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
Note: When ordering parts, you must use the part number as shown for each part, not the index number. Always give
the model and serial number to your parts and service representative.
Note: Items sold in bulk such as seals and hoses are sold by the foot.
Using this manual
Illustrations used were current at the time of printing, but subsequent production changes may cause your machine to
vary slightly in detail. Excel Industries, Inc. reserves the right to redesign and change the machine as deemed necessary, without notification. If a change has been made to your machine which is not reflected in this parts manual, see
106567 7/061-1
Page 6
your Hustler dealer for current information and parts.
Hardware Description Codes & Abbreviations
The following codes are used throughout this parts manual. Refer to this list when ordering parts.
HXHex Head
LWLock Washer
MBMachine Bushing
MSMachine Screw
NTNut
SCSelf Tapping Cap Screw
SHSocket Head
SBShoulder Bolt
SSSet Screw
ODOutside Diameter
IDInside 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.
1. When performing service on mower, disconnect battery ground cable
and do not reconnect to battery until engine is ready to be started. See
Owners Manual.
106567 7/064-3
Page 20
Deck Lift Assembly
1
2
4
5
TRACTOR
FRAME
5
6
7
10
4
3
5
12
11
4
5
13
1
5
10
10
4
6
4
1
1
5
1
8
9
10
4
8
4
14
8
4
9
4-4106567 7/06
9
Page 21
Deck Lift Assembly
ITEM
NO.
13483183483181STOP HANDLE
26004376004371DECK HEIGHT 1/2" PIN W/A
2
{
37830017830011DECK LIFT INDICATOR SUBASSEMBLY
47046437046438NT .437-14 HX FLG ZN
57812947812947CLIP E, 1.00 X .625 X .050
67829957829952DECK LIFT SPRING SUBASSEMBLY
77812297812291CE .750 X 2.25 X 1.75 HEADLESS
80557490557493CS .437-14 X 1.750 HX G5 ZN
93483910188464DECK LIFT CHAIN
100154950154954STRAIGHT GREASE FITTING
110342720342721NT .312-18 HX G5 ZN
127562707562701CS .312-18 X 1.50 FUL THR GR5 ZN
133484583484581DECK LEVELER YOKE
147818317818311CS .437-14 X 1.750 FUL THD G5 ZN
SERVICE
PART NO.
348284N/A1HEIGHT ADJUSTMENT STOP 3/8"
MFG.
PART NO.
QTYDESCRIPTION
NOTES:
1. Apply grease to zerks (see owner’s manual).
2. Verify pin diameter prior to ordering replacement part. For mowers with
3/8" diameter pins, order 348284; for mowers with 1/2" pins, order
600437. Item 3 includes 600437 (1/2" pin).
106567 7/064-5
Page 22
Steering and Park Brake Assembly
1
10
2
3
4
8
6
7
5
3
3
5
9
3
14
3
6
7
3
11
15
16
11
12
17
18
13
4
20
21
7
30
38
19
7
6
21
22
23
7
25
24
3
26
27
3
10
36
35
28
40
31
1
39
30
29
3
28
36
7
33
3
34
29
37
6
7
30
3
15
41
TRACTOR
FRAME
32
2
4-6106567 7/06
Page 23
Steering and Park Brake Assembly
ITEM
NO.
1781260N/A2STEERING BAR GRIP
23487553487552STEERING BAR
376795476795448FW .406 X .812 X .060 SAE HD ZN
403624403624410CS .375-16 X 1.000 HX G5 ZN
57051787051786CS .375-16 X 1.750 HX G5 ZN
60411520411528NT .312-24 HX ZN
776852376852318FW .343X .687 X .051/.080 HD ZN/YL
83489463489462STEERING ARM MOUNT
93488883488881STEERLEVER SUPPORT LH
100558220558228CS .375-16 X .750 HX G5 ZN
117817167817164SS .500-13 X 1.75 SH ZN
120531990531992NT .500-13 HX JAM ZN
133489873489871STEERING CONTROL PANEL
143488623488624STEERLEVER BUSHING
150866600866608NT .375-16 HX LK NY
167815837815832BRAKE ROD ASSEMBLY
170631980631984CS 10-24 X .750 HXFLK ZN
187812117812112PUSH BUTTON SWITCH
197812867812862PUMP ROD ADJUSTER ASSEMBLY
206002216002212CENTERING DAMPER
6
217819227819224DAMPER BALL STUD
227041637041632CS .250-20 X 2.00 HX G5 ZN
237685157685154FW .281 X .625 X .051/.080 HD ZN/YL
240685510685512NT .250-20 HX NL ZN
253675573675572PUMP ARM
263487973487972ADJUSTABLE PIVOT
277811537811534BUSHING
280051160051164CS .375-16 X 1.375 HX G5 ZN
290545020545024NT .375-16 HX GRD 5 ZN
300342720342728NT .312-18 HX G5 ZN
317817657817652BRAKE DRUM-HUB ASSEMBLY
327811127811121BRAKE ASSEMBLY
3
4
330362360362364CS .312-18 X 1.000 HX G5 ZN
343502723502722BRAKE ARM EXTENSION
353503303503301L.S. BRAKE PIVOT ARM
1. Torque to 350-375 ft.-lbs. Included with wheel motor.
2. Torque brake assembly mounting bolts to 100 ft.-lbs.
3. 781112 used on left wheel.
4. 781351 used on right wheel.
5. Includes Item 1 (781260 Steering Bar Grip).
6. Use 783696 on mowers with serial numbers prior to 06071499.
4-8106567 7/06
Page 25
This page intentionally left blank.
106567 7/064-9
Page 26
Pump Belt and Pulleys Installation
TRACTOR
FRAME
3
24
25
26
2
2
6
8
7
10
23
9
13
10
9
1
5
2
4
1
5
6
12
8
10
11
7
2
6
14
10
18
19
16
3
15
17
20
21
22
4-10106567 7/06
Page 27
Pump Belt and Pulleys Installation
INDEX
NO.
17798767798761ENGINE SC SINGLE PULLEY
22120762120761KEY 1/4 SQ X 1.50 LONG
37873667873661WARNER CLUTCH
47838297838291FW .460 X 1.750 X .250 ZNYC
57856597856591CS .437-20 X 2.50 HX G5 ZNYC
60831960831964SS .312-18 X .750 SQ-HD ZN
77681277681272KEY 5MM X 30MM RADIUS ENDS
83253083253082PULLEY & FAN
90081930081932NT .500-13 HX G5 ZNYC
107679627679624FW .531 X 1.063 X .090 SAE HD ZN
110165270165272CS .500-13 X 1.00 HX G5 ZNYC
123667653667651CLUTCH ANCHOR ANGLE
137849187849182RUBBER BUMPER
143497613497611PUMP IDLER ARM
150154950154951STRAIGHT GREASE FITTING
160252960252961FW .760 X 1.625 X .08 ZN
170611010611011NT .750-10 HX NL ZN
187818567818561IDLER PULLEY
190281180281181FW .62 X 1.00 X.134 ZN
207944467944461CS .625-11 X 1.50 HX G5 ZN
217813027813021IDLER SPRING
227814437814431A-SEC PUMP IDLER BELT
237912517912511HARNESS, CLUTCH PIGTAIL(DIODE)
240362360362361CS .312-18X1.000 HX G5 ZNYC
257685237685231FW .343 X .687 X .051/.080 HD ZNYC
260342720342721NT .312-18 HX G5 ZNYC
SERVICE
PART NO.
MFG.
PART NO.
QTYDESCRIPTION
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.
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
106567_0706
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
106567_0706
10-5
Page 86
10-6
106567_0706
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
6
10
2
4
3
11
9
11
9
5
13
8
12
7
1a
6
12
11
11
Figure 10-1a
13
14
15
16
Viewed from bottom of tractor
1b
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
4
4
1
1
3
3
3
2
1
4
1
2
3
3
4
3
54”/66”/72” XR7 deck
60” XR7 deck
Figure 10-1b
106567_0706
Page 89
SERVICE ATOR 50OR 100500
INTERVALS INDICATEDHOURSHOURSHOURS
Verify safety start interlock system Daily
Visually inspect unit for loose
hardware and/or damaged partsDaily
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 fastenedDaily
Discharge chute - securely in place &
in lowest positionDaily
Clean engine and pump compartment Daily
Replace air cleaner paper element (5)As needed
Grease deck idlerx
Grease deck pusher armsx
Grease pump idlerx
Grease deck height pivotsx
Grease gauge wheel bearingsx
Change engine oil & filter (1) (4)x
Clean cylinder and head fins (a)x
Check battery connectionsx
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 housingsx
Replace spark plugsx
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.
106567_0706
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.
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:
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
Page 90
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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Page 91
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
106567_0706
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
Page 92
10-12
The oil drain and oil filter are located at the rear of the engine. Fig. 10-
9
Engine air filter
Perform engine air filter maintenance per the Service Interval chart on
page 10-9.
A specially designed dry filter is standard equipment on the Hustler Z
tractors and supplies clean combustion air to the engine. Fig. 10-10
Recommended service procedure
Many engine failures can be attributed to improper air cleaner
servicing. Ingested dust and dirt will cause cylinder, piston and bearing
damage in a few hours. “Dusted” engines will result from:
1. Overservicing the air filter element.
2. Improper installation.
3. Damaged filter, seals or canister.
4. Incorrect air filter element size.
5. Use of poorly designed aftermarket air filter elements.
Air cleaner servicing is an inexpensive maintenance check that can
prevent costly non-warrantable premature engine damage.
Overservicing
Overservicing occurs when an air filter element is removed for cleaning
or replacement before it is necessary. Each time the filter is removed a
small amount of dirt and dust could fall in the intake system. This
accumulated dirt can cause a dusted engine. It only takes a few grams of
ingested dirt over the normal service life of an engine to cause a dusted
engine.
Do not clean element, replace with a new element only. Cleaning
used air filter elements, through improper cleaning procedures, can get dust
on the inside of the filter causing dirt ingestion and engine failure.
It is important to note that whenever an air filter element is cleaned by
any method, the person or company performing the cleaning assumes
responsibility for the integrity of the filter from then on. The Donaldson
warranty for air filters expires upon cleaning or servicing in any
manner because the condition of the filter after servicing is completely
out of their control. Therefore, on a dust ingested engine failure, there
will be no warranty consideration if the air filter element has been
cleaned or serviced in any manner.
A partially dirty air filter element works better than a new element.
Therefore, a dirty filter element is not bad for the engine unless it is
excessively restricting the air flow and engine performance is affected. The
reason is simple. The media in the filter must be porous to allow air to pass
through it. When dirty air passes through the filter, the dirt plugs some of
the holes in the media and actually acts as part of the filter media. When
the next round of dirt enters, the first dirt helps filter out even smaller
particles making the filter more efficient at stopping dirt from entering the
engine. This is referred to as barrier filtration.
Of course, at some point the filter media becomes too clogged to allow
air to pass.
The mowing conditions will determine the frequency of air filter
element changing.
Improper installation of an air filter element
Dust must not leak past the seals on each end of the air filter element.
The filter must be aligned within the canister and properly seated for an
effective seal so that no dirt can enter the engine.
Damaged filter, seals or canister
Never bang or bump the filter element against the tire or any solid
object, as dust and dirt particles will be forced through the media causing
continual passing of dirt into the engine. Visually inspect the outside of the
air cleaner canister periodically for external damage and replace if
necessary.
Incorrect air cleaner element
Use only the correct Donaldson air filter element, Hustler part number
785261, which is designed to fit the canister properly.
Hustler air filter elements have the correct media composition, filter
area, micron size and dimensions. Always use genuine Hustler filters.
Many aftermarket filters have been found to be incompatible with Hustler’s
canisters and engines.
The air filter must remain intact to block passage of dirt and foreign
particles from entering the engine. Being inclined to disbelieve the need for
more expensive air filter elements used on gasoline engines may cause
some individuals to opt for a less expensive part.
The filter element must be sufficient size and construction to withstand
stresses, caused by rapid cycling of the air volume demanded by the engine,
without cracking or tearing under fatigue and pressure (especially diesel
engines). Therefore, Hustler Turf Equipment and the engine manufacturers
have carefully selected a reliable filter designed to fit the needs of the
engines. The filter specified is a Donaldson filter, Hustler part number
785261.
Owners should be reminded that failure to use original equipment
Figure 10-8
Fuel shut-off valve
Closed position
shown
Left tank
position
Right tank
position
Figure 10-9
Engine oil
drain plug
Engine oil filter
Engine oil filler tube
Kawasaki engine shown
Figure 10-10
Pre-cleaner
Canister
106567_0706
Page 93
replacement parts is an “alteration” and will not be considered for warranty
in the event of engine damage.
Recommended service procedure
1. Release clamps and remove element. Clean the canister with a damp
cloth.
2. Before installing a new element, inspect it by placing a bright light
inside and rotate the element slowly, looking for any holes or tears in
the paper. Also check gaskets for cuts or tears. Do not attempt to
use a damaged element which will allow abrasive particles to enter
the engine.
3. Reinstall the dust cup. Make sure it seals all the way around the air
cleaner body, then tighten the clamps.
4. Check all fittings and clamps periodically for tightness and inspect
hoses for holes or cracks.
5. Periodically check the intake hose for signs of ingested dust. Locate
and repair the source of ingested dirt.
6. Never operate a machine without an air filter installed.
Air restriction indicator
Any unit with a Kohler or Kawasaki engine will have an air restriction
indicator installed in the air cleaner. Fig. 10-11
Replace the element whenever the restriction indicator shows reaches the
change filter red line. Check the indicator daily and replace element as
needed or annually whichever occurs first.
Reset the indicator by pushing in on the yellow button after each element
change. Fig, 10-11
A restriction indicator takes the guesswork out of air cleaner servicing
and allows you to safely benefit from the filter’s optimum performance.
General engine maintenance
Detailed instructions and recommendations for break-in and regular
maintenance are specified in the Engine Owner’s manual. Please refer to
this manual for engine servicing, lubricating oil levels with quality and
viscosity recommendations, bolt torques, etc. The engine warranty is
backed by the manufacturer. Special attention should be paid to applicable
data which will not be duplicated here.
Belt replacement
Figures 10-12, 10-13 and 10-14 show diagrams and descriptions of the
unit’s belt drive systems.
Inspect these belts frequently for wear and serviceability. Replace a belt
that shows signs of severe cuts, tears, separation, weather checking and
cracking, or burns caused by slipping. Slight raveling of belt covering does
not indicate failure, trim ravelings with a sharp knife.
WARNING: If the pump belt fails, loss of control will occur
especially when operating on a slope. If you lose steering
control while operating the machine, place the steering
control levers in the park brake position immediately. Inspect
the machine and involve your Hustler dealer to resolve the
problem before continuing to operate.
Inspect the belt pulley grooves and flanges for wear. A new belt, or one
in good condition, should never run against the bottom of the groove.
Replace the pulley when this is the case, otherwise belt will lose power and
slip excessively.
Never pry a belt to get it on a pulley as this will cut or damage the
fibers of the belt covering.
Keep oil and grease away from belts, and never use belt dressings. Any
of these will destroy the belt composition in a very short time.
Mower blade maintenance
Check the mower blades daily, they are the key to power efficiency and
well groomed turf. Keep them sharp, a dull blade will tear rather than cut
the grass, leaving a brown ragged top on the grass within a few hours. A
Figure 10-13
2
2
2
6
4
3
5
Deck Belt Drive Layout
1. Spindle drive belt
2. Deck blade spindle pulley
3. Spindle belt tension idler
4. Spindle belt tension idler spring
(9.0" at operation)
5. Deck belt idler
6. Idler arm
1
5
54”/66”/72” XR7 deck
Figure 10-12
1
3
2, 6
4
5
1. Pump belt
2. Engine pulley
3. Pump idler pulley
4. Pump idler arm
5. Pump pulley
6. Electric deck clutch
7. Pump idler spring
7
Viewed from
bottom for unit
5
10-13
Figure 10-11
Indicator
Reset
button
106567_0706
Page 94
dull blade also requires more power from the engine.
Replace any blade which is bent, cracked or broken.
WARNING: Never attempt to straighten a bent blade by heating,
or weld a cracked or broken blade as the blade may break and
cause serious injury.
DANGER: Never work with blades while engine is running or
deck clutch switch is engaged (on). Always place deck clutch
switch in the disengaged position, place control levers in the park
brake position and turn engine off and disconnect negative battery
cable. Block up mower when you must work under it. Wear
gloves when handling blades. Always check for blade damage
if mower strikes rock, branch or other foreign object during
mowing!
WARNING: Always wear adequate eye protection when
grinding mower blades.
Mower blade removal
Use a 15/16" wrench to remove the 5/8" cap screw holding the blade to
the spindle shaft from underneath. Sharpen the blades on a grinder
following pattern as shown (Fig. 10-15). Touch-up sharpening can be done
with a file.
Check the blades for balance following grinding. A commercial
balancing tool is available through most hardware supply stores, or
balancing can be done by placing the blade on an inverted line punch or
1/2" bolt. Blade should not lean or tilt. Spin the blade slowly, blade should
not wobble. If blade is out of balance, true it up before reinstalling.
Lay the blade on a flat surface and check for distortion (Fig. 10-16 and
10-17). Replace any distorted blade.
Do not re-use spindle bolts which have stripped, worn or undercut
threads. Torque bolts to 118 foot-pounds when reinstalling blades.
WARNING: When mounting blades, rotate them after
installation to ensure blade tips do not touch each other or sides of
the mower.
WARNING: Failure to correctly torque the bolt may result in the
loss of the blade which can cause serious injury.
WARNING: Mower blades are sharp and can cut. Wrap the
blade(s) or wear gloves and use extra caution when servicing
them.
Figure 10-14
2
2
2
6
4
5
3
5
Deck Belt Drive Layout
1. Spindle drive belt
2. Deck blade spindle pulley
3. Spindle belt tension idler
4. Spindle belt tension idler spring
(9.0" at operation)
5. Deck belt idler
6. Idler arm
1
5
60” XR7 deck
Warped Blade (Replace)
Straight Blade
Comparison of Warped and Straight Blades
Cutting
Plane
Figure 10-16
Figure 10-15
Resharpening Pattern
Do not sharpen to original pattern (below).
It is easier to get a straight cutting edge following
the resharpening pattern shown above.
Original Edge
Figure 10-17
Twisted Blade Edge
(Replace)
Cutting Edge
Straight Blade Edge
End view of blades, comparing
twisted and straighten blades.
Cutting Plane
Cutting Edge
10-14
106567_0706
Page 95
ADJUSTMENTS
Introduction
Your Hustler Z was adjusted before it left the factory and was checked
during predelivery setup. However, after start-up and continued use, a
certain amount of break-in wear will cause some adjustments to change.
Remain alert for unusual noises, they could be signaling a problem.
Visually inspect the machine for any abnormal wear or damage. A good
time to detect potential problems is while performing scheduled
maintenance service. Correcting the problem as quickly as possible is the
best insurance.
Clear away heavy build-up of grease, oil and dirt, especially in the area
of reservoir and oil and engine combustion air; minute dust particle are
abrasive to close-tolerance engine and hydraulic assemblies.
Some repairs require the assistance of a trained service mechanic and
should not be attempted by unskilled personnel. Consult your Hustler
service center when assistance is needed.
Steering linkage
The neutral adjustment for the control levers in the neutral position is
discussed in this section.
The tractor steering has been factory adjusted to eliminate creeping
when the control levers are in the neutral position (Fig. 10-18). However,
should the tractor begin to creep, the control lever linkage can be adjusted
as follows:
Control Lever Neutral Adjustment
Before considering any adjustment, check the tire air pressure and make
certain hydraulic system oil is at operating temperature. Unequal tire
pressure will cause the tractor to drift to one side. Refer to tire pressure
information in the Maintenance section of this manual.
Fine adjustment to the unit’s steering is made with the adjustable pump
linkage rods located between the control lever and pump arms. Fig. 10-19
Neutral is properly adjusted when the control levers are in the neutral
position and the drive wheels are not turning.
If the tractor creeps in the neutral position the control linkage may be
adjusted as follows:
1. Raise and block the tractor up so the drive wheels are off of the
floor.
WARNING: Never work under the machine or attachment
unless it is safely supported with jack stands. Make certain
machine is secure when it is raised and placed on the jack stands.
The jack stands should not allow the machine to move when the
engine is running and the drive wheels are rotating. Use onlycertified 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
106567_0706
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.
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 certifiedjack stands. Use only appropriate jack stands, with a minimum
weight rating of 2000 pounds to block the unit up. Use in pairs
only. Follow the instructions supplied with the vehicle stands.
NOTE: The front brake link is not adjustable. Fig. 10-23
2. Raise and block the tractor up so the drive wheels are off of the
floor.
3. Open the hydraulic pump’s bypass valve (Fig. 10-24), on the side
that is being adjusted, by turning bypass valves counter clockwise
one-half to one revolution. The valve stems on each hydraulic pump
are located near the top and are identified as a hex stud.
4. Rotate the tire. The tire should rotate. Remember hydraulic oil
resistance will prevent the tire from rotating freely even with the
bypass valves open. There should be no resistance from the brakes
10-16
Figure 10-22
Cap screw
Upper
control
lever
Lower control
lever
Figure 10-21
Spring
housing
Front ball
stud
Figure 10-23
Front brake link
(right side)
106567_0706
Page 97
Figure 10-25
Travel slot
Outside edge
Control lever
Park brake
slot
Bypass valve
Figure 10-24
at this point.
5. Move the control lever to where it is touching the outside edge of the
lever’s travel slot. Fig. 10-25
NOTE: When the control lever is against the outside edge of the the
slot, the brakes should not be engaged.
6. Rotate the tire. If the brake is adjusted properly the tire will still
rotate but friction will start to become noticeable here. However, if
no brake resistance is noticed, the brake needs adjusted as follows:
7. Loosen the brake linkage jam nuts. Fig. 10-26
8. Rotate the tire and at the same time rotate the turnbuckle to shorten
the length of the brake linkage to increase the brake pressure. When
you feel the brake begin to engage, stop adjusting the turnbuckle.
Re-tighten the jam nuts on the turnbuckle.
9. Place the control lever in the park brake slot (Fig. 10-25). The tire
should not rotate when the control lever is in the park brake position.
10. Place the control lever in the neutral position. The tire should rotate
freely.
11. Close the hydraulic pump’s bypass valve.
12. Repeat steps 3 thru 11 for the other side.
13. Remove the jack stands and lower the unit. It is now ready to
operate.
Hydraulic pump belt adjustment
The pump drive belt tension remains constant by means of a tension idler
and spring (Fig. 10-27). There is no tension adjustment of this belt.
NOTE: Replace the belt every 400 hours or every two (2) years
whichever comes first.
WARNING: If the pump belt fails, loss of control will occur
especially when operating on a slope. If you lose steering
control while operating the machine, place the steering
control levers in the park brake position immediately. Inspect
the machine and involve your Hustler dealer to resolve the
problem before continuing to operate.
Deck drive belt adjustment
The spindle belt tension remains constant by means of a tension idler and
spring (Fig. 10-28). The spring tension should be such that the belt does
not slip under normal operating load conditions, assuming the belt is not
excessively worn or damaged. As belt stretches and wears in, adjustment
may become necessary. To increase belt tension, move the spring chain
one (or more) link(s) at the anchor bracket (Fig. 10-28). Installed spring
length should be 9.0" ± .3" (22.8 cm ± .76 cm) originally with adjustments
of .60" (15.2mm) per chain link. (Fig. 10-29)
IMPORTANT: Do not over tension the spring to compensate for a
badly worn belt or pulley.
Engine RPM setting
The Hustler Z is designed so that the engine will run at 3600 rpm static
pump load only. At this speed the hydraulic pumps are running at their
maximum rated speed.
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Jam nut
Brake linkage
Jam nut
Turnbuckle
Figure 10-26
Deck leveling and height adjustment
The mower deck has three areas that may need to be checked and
adjusted periodically. Before considering any mower deck leveling
adjustments, check that the tire air pressure is within the specified range.
Deck level adjustments
Leveling the deck must be done in the following manner and order:
1. Check tire pressures to make certain they are properly inflated before
starting to level deck. The recommended pressures are as follows:
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.
10-17
Page 98
9. Set the amount of threads protruding on the deck lift rod from the lift
block at approximately 1". Fig. 10-36
10. Jam both nuts against the block.
11. Push or pull on the deck lift foot pedal until the chain on the left
front just becomes tight, making sure that the deck stays tight against
the 4" block.
12. While keeping the chain tight, tighten the nuts against the deck lift
block on the height indicator rod. Fig. 10-35
13. Go to the right front of the tractor.
14. Loosen the 5/16" jam nut on the adjuster lift chain (10-34), and back
the adjuster bolt out to allow the adjuster to move up and down
freely.
15. Be sure that adjuster is free to move up and down.
16. Tighten the adjuster bolt until the chain just becomes tight, making
sure that the deck stays tight against the 4" block.
17. Tighten the adjuster bolt jam nut to prevent the adjuster bolt from
moving. Fig. 10-34
18. Tighten the hardware holding the chain and adjuster onto the deck
lift arm.
19. Go to the right rear of the tractor.
20. Make sure that there is still slack in the chain. If not, loosen the two
nuts on the block holding the threaded rod until there is slack in the
deck lift chain. Fig. 10-33
21. Tighten the appropriate nut until the chain just becomes tight,
making sure that the deck stays tight against the 3" block.
22. Tighten the other nut on the opposite side of the block, and jam them
tightly together against the block.
23. Go to the left rear of the tractor.
24. Make sure that there is still slack in the chain. If not, loosen the two
nuts on the block holding the threaded rod until there is slack in the
deck lift chain. Fig. 10-32
25. Tighten the appropriate nut until the chain just becomes tight.
26. Tighten the other nut on the opposite side of the block, and jam them
tightly together against the block.
27. Compress the deck lift assist springs so that there is 1” of space
between the front nut and on the spring and the rear nut on the deck
lift block (Fig. 10-36). Typical both sides.
28. When completed, all chains will be tight, and deck cutting height
will be set to the deck height indicator.
Figure 10-28
Spring
Tension idler
Chain
Anchor
bracket
10-18
Figure 10-29
3.0”
Spring Extension
9.0”
6.0”
Figure 10-27
Spring
Tension
idler
Pump drive
belt
Normal Spring Length
Figure 10-30
Blocks
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Page 99
10-19
Figure 10-31
Height
adjusting
stop
Stop
handle
Figure 10-32
Deck lift
threaded
rod
Nut
Nut
Chains
Figure 10-33
Deck lift
threaded
rod
Nut
Nut
Chains
Figure 10-34
5/16” bolt
Adjuster
Hardware
Jam nut
Figure 10-35
Foot
pedal
Nuts
Figure 10-36
Lift block
1”
Deck lift rod
1”
Deck lift
assist springs
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10-20
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