the service intervals. Fig. 10-2
Hour
meter
Figure 10-2
Lubrication
1. Grease the front gauge wheel bearings per the Maintenance Schedule. Use SAE multi-purpose grease.
2. Grease the four deck lift pivots, located to the side of the operator’s footrest per the Maintenance Schedule. Use SAE multi-purpose grease.
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10-10
3. Grease the deck idler per the Maintenance Schedule. Use SAE multi-purpose grease.
4. Grease the pump idler per the Maintenance Schedule. Use SAE multi-purpose grease.
5. Grease the two deck pusher arm pivots per the Maintenance Schedule. Use SAE multi-purpose grease.
6. Grease the blade spindle assemblies per the Maintenance Schedule. The spindle assemblies require lubrication annually. Each spindle shaft is equipped with a grease zerk located under the deck. Use no more than one or two ounces of SAE multi-purpose grease, (1 to 2 pumps on an average grease gun). Do not force lubricant in to grease zerks. Bearings are sealed and do not require much lubricant.
Electrical system
The electrical system is a 12 volt, negative ground. Recommended battery size is a garden tractor BCI group U1R with 225 or better cranking AMP rating. A maintenance-free battery is recommended. Otherwise, follow battery manufacturer’s maintenance, safety, storing and charging specifications.
The battery is located under the seat. Fig. 10-3
WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm. Wash hands after handling.
WARNING: Avoid skin 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 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. Use soda mixed in water to clean corrosion off the terminals.
WARNING: Shorts caused by battery terminals or metal tools touching metal tractor 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 tractor parts when removing or installing the battery. Do not allow metal tools to short between the battery terminals and metal tractor parts.
WARNING: Incorrect battery cable routing could cause damage to the tractor 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 before disconnecting the positive (red) cable.
Common circuit failures are usually caused by shorting, corroded or dirty terminals; loose connections, defective wire insulation or broken wires. Switches, solenoids and ignition components may also fail, causing a shorted or open circuit.
Before attempting any failure diagnosis of the electrical system, use a test light or voltmeter to check the battery voltage. If the battery voltage is satisfactory, check the cleanliness and tightness of the terminals and ground connections. A general understanding of electrical servicing and use of basic test equipment is necessary for troubleshooting and repair.
Major overhaul or repair of the starting motor or alternator should be performed by trained technicians only.
Access to engine and hydraulic pumps
The hydraulic pumps are accessed by lifting the seat platform. The seat platform is hinged at the front. To raise it, release seat latch and tilt seat platform up and forward. The seat platform catch (Fig. 10-4) will prevent the seat from going all the way over. However, if more access is desired
under the seat platform, the seat platform catch can be raised allowing the seat to pivot more. Make certain to place the control arms in the park
brake position and pivot the arm rests upward before placing the seat platform in the full forward position to prevent arm rest damage.
WARNING: Always wear adequate eye protection when servicing the hydraulic system and battery.
Hydraulic system
IMPORTANT: Never use hydraulic or automatic transmission fluid in
this system; use only motor oil as specified. Remember, dirt is the primary enemy of any hydraulic system.
WARNING: Hydraulic oil escaping under pressure can penetrate skin. Hydraulic oil may cause infection in a minor cut or opening in the skin. If exposed to hydraulic fluid, see a doctor at once. 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 1.0 U.S. gallon (3.79 liter) hydraulic reservoir is located in front of
the engine and under the operator’s platform. Fig. 10-5
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.
Fluid level should be 1” from top of reservoir. Use only SAE 10W40 SG, SF/CC, CD service motor oil.
Change hydraulic system filter element (Fig. 10-5) after first 50 hours of tractor operation, then replace filter and oil in reservoir every 500 hours thereafter. When changing hydraulic oil use 1/2 unit (approximately 3.5 oz.) of Lubrizol additive (Hustler P/N 027912). This additive, available from your Hustler dealer, will increase the performance life of the hydraulic
Figure 10-3
Battery
Figure 10-4
Seat platform catch
Control lever
Seat platform
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system components.
The system filter is located directly in front of the hydraulic reservoir. A standard oil filter wrench is used to change filter, threads are right handed. Use a Hustler approved filter element only.
IMPORTANT: Prefill the filter element with clean oil, before installing, to prevent drawing air into the system pump.
1. Fill the filter element with clean system oil. Smear a light coating of oil on upper surface of rubber seal.
2. Install the filter element on base. Tighten the oil filter by hand until the filter seal makes contact with the filter head, then tighten an additional 3/4 - 1 turn with an oil filter wrench. — DO NOT OVERTIGHTEN.
3. Start tractor engine and let run at approximately 2/3 throttle for a few minutes to work any trapped air out of the system before engaging the steering control lever.
4. Stop the engine and check the filter and connections for leaks.
5. Check the hydraulic reservoir for specified oil level. Add clean oil
as necessary.
Clean or replace hydraulic reservoir cap annually. Cap may be cleaned by dipping in or flushing with cleaning solvent. Follow manufacturer’s instructions and warnings for application of solvent type selected.
Fuel system
DANGER: Observe usual fuel handling precautions:
Do not smoke while refueling. Do not fill tank with engine running or while engine is hot. Clean up any gasoline spills. Allow engine to cool before storing machine inside a building. Keep fuel away from open flame or spark and store machine away from open flame or spark if there is fuel in the tank. Use extra caution when handling gasoline and other fuels. They are flammable and vapors are explosive. A fire or explosion from gasoline can burn you and others and can damage property. Refuel outdoors preferably, or in well ventilated areas. Never attempt to start engine when there is a strong odor of gasoline fumes present. Locate and correct cause. Store gasoline in an approved container and keep it out of the reach of children. Never buy more than a 30 day supply of gasoline. Always place gasoline containers on the ground away from your vehicle before filling. Do not fill gasoline containers inside a vehicle or on a truck or trailer as interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge. When practical, remove equipment from the truck or trailer and refuel the equipment with its wheels on the ground. If this is not possible, then refuel the equipment on the truck or trailer using a portable container and not a gasoline dispenser nozzle. If a gasoline 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.
Hydraulic reservoir
Hydraulic filter
Figure 10-5
Fuel tank
Figure 10-6
Fuel filter
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 conditioner opening. Keep gas away from eyes and skin.
The fuel tanks are located in the tractor’s fenders. (Fig. 10-6) Total capacity for the fuel tanks is 15 U.S. gallon (56.8 liter)
Use regular unleaded gasoline with an octane rating of 87 or higher.
The fuel filter (Fig. 10-7) is installed in the fuel line between fuel tanks and engine fuel pump. Replace filter annually or after every 500 hours of operation, whichever occurs first.
When replacing the fuel filter, check the fuel line hoses and fuel shut­off valve grommet for any cracks or leaks. Replace as needed.
Hustler Z tractors are equipped with a fuel shutoff valve located on the right fuel tank mount (Fig. 10-8). Rotate the valve to the middle position (shown) to prevent fuel flow to the fuel pump. The forward position allows fuel to flow from the right fuel tank to the fuel pump. The rear position
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Kawasaki engine shown
Figure 10-7
allows fuel to flow from the left fuel tank to the fuel pump. Close this valve to prevent fuel flow to the engine when servicing the fuel system or when transporting the unit on a trailer or truck.
Engine oil and filter
Check engine oil daily and after every 4 hours of operation. Crankcase dipstick and oil filler tube are located at the rear of the machine (Fig. 10-9). Tractor 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, per the engine manufacturer’s recommendations after that. If tractor is being operated in extremely dirty conditions, then it is recommended oil be changed more frequently.
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10-12
The oil drain and oil filter are located at the rear of the engine. Fig. 10-
9
Engine air filter
Perform engine air filter maintenance per the Service Interval chart on
page 10-9.
A specially designed dry filter is standard equipment on the Hustler Z
tractors and supplies clean combustion air to the engine. Fig. 10-10
Recommended service procedure
Many engine failures can be attributed to improper air cleaner servicing. Ingested dust and dirt will cause cylinder, piston and bearing damage in a few hours. “Dusted” engines will result from:
1. Overservicing the air filter element.
2. Improper installation.
3. Damaged filter, seals or canister.
4. Incorrect air filter element size.
5. Use of poorly designed aftermarket air filter elements.
Air cleaner servicing is an inexpensive maintenance check that can prevent costly non-warrantable premature engine damage.
Overservicing
Overservicing occurs when an air filter element is removed for cleaning or replacement before it is necessary. Each time the filter is removed a small amount of dirt and dust could fall in the intake system. This accumulated dirt can cause a dusted engine. It only takes a few grams of ingested dirt over the normal service life of an engine to cause a dusted engine.
Do not clean element, replace with a new element only. Cleaning used air filter elements, through improper cleaning procedures, can get dust on the inside of the filter causing dirt ingestion and engine failure.
It is important to note that whenever an air filter element is cleaned by any method, the person or company performing the cleaning assumes responsibility for the integrity of the filter from then on. The Donaldson
warranty for air filters expires upon cleaning or servicing in any manner because the condition of the filter after servicing is completely out of their control. Therefore, on a dust ingested engine failure, there will be no warranty consideration if the air filter element has been cleaned or serviced in any manner.
A partially dirty air filter element works better than a new element. Therefore, a dirty filter element is not bad for the engine unless it is excessively restricting the air flow and engine performance is affected. The reason is simple. The media in the filter must be porous to allow air to pass through it. When dirty air passes through the filter, the dirt plugs some of the holes in the media and actually acts as part of the filter media. When the next round of dirt enters, the first dirt helps filter out even smaller particles making the filter more efficient at stopping dirt from entering the engine. This is referred to as barrier filtration.
Of course, at some point the filter media becomes too clogged to allow air to pass.
The mowing conditions will determine the frequency of air filter element changing.
Improper installation of an air filter element
Dust must not leak past the seals on each end of the air filter element. The filter must be aligned within the canister and properly seated for an effective seal so that no dirt can enter the engine.
Damaged filter, seals or canister
Never bang or bump the filter element against the tire or any solid object, as dust and dirt particles will be forced through the media causing continual passing of dirt into the engine. Visually inspect the outside of the air cleaner canister periodically for external damage and replace if necessary.
Incorrect air cleaner element
Use only the correct Donaldson air filter element, Hustler part number 785261, which is designed to fit the canister properly.
Hustler air filter elements have the correct media composition, filter area, micron size and dimensions. Always use genuine Hustler filters. Many aftermarket filters have been found to be incompatible with Hustler’s canisters and engines.
The air filter must remain intact to block passage of dirt and foreign particles from entering the engine. Being inclined to disbelieve the need for more expensive air filter elements used on gasoline engines may cause some individuals to opt for a less expensive part.
The filter element must be sufficient size and construction to withstand stresses, caused by rapid cycling of the air volume demanded by the engine, without cracking or tearing under fatigue and pressure (especially diesel engines). Therefore, Hustler Turf Equipment and the engine manufacturers have carefully selected a reliable filter designed to fit the needs of the engines. The filter specified is a Donaldson filter, Hustler part number
785261.
Owners should be reminded that failure to use original equipment
Figure 10-8
Fuel shut-off valve
Closed position
shown
Left tank
position
Right tank
position
Figure 10-9
Engine oil drain plug
Engine oil filter
Engine oil filler tube
Kawasaki engine shown
Figure 10-10
Pre-cleaner
Canister
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replacement parts is an “alteration” and will not be considered for warranty in the event of engine damage.
Recommended service procedure
1. Release clamps and remove element. Clean the canister with a damp cloth.
2. Before installing a new element, inspect it by placing a bright light inside and rotate the element slowly, looking for any holes or tears in the paper. Also check gaskets for cuts or tears. Do not attempt to use a damaged element which will allow abrasive particles to enter the engine.
3. Reinstall the dust cup. Make sure it seals all the way around the air cleaner body, then tighten the clamps.
4. Check all fittings and clamps periodically for tightness and inspect hoses for holes or cracks.
5. Periodically check the intake hose for signs of ingested dust. Locate and repair the source of ingested dirt.
6. Never operate a machine without an air filter installed.
Air restriction indicator
Any unit with a Kohler or Kawasaki engine will have an air restriction
indicator installed in the air cleaner. Fig. 10-11
Replace the element whenever the restriction indicator shows reaches the change filter red line. Check the indicator daily and replace element as needed or annually whichever occurs first.
Reset the indicator by pushing in on the yellow button after each element change. Fig, 10-11
A restriction indicator takes the guesswork out of air cleaner servicing and allows you to safely benefit from the filter’s optimum performance.
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 manufacturer. Special attention should be paid to applicable data which will not be duplicated here.
Belt replacement
Figures 10-12, 10-13 and 10-14 show diagrams and descriptions of the unit’s belt drive systems.
Inspect these belts frequently for wear and serviceability. Replace a belt that shows signs of severe cuts, tears, separation, weather checking and cracking, or burns caused by slipping. Slight raveling of belt covering does not indicate failure, trim ravelings with a sharp knife.
WARNING: If the pump belt fails, loss of control will occur especially when operating on a slope. If you lose steering
control while operating the machine, place the steering control levers in the park brake position immediately. Inspect the machine and involve your Hustler dealer 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 belt will lose power and slip excessively.
Never pry a belt to get it on a pulley as this will cut or damage 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.
Mower blade maintenance
Check the mower blades daily, they are the key to power efficiency and well groomed turf. Keep them sharp, a dull blade will tear rather than cut the grass, leaving a brown ragged top on the grass within a few hours. A
Figure 10-13
2
2
2
6
4
3
5
Deck Belt Drive Layout
1. Spindle drive belt
2. Deck blade spindle pulley
3. Spindle belt tension idler
4. Spindle belt tension idler spring
(9.0" at operation)
5. Deck belt idler
6. Idler arm
1
5
54”/66”/72” XR7 deck
Figure 10-12
1
3
2, 6
4
5
1. Pump belt
2. Engine pulley
3. Pump idler pulley
4. Pump idler arm
5. Pump pulley
6. Electric deck clutch
7. Pump idler spring
7
Viewed from
bottom for unit
5
10-13
Figure 10-11
Indicator
Reset
button
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dull blade also requires more power from the engine.
Replace any blade which is bent, cracked or broken.
WARNING: Never attempt to straighten a bent blade by heating, or weld a cracked or broken blade as the blade may break and cause serious injury.
DANGER: Never work with blades while engine is running or deck clutch switch is engaged (on). Always place deck clutch switch in the disengaged position, place control levers in the park brake position and turn engine off and disconnect negative battery cable. Block up mower when you must work under it. Wear gloves when handling blades. Always check for blade damage if mower strikes rock, branch or other foreign object during mowing!
WARNING: Always wear adequate eye protection when grinding mower blades.
Mower blade removal
Use a 15/16" wrench to remove the 5/8" cap screw holding the blade to the spindle shaft from underneath. Sharpen the blades on a grinder following pattern as shown (Fig. 10-15). 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 1/2" bolt. Blade should not lean or tilt. Spin the blade slowly, blade should not wobble. If blade is out of balance, true it up before reinstalling.
Lay the blade on a flat surface and check for distortion (Fig. 10-16 and 10-17). Replace any distorted blade.
Do not re-use spindle bolts which have stripped, worn or undercut threads. Torque bolts to 118 foot-pounds when reinstalling blades.
WARNING: When mounting blades, rotate them after installation to ensure blade tips do not touch each other or sides of the mower.
WARNING: Failure to correctly torque the bolt may result in the loss of the blade which can cause serious injury.
WARNING: Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves and use extra caution when servicing them.
Figure 10-14
2
2
2
6
4
5
3
5
Deck Belt Drive Layout
1. Spindle drive belt
2. Deck blade spindle pulley
3. Spindle belt tension idler
4. Spindle belt tension idler spring
(9.0" at operation)
5. Deck belt idler
6. Idler arm
1
5
60” XR7 deck
Warped Blade (Replace)
Straight Blade
Comparison of Warped and Straight Blades
Cutting
Plane
Figure 10-16
Figure 10-15
Resharpening Pattern
Do not sharpen to original pattern (below). It is easier to get a straight cutting edge following the resharpening pattern shown above.
Original Edge
Figure 10-17
Twisted Blade Edge
(Replace)
Cutting Edge
Straight Blade Edge
End view of blades, comparing
twisted and straighten blades.
Cutting Plane
Cutting Edge
10-14
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ADJUSTMENTS

Introduction
Your Hustler Z was adjusted before it left the factory and was checked during predelivery setup. However, after start-up and continued use, a certain amount of break-in wear will cause some adjustments to change.
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 area of reservoir and oil and engine combustion air; minute dust particle are abrasive to close-tolerance engine and hydraulic assemblies.
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.
Steering linkage
The neutral adjustment for the control levers in the neutral position is
discussed in this section.
The tractor steering has been factory adjusted to eliminate creeping when the control levers are in the neutral position (Fig. 10-18). However, should the tractor begin to creep, the control lever linkage can be adjusted as follows:
Control Lever Neutral Adjustment
Before considering any adjustment, check the tire air pressure and make certain hydraulic system oil is at operating temperature. Unequal tire pressure will cause the tractor to drift to one side. Refer to tire pressure information in the Maintenance section of this manual.
Fine adjustment to the unit’s steering is made with the adjustable pump linkage rods located between the control lever and pump arms. Fig. 10-19
Neutral is properly adjusted when the control levers are in the neutral position and the drive wheels are not turning.
If the tractor creeps in the neutral position the control linkage may be adjusted as follows:
1. Raise and block the tractor up so the drive wheels are off of the floor.
WARNING: Never work under the machine or attachment unless it is safely supported with jack stands. Make certain machine is secure when it is raised and placed on the jack stands. The jack stands should not allow the machine 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 to block the unit up. Use in pairs only. Follow the instructions supplied with the vehicle stands.
Control lever in the
neutral position
Park brake slot
Control
lever
Figure 10-18
Pump linkage rod
Pump arm
Jam nut
Figure 10-19
Jam nut
2. Position the control lever in the neutral position. Disengage the deck clutch.
3. Start the engine and observe which way the wheels are rotating.
4. If wheel(s) are rotating forward, loosen the jam nuts on the pump
linkage rods and rotate the rod to lengthen the steering control linkage until the wheel(s) come to a stop. Fig. 10-19 NOTE: The left linkage controls the left hydraulic pump and the right linkage controls the right hydraulic pump. Repeat for the opposite side if necessary.
5. If wheel(s) are rotating in reverse then loosen the jam nuts on the pump linkage rods and rotate the rod to shorten the steering control linkage until the wheel(s) come to a stop. Fig. 10-19 NOTE: The left linkage controls the left hydraulic pump and the right linkage controls the right hydraulic pump. Repeat for the opposite side if necessary.
6. When both wheels remain in neutral, tighten the jam nuts to lock the turnbuckle in place.
7. Test again by moving the control levers forward and backward before returning them to the neutral position. If the tires are in
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Stop
Control
lever
Figure 10-20
neutral, the unit is now ready for operation.
8. After adjusting for neutral it may be necessary to re-adjust the control lever stop. Fig. 10-20
Control lever stops
The control lever stops (Fig. 10-20) are designed to do two things: First, and most important, they must keep the pumps from bottoming out internally. Secondly, the stops may be adjusted to help drive straight when
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Page 96
the control levers are pushed forward against the stops.
To keep the pumps from bottoming out internally use the following
procedure:
1. To make the first adjustment the tractor engine must NOT be running.
2. Check to make sure the control levers are against the stops before the pumps are bottomed out internally. To do this, gently and slowly move the control levers forward and feel if there is some resistance on the pump lever before the control levers hit the stops. Check one side at a time. If you sense that the pump arms are stopping the forward motion of the control arms, loosen the jam nut on the adjustable stop of the corresponding side and turn the stop (set screw) inward to stop the control levers slightly before the pump bottoms out. Lock in place when the adjustment is correct by re-tightening the jam nut.
3. Do this for each side.
To adjust the stops for driving straight when control levers are against
the stops during operation:
1. Determine which drive tire is rotating too fast when both control levers are against the stops. Then stop the tractor and loosen the lock nut on the side which is rotating too fast and turn the stop (set screw) inward to stop the control lever sooner. Tighten the lock nut on the stop and test again. Repeat this procedure until unit drives straight.
NOTE: Since this is a hydrostatic drive, variables such as temperature of
oil, efficiency of pumps and motors, tire pressure etc. may effect the consistency of the ability to rely on the stops to drive straight without the operator making minor steering adjustments with the control arms.
Steering dampener
The steering dampener (Fig. 10-21) is spring loaded to return the control levers to the neutral position from the reverse position. This gives the operator a sense of neutral during operation.
To set the steering dampeners in the correct operating position follow these steps:
1. Place the control lever in the neutral position.
2. Loosen the steering dampener’s front ball stud.
3. Pull the dampener spring housing pass the point that the internal
spring is engaged.
4. Release the dampener spring housing and allow the internal spring to bring the housing back to the neutral position.
5. Tighten the nut on the steering dampener’s front ball stud.
Control lever adjustment
The control levers can be adjusted for operator comfort. By loosening the cap screws that attaches the upper control lever to the lower lever (Fig. 10-22), the upper control lever can be pivoted to fit the operator’s personal preference.
The control levers should be adjusted so that they align with each other when in the neutral position.
Park brake adjustment
Occasionally check the park brakes and adjustment using the following method:
1. Position the control levers in the neutral position. Disengage the deck clutch.
WARNING: Never work under the machine or attachment unless it is safely supported with jack stands. Make certain machine is secure when it is raised and placed on the jack stands. The jack stands should not allow the machine 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 to block the unit up. Use in pairs only. Follow the instructions supplied with the vehicle stands.
NOTE: The front brake link is not adjustable. Fig. 10-23
2. Raise and block the tractor up so the drive wheels are off of the floor.
3. Open the hydraulic pump’s bypass valve (Fig. 10-24), on the side
that is being adjusted, by turning bypass valves counter clockwise one-half to one revolution. The valve stems on each hydraulic pump are located near the top and are identified as a hex stud.
4. Rotate the tire. The tire should rotate. Remember hydraulic oil resistance will prevent the tire from rotating freely even with the bypass valves open. There should be no resistance from the brakes
10-16
Figure 10-22
Cap screw
Upper
control
lever
Lower control
lever
Figure 10-21
Spring
housing
Front ball
stud
Figure 10-23
Front brake link
(right side)
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Figure 10-25
Travel slot
Outside edge
Control lever
Park brake
slot
Bypass valve
Figure 10-24
at this point.
5. Move the control lever to where it is touching the outside edge of the lever’s travel slot. Fig. 10-25 NOTE: When the control lever is against the outside edge of the the slot, the brakes should not be engaged.
6. Rotate the tire. If the brake is adjusted properly the tire will still rotate but friction will start to become noticeable here. However, if no brake resistance is noticed, the brake needs adjusted as follows:
7. Loosen the brake linkage jam nuts. Fig. 10-26
8. Rotate the tire and at the same time rotate the turnbuckle to shorten
the length of the brake linkage to increase the brake pressure. When you feel the brake begin to engage, stop adjusting the turnbuckle. Re-tighten the jam nuts on the turnbuckle.
9. Place the control lever in the park brake slot (Fig. 10-25). The tire should not rotate when the control lever is in the park brake position.
10. Place the control lever in the neutral position. The tire should rotate freely.
11. Close the hydraulic pump’s bypass valve.
12. Repeat steps 3 thru 11 for the other side.
13. Remove the jack stands and lower the unit. It is now ready to
operate.
Hydraulic pump belt adjustment
The pump drive belt tension remains constant by means of a tension idler
and spring (Fig. 10-27). There is no tension adjustment of this belt.
NOTE: Replace the belt every 400 hours or every two (2) years whichever comes first.
WARNING: If the pump belt fails, loss of control will occur especially when operating on a slope. If you lose steering
control while operating the machine, place the steering control levers in the park brake position immediately. Inspect the machine and involve your Hustler dealer to resolve the problem before continuing to operate.
Deck drive belt adjustment
The spindle belt tension remains constant by means of a tension idler and spring (Fig. 10-28). The spring tension should be such that the belt does not slip under normal operating load conditions, assuming the belt is not excessively worn or damaged. As belt stretches and wears in, adjustment may become necessary. To increase belt tension, move the spring chain one (or more) link(s) at the anchor bracket (Fig. 10-28). Installed spring length should be 9.0" ± .3" (22.8 cm ± .76 cm) originally with adjustments of .60" (15.2mm) per chain link. (Fig. 10-29)
IMPORTANT: Do not over tension the spring to compensate for a badly worn belt or pulley.
Engine RPM setting
The Hustler Z is designed so that the engine will run at 3600 rpm static pump load only. At this speed the hydraulic pumps are running at their maximum rated speed.
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Jam nut
Brake linkage
Jam nut
Turnbuckle
Figure 10-26
Deck leveling and height adjustment
The mower deck has three areas that may need to be checked and adjusted periodically. Before considering any mower deck leveling adjustments, check that the tire air pressure is within the specified range.
Deck level adjustments
Leveling the deck must be done in the following manner and order:
1. Check tire pressures to make certain they are properly inflated before starting to level deck. The recommended pressures are as follows:
Drive wheels tire pressure ........................................8 - 10 psi
Gauge wheels tire pressure.......................................8 - 10 psi
WARNING: Stop engine. Make sure deck clutch switch is in the down (OFF) position. Place control levers in the brake
position before leaving machine.
2. Park the unit on a flat surface.
3. Raise deck and place 3” block under the back of the deck and a 4”
block under the front of the deck. (Fig. 10-30). This will set the cutting height at 3-1/2 ". NOTE: Back of deck will automatically be set ¼" higher.
4. Set cutting height at 3-1/2" in the height indicator by placing the height adjusting stop in the 3-1/2" hole, and turning the height stop so that the pin side is against the stop handle. Fig. 10-31
5. Clamp the height adjusting stop against the stop handle (10-31). This will assure that the height will not move during the setting process. Otherwise, spring pressure from the deck lift springs will tend to pull the stop away from the handle.
6. Loosen all nuts on the deck lift threaded rods, and the hardware on the adjuster (on the right front), until all the deck lift chains are loose, and the deck is sitting tightly on all four blocks. Fig. 10-32, 10-33, 10-34
7. Loosen the two nuts on the front of height indicator so that the foot pedal is free. Fig. 10-35
8. Start the leveling process on the left front of the tractor.
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Page 98
9. Set the amount of threads protruding on the deck lift rod from the lift block at approximately 1". Fig. 10-36
10. Jam both nuts against the block.
11. Push or pull on the deck lift foot pedal until the chain on the left
front just becomes tight, making sure that the deck stays tight against the 4" block.
12. While keeping the chain tight, tighten the nuts against the deck lift block on the height indicator rod. Fig. 10-35
13. Go to the right front of the tractor.
14. Loosen the 5/16" jam nut on the adjuster lift chain (10-34), and back
the adjuster bolt out to allow the adjuster to move up and down freely.
15. Be sure that adjuster is free to move up and down.
16. Tighten the adjuster bolt until the chain just becomes tight, making
sure that the deck stays tight against the 4" block.
17. Tighten the adjuster bolt jam nut to prevent the adjuster bolt from moving. Fig. 10-34
18. Tighten the hardware holding the chain and adjuster onto the deck lift arm.
19. Go to the right rear of the tractor.
20. Make sure that there is still slack in the chain. If not, loosen the two
nuts on the block holding the threaded rod until there is slack in the deck lift chain. Fig. 10-33
21. Tighten the appropriate nut until the chain just becomes tight, making sure that the deck stays tight against the 3" block.
22. Tighten the other nut on the opposite side of the block, and jam them tightly together against the block.
23. Go to the left rear of the tractor.
24. Make sure that there is still slack in the chain. If not, loosen the two
nuts on the block holding the threaded rod until there is slack in the deck lift chain. Fig. 10-32
25. Tighten the appropriate nut until the chain just becomes tight.
26. Tighten the other nut on the opposite side of the block, and jam them
tightly together against the block.
27. Compress the deck lift assist springs so that there is 1” of space between the front nut and on the spring and the rear nut on the deck lift block (Fig. 10-36). Typical both sides.
28. When completed, all chains will be tight, and deck cutting height will be set to the deck height indicator.
Figure 10-28
Spring
Tension idler
Chain
Anchor bracket
10-18
Figure 10-29
3.0”
Spring Extension
9.0”
6.0”
Figure 10-27
Spring
Tension
idler
Pump drive
belt
Normal Spring Length
Figure 10-30
Blocks
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Page 99
10-19
Figure 10-31
Height
adjusting
stop
Stop
handle
Figure 10-32
Deck lift
threaded
rod
Nut
Nut
Chains
Figure 10-33
Deck lift
threaded
rod
Nut
Nut
Chains
Figure 10-34
5/16” bolt
Adjuster
Hardware
Jam nut
Figure 10-35
Foot
pedal
Nuts
Figure 10-36
Lift block
1”
Deck lift rod
1”
Deck lift
assist springs
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10-20
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