Hustler 106567 User Manual

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Page 1

Hustler Z XR7

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.

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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

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

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Chapter 10

Maintenance & Adjustments Safety Precautions . . . . . . . . . . . . .10-3

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-7

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-15

Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1

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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

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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.

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Chapter 2 Contents

Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

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Rivet Nut Installation

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

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.

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Footrest Assembly

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.

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Chapter 3 Contents

Hydraulic System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

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Hydraulic System Installation

FRONT

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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)

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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)

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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

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Battery Installation

TRACTOR FRAME

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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.

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Deck Lift Assembly

TRACTOR FRAME

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Deck Lift Assembly

ITEM

NO.

1 348318 348318 1 STOP HANDLE

2 600437 600437 1 DECK HEIGHT 1/2" PIN W/A

{

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).

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Steering and Park Brake Assembly

TRACTOR FRAME

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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

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

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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.

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This page intentionally left blank.

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Pump Belt and Pulleys Installation

TRACTOR FRAME

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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.

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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

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Kawasaki Engine Installation

TO ENGINE SENSOR

ELLOW

TO SPADE

TERMINAL

TO BULLET

TERMINALS

RED/BLK

PAR T OF ENGINE

STARTER SELENOID GROUND

NEGATIVE BATTERY CABLE

POSITIVE BATTERY CABLE

PURPLE

TRACTOR FRAME

PART OF COMMON WIRE HARNESS

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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

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

YEL

BLK

NEGATIVE BATTERY CABLE

RED/BLK

PART OF COMMON WIRE HARNESS

PAR T OF ENGINE

ORG

BRN

GRA/PUR

PUR

POSITIVE BATTERY CABLE

TRACTOR FRAME

5-6 106567 7/06

Page 35

Honda Engine Installation

ITEM

NO.

1 785014 785014 1 HONDA 24HP ENGINE

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

POSITIVE BATTERY CABLE

TRACTOR FRAME

PUR (P/O ENGINE)

RED/BLK

BLK

NEGATIVE BATTERY CABLE

PART OF COMMON WIRE HARNESS

5-10 106567 7/06

Page 39

Kohler Engine Installation

ITEM

NO.

1 788216 788216 1 KOHLER 27HP ENGINE

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

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

FUSE SIZE AND LOCATION

10a

15a

RIGHT SIDE FUEL TANK

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)

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

TRACTOR FRAME

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

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.

QTY DESCRIPTION

NOTES:

6-4 106567 7/06

Page 49

Optional Semi-Pneumatic Tire/Wheel—789537

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

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)

SERVICE

PART NO.

1. Torque to 65-75 ft. lbs.

2. Inflate tire to 8-10 psi.

PART NO. QTY DESCRIPTION

NOTES:

6-6 106567 7/06

Page 51

Anti-Rollover Wheel Assembly

TRACTOR FRAME

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.

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

}

Optional Anti-Scalp Wheels

7-2 106567 7/06

Page 55

66" Deck Assembly

INDEX

NO.

1 547737 103929 1 66" DECK CRATED

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

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

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

BELT GUIDE INDEXING

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

}

Optional Anti-Scalp

7-6 106567 7/06

Wheels

Page 59

60" Deck Assembly

INDEX NO.

1 547745 314021 1 60" DECK CRATED

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

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

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

60" DECK

15 4

23 24

BELT GUIDE INDEXING

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

}

7-10 106567 7/06

Optional Anti-Scalp Wheels

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

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

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

54" DECK ASSY

BELT GUIDE POSITIONING

7-12 106567 7/06

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.

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Page 66

Spindle Assembly–796235

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

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Deck Installation

TRACTOR ASSEMBLY

DECK ASSEMBLY

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

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Deck Belt Routing and Tensioning

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

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

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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

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Tractor Decals

TOP OF SEAT PAN

BOTTOM OF SEAT PAN

9-2 106567 7/06

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Tractor Decals

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

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

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

NOTES:

106567 7/06 9-5

Page 80

54" Deck Decals

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

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

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10-2

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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

106567_0706

10-3

Page 84

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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Page 85

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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10-5

Page 86

10-6

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Page 87

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

Figure 10-1a

Viewed from bottom of tractor

106567_0706

Page 88

10-8

MAINTENANCE LOCATOR

CHART

1. Deck Pusher Arm Zerks (2)

2. Deck Belt

3. Spindle Housing Zerk (3)

4. Blades

54”/66”/72” XR7 deck

60” XR7 deck

Figure 10-1b

106567_0706

Page 89

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.

10-9

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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.

10-11

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10-12

The oil drain and oil filter are located at the rear of the engine. Fig. 10-

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

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

54”/66”/72” XR7 deck

Figure 10-12

2, 6

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

Viewed from

bottom for unit

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

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

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.

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

10-15

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.

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.

106567_0706

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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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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10-19

Figure 10-31

Height

adjusting

stop

Stop

handle

Figure 10-32

Deck lift

threaded

rod

Nut

Chains

Figure 10-33

Deck lift

threaded

rod

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

106567_0706

Hustler 106567 User Manual

Table of Contents

Chapter 1

General Information

Chapter 2 Contents

Rivet Nut Installation

Footrest Assembly

Chapter 3 Contents

Hydraulic System Installation

Chapter 4 Contents

Battery Installation

Deck Lift Assembly

Steering and Park Brake Assembly

Pump Belt and Pulleys Installation

Chapter 5 Contents

Kawasaki Engine Installation

Honda Engine Installation

Kohler Engine Installation

Fuel System Installation

Instrument Panel Assembly

Electrical Schematic (799320)

Chapter 6 Contents

Front Wheel Assembly

Drive Wheel Assembly Installation

Anti-Rollover Wheel Assembly

Chapter 7 Contents

66" Deck Assembly

66" Deck Pulley Assembly

60" Deck Assembly

60" Deck Pulley Assembly

54" Deck Assembly

54" Deck Pulley Assembly

Chapter 8 Contents

Deck Installation

Deck Belt Routing and Tensioning

Seat Installation

Chapter 9 Contents

Tractor Decals

66" Deck Decals

60" Deck Decals

54" Deck Decals

Chapter 10 Contents

MAINTENANCE

ADJUSTMENTS