Hustler 107906 User Manual

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Page 1

Hustler ATZ

Parts Manual

107906 Rev. 6/06

•••••••

Hustler Turf Equipment

•••••

P.O. Box 7000

•••

Hesston, Kansas

•

67062-2097

Page 2

WARNING:

The engine exhaust from this p rod uct

contains chemicals known to the State

of Cal if orn ia to c au se c an cer, bir t h

defects or other reproductive harm.

IMPORTANT: This engine is not equipped with a spark arrest er muffler. It is a v io lation o f California Public Resourc e Code Section 4442 to use or operate t his engi n e on any f orest-covered, b r ush-c overe d, or grass-co ve red u nimproved 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, maintenan ce and warranty.

Keep E ngine Owner’ s Ma nual with your unit. Should the Engine Owner’s Ma nual beco me damaged or i l legible, replace immedia tely. Re pl acements may be orde red per the information found in the Product Informati on sec tion of t he

owne r ’ 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

Kohler 27 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Fuel System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Instrument Panel Assembly/Installation . . . . . . . . . . . . . . . . . . . . . 5-7

Electrical Schematic - Kohler (799320). . . . . . . . . . . . . . . . . . . . . . 5-9

Chapter 6 Contents

Front Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Drive Wheel Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Anti-Rollover Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Chapter 7 Contents

Weight Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

ROPS Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Chapter 8 Contents

72" Side Discharge Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . 8-2

72" Side Discharge Deck Pulley Assembly. . . . . . . . . . . . . . . . . . . 8-4

60" Side Discharge Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . 8-6

60" Side Discharge Deck Pulley Assembly. . . . . . . . . . . . . . . . . . . 8-8

Spindle Assembly–796235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

Chapter 9 Contents

Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Deck Belt Routing and Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

Chapter 10 Contents

Tractor Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

72" and 60" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

Chapter 11 Contents

Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

107906 6/06

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Chapter 12 Contents

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

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

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

107906 6/06

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Chapter 1

General Information

This Manual covers Huslter ATZ model 928226 & Hustler ATZ model 928234

Frequently Ordered Parts

PART NO. DESCRIPTION

027912 LUBRIZOL 7 OZ. BOTTLE 027920 LUBRIZOL 10 OZ. BOTTLE 783936 FILTER ELEMENT 781443 PUMP DRIVE BELT 784207 B-SECTION BELT, 72" DECK 797720 B-SECTION BELT, 60" DECK 068478 FUEL FILTER 785261 MAIN AIR FILTER ELEMENT 785279 SAFETY AIR FILTER ELEMENT 747303 KOHLER ENGINE OIL FILTER 783977 24" OFFSET FLAT BLADE 782516 21" CW BLADE

Service Literature

PART NO. DESCRIPTION

397463 ATZ OWNER’S MANUAL 742684 KOHLER ENGINE 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 your Hustler dealer for current information and parts.

1079066/06 1-1

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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 M16 160 215 .875 420 565 M20 320 435

1.00 625 850 M24 555 750

NOTE:

Loctite 592 to be used on all pipe threads. Lubricate all grease zerks.

1-2 107906 6/06

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Chapter 2 Contents

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

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

107906 6/06 2-1

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Rivet Nut Installation

INDEX

NO.

SERVICE

PAR T NO.

1 546572 381848 1 ATZ FRAME

2 N/A 808493 15 RIVET NUT, 3/8-16 THREAD

3 N/A 600961 8 RIVET NUT, 1/2-13 THREAD

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

2-2 107906 6/06

Page 9

Footrest Assembly

INDEX

NO.

SERVICE

PAR T NO.

1 359547 359547 2 STEP TREAD

2 395533 395533 1 FLOOR PLATE

3 305615 305615 2 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 052860 052860 2 CS .375-16 X 1.25 HX G5 ZNYC

7 781880 781880 2 RUBBER BUMPER

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Do not tighten, Floor must be able to pivot on these bolts.

107906 6/06 2-3

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2-4 107906 6/06

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Chapter 3 Contents

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

107906 6/06 3-1

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Hydraulic System Installation

SUPER Z HOOD

3-2 107906 6/06

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Hydraulic System Installation

INDEX

NO.

10 357616 357616 1 SUPER Z RESERVOIR

11 034272 034272 4 NT .312-18 HX G5 ZNYC

12 768523 768523 4 FW .343 X .687 X .051/.080 HD ZNYC

13 788042 788042 2 PUMP, HYDRO-GEAR BDP-21L-408

14 008193 008193 4 NT .500-13 HX G5 ZNYC

15 767962 767962 12 FW .531 X 1.063 X .090 SAE HD ZN

16 783928 783928 1 ZAF SERIES FILTER HEAD

17 783936 783936 1 FILTER ELEMENT

18 077859 077859 8 CS .500-13 X 3.250 HX G5 ZNYC

19 789339 789339 2 WHITE MOTOR RC28

20 700484 700484 2 HOSE CLAMP

21 784132 N/A 2 RETURN HOSE ASSY, #6 17.375" LONG

22 784124 N/A 2 RETURN HOSE, #6 16.5" LONG

23 784108 N/A 2 FITTING, #6 BEADED TUBE-ORB 45°

24 784082 N/A 2 FITTING, #8 BEADED TUBE-ORB 90°

25 781534 N/A 4 FITTING, STR-8MORB/-8MSL

26 781658 N/A 1 HEX PLUG FITTING, STR-8MORB

27 784025 N/A 1 SUCTION HOSE ASSY, FILTER-PUMP

28 783993 N/A 1 SUCTION HOSE, TANK-FILTER

29 764126 N/A 1 FITTING, T -8MJIC/8MJIC/8MORIN

30 783985 N/A 1 FITTING, 10 FX05-S

31 784116 N/A 1 SUCTION HOSE, #12 16" LONG

32 782870 N/A 1 TUBE, HYDRAULIC LINE

33 782880 N/A 1 TUBE, HYDRAULIC LINE

34 782458 N/A 1 TUBE, HYDRAULIC LINE

35 782441 N/A 1 TUBE, HYDRAULIC LINE

36 781526 N/A 4 FITTING, 90-10MORB/-8MSL

37 N/A 783720 1 HYDRO KIT (INCLUDES ITEMS 21-37)

SERVICE

PART NO.

1 705608 705608 4 CS .250-20 X 2.25 HX G5 ZNYC

2 768515 768515 10 FW .281 X .625 X .051/.080 HD ZNYC

3 713198 713198 2 SEAL 3/8 X 3/4 X 7.25" LONG

4 783704 783704 2 OIL COOLER

5 033035 033035 2 WEATHERSTRIP 1/8 X 3/4 X 5.88" LONG

6 068551 068551 4 NT .250-20 HX NL ZNYC

7 032763 032763 1 BREATHER CAP

8 032771 032771 1 STRAINER

9 055947 055947 2 CS .250-20 X .50 HX G5 ZNYC

MFG. PART

NO.

QTY DESCRIPTION

NOTES:

1. Add 3.5 oz. Lubrizol (027912) to new system or 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 8 (032771 Strainer).

107906 6/06 3-3

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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; 784983 (BDP21L Overhaul Seal Kit)

3-4 107906 6/06

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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

107906 6/06 4-1

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Battery Installation

RED WIRE, PART OF WIRE HARNESS

BLACK WIRE,

PART OF WIRE HARNESS

TRACTOR FRAME

4-2 107906 6/06

Page 17

Battery Installation

ITEM

NO.

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.

1 024927 024927 2 NT .250-20 HX GR 5 ZN

2 771428 771428 1 RED BATTERY CABLE BOOT

3 768820 768820 1 BATTERY GROUND CABLE

4 744276 744276 1 POSITIVE BATTERY CABLE

5 768523 768523 3 FW .343 X .687 X .051/.080 HD ZNYC

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

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. When performing service on mower, disconnect battery ground cable

and black wire of harness and do not reconnect to battery until engine is ready to be started. See Owners Manual.

107906 6/06 4-3

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Deck Lift Assembly

TRACTOR FRAME

4-4 107906 6/06

Page 19

Deck Lift Assembly

INDEX

NO.

1 348318 348318 1 STOP HANDLE

2 348284 348284 1 HEIGHT ADJUSTMENT STOP (3/8" DIA PIN)

2 2

3 783001 783001 1 DECK LIFT INDICATOR

4 704643 704643 8 NT .437-14 HX FLG ZN

5 781294 781294 7 CLIP E, 1.00 X.625X .050

6 782995 782995 2 DECK LIFT SPRING ASSEMBLY

7 015495 015495 4 STRAIGHT GREASE FITTING

8 055749 055749 3 CS .437-14X1.750 HX G5 ZNYC

9 348391 348391 4 DECK LIFT CHAIN

10 756270 756270 1 CS .312-18 X 1.50 FLTHR GR5 ZNYC

11 034272 034272 1 NT .312-18 HX G5 ZNYC

12 348458 348458 1 DECK LEVELER YOKE W/A

13 781229 781229 1 CE .750X2.25 X1.75 HEADLESS

14 781831 781831 1 CS .437-14 X 1.750 FULTH G5 ZNYC

SERVICE

PART NO.

600437 600437 1 HEIGHT ADJUSTMENT STOP (½" DIA PIN)

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. Apply grease to zerks (see owners manual).

2. Order replacement pin to match holes in Deck Lift Indicator.

107906 6/06 4-5

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Steering and Park Brake Assembly

4-6 107906 6/06

Page 21

Steering and Park Brake Assembly

ITEM

NO.

1 781260 N/A 2 STEERING BAR GRIP

2 348755 348755 2 STEERING BAR

3 767954 767954 43 FW .406 X .812 X .060 SAE HD ZN

4 036244 036244 10 CS .375-16 X 1.000 HX G5 ZN

5 055822 055822 8 CS .375-16 X .750 HX G5 ZN

6 781716 781716 4 SS .500-13 X 1.75 SH ZN

7 053199 053199 2 NT .500-13 HX JAM ZN

8 348987 348987 1 STEERING CONTROL PANEL

9 348946 348946 2 STEERING ARM MOUNT

10 041152 041152 8 NT .312-24 HX ZN

11 768523 768523 10 FW .34 3X .687 X .051/.080 HD ZN/YL

12 348862 348862 4 STEERLEVER BUSHING

13 705178 705178 6 CS .375-16 X 1.750 HX G5 ZN

14 348888 348888 1 STEERLEVER SUPPORT LH

15 086660 086660 8 NT .375-16 HX LK NY

16 781583 781583 2 BRAKE ROD ASSEMBLY

17 781286 781286 2 PUMP ROD ADJUSTER ASSEMBLY

18 783696 783696 2 CENTERING DAMPENER

19 781922 781922 4 DAMPENER BALL STUD

20 704163 704163 2 CS .250-20 X 2.00 HX G5 ZN

21 768515 768515 4 FW .281 X .625 X .051/.080 HD ZN/YL

22 347684 347684 2 SUPER Z PUMP ARM

23 068551 068551 2 NT .250-20 HX NL ZN

24 034272 034272 8 NT .312-18 HX G5 ZN

25 782979 782979 2 CS .375-16 X 4.75 HX G5 ZN

26 348797 348797 2 ADJUSTABLE PIVOT

27 781153 781153 4 BUSHING

28 063198 063198 4 CS 10-24 X .750 HXFLK ZN

29 781211 781211 2 PUSH BUTTON SWITCH

30 059832 059832 4 NT #10-24 HX NL ZN

31 350330 350330 1 L.S. BRAKE PIVOT ARM

32 765339 765339 4 BUSHING

33 054502 054502 4 NT .375-16 HX GRD 5 ZN

34 005116 005116 4 CS .375-16 X 1.375 HX G5 ZN

35 783852 N/A 2 KEY FOR WHITE MOTOR

36 350397 350397 2 BRAKE LINK TURNBUCKLE

37 354035 354035 2 WHITE BRAKE LEVER EXTENSION

38 036236 036236 4 CS .312-18 X 1.000 HX G5 ZN

39 783126 783126 1 LH WHITE BRAKE ASSY

3 4

40 712927 712927 8 FW .344 X 1.00 X .12 HRD ZNYC

41 048876 048876 8 CS .312-18 X .750 HX G8 ZNYC

42 789321 789321 2 WHITE HUB ASSEMBLY

43 789644 N/A 2 NUT FOR WHITE MOTOR (RC28)

SERVICE

PART NO.

348714 348714 1 STEERLEVER SUPPORT RH

350264 350264 1 R.S. BRAKE PIVOT ARM

783118 783118 1 RH WHITE BRAKE ASSY

MFG.

PART NO.

QTY DESCRIPTION

107906 6/06 4-7

Page 22

NOTES:

1. Torque to 280-310 ft.-lbs. Included with wheel motor.

2. Torque to 24 ft.-lbs.

3. 783126 used on left wheel.

4. 783118 used on right wheel.

5. Includes Item 1 (781260 Steering Bar Grip).

4-8 107906 6/06

Page 23

This page intentionally left blank.

107906 6/06 4-9

Page 24

Pump Belt and Pulleys Installation

TRACTOR FRAME

4-10 107906 6/06

Page 25

Pump Belt and Pulleys Installation

INDEX

NO.

1 783761 783761 1 SUPER Z SINGLE ENGINE 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 .312-18X .750 SQ-HD ZN

7 782466 782466 2 PULLEY & FAN FOR BDP-21

8 783712 783712 2 KEY FOR BDP21L

9 791251 791251 1 CLUTCH PIGTAIL HARNESS WITH DIODE

10 008193 008193 2 NT .500-13 HX G5 ZNYC

11 767962 767962 4 FW .531 X 1.063 X .090 SAE HD ZN

12 016527 016527 2 CS .500-13 X 1.00 HX G5 ZNYC

13 366765 366765 1 CLUTCH ANCHOR ANGLE

14 784918 784918 2 RUBBER BUMPER

15 349761 349761 1 PUMP IDLER ARM

16 015495 015495 1 STRAIGHT GREASE FITTING

17 025296 025296 1 FW .760 X 1.625 X .08 ZN

18 061101 061101 1 NT .750-10 HX NL ZN

19 781856 781856 1 IDLER PULLEY

20 028118 028118 1 FW .62 X 1.00 X.134 ZN

21 794446 794446 1 CS .625-11 X 1.50 HX G5 ZN

22 781302 781302 1 IDLER SPRING

23 781443 781443 1 A-SEC PUMP IDLER BELT

24 036236 036236 1 CS .312-18 X 1.00 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 owners manual).

4. Do not torque Item 18 (NT .750-10 HX NL ZN), Item 15 (349761 Pump Idler Arm) should pivot freely.

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.

107906 6/06 4-11

Page 26

4-12 107906 6/06

Page 27

Chapter 5 Contents

Kohler 27 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Fuel System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Instrument Panel Assembly/Installation. . . . . . . . . . . . . . . . . . . . . . . 5-8

Electrical Schematic - Kohler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

107906 6/06 5-1

Page 28

Kohler 27 HP Engine Installation

BLK

TAN/RED

HOUR METER CONNECTION

POSITIVE BATTERY CABLE

RED/BLK

BLK

NEGATIVE

BATTERY CABLE

PUR (P/O ENGINE)

5-2 107906 6/06

Page 29

Kohler 27 HP Engine Installation

ITEM

NO.

1 788216 788216 1 KOHLER 27HP ENGINE

2 788018 788018 1 MUFFLER

3 788026 788026 1 MUFFLER MANIFOLD

4 785378 785378 1 1.50" MUFFLER CLAMP

5 029751 029751 2 CS .375-16 X 1.00 HXFLK ZNYC

6 705137 705137 4 FW .391 X 1.250 X .060 ZNYC

7 016899 016899 2 NT .375-16 HXFLK ZNYC

8 786673 786673 1 DONALDSON AIR CLEANER CAP

9 057661 057661 2 HOSE CLAMP

10 782763 782763 1 AIR CLEANER

11 785741 785741 1 MOUNTING BAND

12 034272 034272 11 NT .312-18 HX G5 ZN

13 768523 768523 21 FW .343 X .687 X .051/.080 HD ZN/YL

14 796672 796672 1 3/8-18 OIL DRAIN VALVE

15 787713 787713 1 .50" LOW PRESSUR HOSE

16 357780 357780 1 HOOD SCOOP

17 055939 055939 6 CS .250-20 X .750 HX G5 ZNYC

18 768515 768515 6 FW .281 X .625 X .051/.080 HD ZNYC

19 036236 036236 3 CS .312-18 X 1.00 HX G5 ZNYC

20 783837 783837 1 ELECTRIC COOLER FAN

21 044818 044818 4 CN ZN TIN-C7343-1420

22 356121 356121 1 SUPER Z HOOD

23 778738 778738 1 .312 WIRING CLAMP

24 034280 034280 4 CS .312-18X .750 HX G5 ZNYC

25 795310 795310 1 REMOTE AIR FILTER HOSE

26 029876 029876 1 LW .312 INT-EXT TOOTH ZN

27 052837 052837 4 CS .312-18 X 1.500 HX G5 ZN

28 377994 377994 1 MMZ ROLLER HEAT SHIELD

29 799320 799320 1 SUPER Z KOHLER WIRE HARNESS

30 047654 047654 2 CLIP

31 788943 788943 1 AIR FILTER INDICATOR

SERVICE

PART NO.

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. Includes mounting hardware.

2. Part of Item 30 (788000 Tractor Wire Harness).

3. Engine oil capacity; 2 US quarts.

4. Engine RPM to be set at 3600± 50.

5. Includes one (1) of 057661 Hose Clamp.

6. Supplied with engine.

7. Air filter service parts:

785261 MAIN AIR FILTER ELEMENT

763318 VACUATOR VALVE

107906 6/06 5-3

Page 30

Fuel System Installation

TRACTOR FRAME WITH ENGINE

5-4 107906 6/06

Page 31

Fuel System Installation

ITEM

NO.

1 779306 779306 2 3.5" FUEL CAP

2 793240 793240 1 LEFT SIDE Z FUEL TANK

3 793232 793232 1 RIGHT SIDE Z FUEL TANK

4 349944 349944 1 REAR SEAT SUPPORT

5 712919 712919 12 FW .406 X 1.00 X .12 HRD ZN

6 767954 767954 3 FW .406 X .812 X .060 SAE HD ZN

7 055822 055822 11 CS .375-16 X .750 HX G5 ZN

8 000398 000398 1 CLAMP

9 036244 036244 4 CS .375-16 X 1.000 HX G5 ZN

10 045088 045088 1 HOSE CLAMP 1"

11 347989 347989 1 FUEL SHUT-OFF BRACKET

12 015818 015818 1 FUEL LINE 50” TOTAL

13 015818 015818 1 FUEL LINE 39” TOTAL

14 015818 015818 1 FUEL LINE 7” TOTAL

15 000323 000323 6 CLIP

16 016527 016527 8 CS .500-13 X 1.00 HX G5 ZN

17 767962 767962 8 FW .531 X 1.063 X .090 SAE HD ZN

18 745059 797055 1 3-WAY FUEL VALVE

SERVICE

PART NO.

000331 000331 3 BLACK CABLE TIE (NOT SHOWN)

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. Torque to 20 ft.-lbs.

2. Included with new fuel tank.

3. Used on mowers with serial numbers 05042114 and higher.

4. Fuel tank service parts not shown:

PART NO. DESCRIPTION

794107 1/4 ID, 3/8 OD, 1/16 WALL TUBING (25" LONG)

794081 FUEL FILTER SCREEN

785295 FLANGE GROMMET

792986 SITE-LINE FUEL FITTING

107906 6/06 5-5

Page 32

Instrument Panel Assembly/Installation

15a 15a10a

FUSE SIZE AND LOCATION

RIGHT SIDE FUEL TANK

5-6 107906 6/06

Page 33

Instrument Panel Assembly/Installation

ITEM

NO.

1 776476 776476 1 PTO SWITCH

2 785808 785808 1 INDAK COATED KEY

3 083022 N/A 2 IGNITION KEY

4 045898 045898 1 KEY SWITCH

5 000430 000430 2 SMALL/LONG WIRE TIE

6 786657 786657 1 CHOKE CABLE

7 712257 712257 1 RED INDICATOR LIGHT

8 714998 714998 2 MS #10-24 X .625 HX ZN

9 704932 704932 4 FW .219 X .500 X .048 ZN

10 769166 769166 1 HOUR METER

11 059832 059832 2 NT #10-24 HX NL ZN

12 778365 778365 1 THROTTLE CABLE

13 055947 055947 3 CS .250-20 X .500 HX G5 ZN

14 768515 768515 3 FW .281 X .625 X .051 /.080 HD ZN/YL

15 349308 349308 1 INSTRUMENT PANEL

‘ 026237 N/A 3 RELAY (NOT SHOWN)

SERVICE

PART NO.

762195 N/A 1 DELAY MODULE (NOT SHOWN)

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. Part of 788000 (Wire Harness)

107906 6/06 5-7

Page 34

Electrical Schematic - Kohler (799320)

5-8 107906 6/06

Page 35

Chapter 6 Contents

Front Wheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Drive Wheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Anti-Rollover Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

107906 6/06 6-1

Page 36

Front Wheel Assembly

TRACTOR FRAME

6-2 107906 6/06

Page 37

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 798603 798603 2 FW .530 X 1.750 X .125 HD ZN

4 263517 263517 2 BEARING DISC

5 784223 784223 4 BEARING W/O COLLAR

6 387035 387035 2 SPACER, 1.07 X 1.312 X 2.793

7 045765 045765 2 FW 1.030 X 1.500 X.134 ZN

8 349266 349266 2 FORK

9 041475 041475 2 CS .750-10 X 9.50 HX ZN

10 025296 025296 4 FW .760 X 1.625 X .08 ZN

11 061101 061101 2 NT .750-10 HX NL ZN

12 789537 789537 2 WHEEL & TIRE ASSY

SERVICE

PART NO.

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. Apply grease to zerks (see owners manual).

2. Torque to 100 ft.-lbs.

3. Assemble with extended inner race toward item 6 (387035 Spacer, 1.07

x 1.312 x 2.793).

107906 6/06 6-3

Page 38

Drive Wheel Assembly Installation

INDEX

NO.

1 789529 789529 1 LH TIRE/WHEEL ASSEMBLY

2 783563 N/A TIRE 24 X 12-12 AT101

3 784066 N/A WHEEL ASSY 12 X 8.50 (ATZ)

4 019521 N/A TIRE VALVE

5 061077 061077 5 WHEEL NUT (QTY PER WHEEL)

6 770859 N/A 10 ½" WHEEL LUG STUD

SERVICE

PART NO.

789420 789420 1 RH TIRE/WHEEL ASSEMBLY

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. Torque to 65-75 ft. lbs.

2. Inflate tire to 8-10 psi.

6-4 107906 6/06

Page 39

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.

107906 6/06 6-5

Page 40

6-6 107906 6/06

Page 41

Chapter 7 Contents

Weight Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

ROPS Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

107906 6/06 7-1

Page 42

Weight Installation

TIRE/WHEEL ASSEMBLY

TRACTOR FRAME

7-2 107906 6/06

Page 43

Weight Installation

INDEX

NO.

10 089938 089938 4 CS .500-13 X 4.00 HX G5 ZNYC

SERVICE

PAR T NO.

1 008193 008193 8 NT .500-13 HX G5 ZNYC

2 767962 767962 18 FW .531 X 1.063 X .090 SAE HD ZN

3 789214 789214 2 MMZ WHEEL WEIGHT

4 392597 392597 2 WHEEL WEIGHT BACKING PLATE

5 792077 792077 8 CB .50-13 X 6 STD ZN

6 781567 781567 4 NT .50-13 HX LK NY

7 392035 392035 2 ATZ TOP WEIGHT PLATE

8 392191 392191 2 ATZ MIDDLE WEIGHT PLATE

9 392357 392357 4 ATZ BOTTOM WEIGHT PLATE

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

107906 6/06 7-3

Page 44

ROPS Installation

7-4 107906 6/06

Page 45

ROPS Installation

INDEX

NO.

10 392613 392613 1 R.H. ROPS

11 392605 392605 1 L.H. ROPS

12 078386 078386 4 FW .510 X 1.75 X .18 ZNYC

13 077859 077859 2 CS .500-13 X 3.25 HX G5

14 381723 381723 1 ATZ REAR R.S. ROPS

15 381731 381731 1 ATZ REAR L.S. ROPS

16 017616 017616 8 CS .500-13 X 1.75 HX G5 ZNYC

17 016642 016642 2 CS .625-11 X 2.00 HX G5 ZNYC

18 768002 768002 4 FW .687 X 1.750 X .105/.160 HD ZNYC

19 016972 016972 2 NT .625-11 HX G5 ZNYC

20 382168 382168 1 MUFFLER GUARD

21 381749 381749 1 ATZ ENGINE GUARD

22 768523 768523 3 FW .343 X .687 X .051/.080 HD ZNYC

23 036236 036236 3 CS .312-18 X 1.00 HX G5 ZNYC

24 789404 789404 2 UB .50-13 X 2.0 X 3.0

25 083279 N/A 1 TURF PRODUCT SERIAL NO PLATE

SERVICE

PAR T NO.

1 008193 008193 16 NT .500-13 HX G5 ZNYC

2 767962 767962 30 FW .531 X 1.063 X .090 SAE HD ZN

3 391375 391375 1 ATZ ROOF

4 381657 381657 1 ATZ FRONT R.S. ROPS

5 381665 381665 1 ATZ FRONT L.S. ROPS

6 381673 381673 2 ATZ ROPS CROSS SECTION

7 008573 008573 6 CS .500-13 X 2.50 HX G5 ZNYC

8 392985 392985 1 ROPS CONNECTOR

9 789412 789412 2 UB .50-13 X 3.25 X 3.0

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Torque to 73 ft.-lbs. (8 places).

2. Torque to 145 ft.-lbs. (2 places).

107906 6/06 7-5

Page 46

7-6 107906 6/06

Page 47

Chapter 8 Contents

72" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

72" Deck Pulley Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

60" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

60" Deck Pulley Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Spindle Assembly–796235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

107906 6/06 8-1

Page 48

72" Side Discharge Deck Assembly

8-2 107906 6/06

Page 49

72" Side Discharge Deck Assembly

INDEX

NO.

1 547935 107375 1 72" DECK CRATED

2 798694 798694 1 RUBBER CHUTE ASSEMBLY

3 052860 052860 8 CS .375-19 X 1.250 HX G5 ZN

4 767954 767954 30 FW .406 X .812 .060 SAE HD ZN

5 086660 086660 18 NT .375-16 HXZY NL

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 103184 103184 2 REAR ANTI-SCALP BRACKET

16 025395 025395 6 CB .375-16 X 1.00 STD CD

17 107629 107629 2 72, AIR FLOW FLOOR

18 808493 808493 2 3/8-16 THREAD RIVET NUT

19 005116 005116 4 CS .375-16X1.375 HX G5

SERVICE

PAR T NO.

788166 788166 6 ANTI SCALP WHEEL ASSY

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. Do not torque, Item 2 (798694 Discharge Chute) must pivot freely.

2. Factory assembled in top hole for shipping purposes.

3. Includes Items 7 through 10.

4. Service part deck included decals, see “72" and 60" Deck Decals” on

page 10-4.

107906 6/06 8-3

Page 50

72" Side Discharge Deck Pulley Assembly

72" DECK ASSY

BELT GUIDE INDEXING

8-4 107906 6/06

Page 51

72" Side Discharge Deck Pulley Assembly

ITEM

NO.

1 784207 784207 1 B-SECTION BELT

2 797910 797910 6 CS .312-18 X 1.50 FLT SH ZNYC

3 600189 600189 1 RS IDLER UHMW SLIDE

4 600171 600171 1 LS IDLER UHMW SLIDE

5 025007 025007 1 CS .625-11 X 1.75 HX G5 ZNYC

6 347443 347443 1 DECK BELT IDLER GUIDE

7 028118 028118 5 FW .62 X 1.00X.134 ZN

8 781856 781856 1 5.00" IDLER PULLEY

9 259812 059931 1 CHAIN DECK LIFT SPRING (13 LINKS)

10 781302 781302 1 IDLER SPRING

11 350884 350884 1 DECK IDLER

12 786335 786335 1 .03 THICK UHMW

13 107620 107620 1 RS PULLEY COVER 72" XR7

14 107621 107621 1 LS PULLEY COVER 72" XR7

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 723486 723486 3 DRIVE PULLEY DB-112

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 798702 798702 3 BLADE, F24.50"-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.

798728 N/A 3 OPTIONAL BLADE, 24.50"-GAT-F-CW

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. Torque to 118 ft. lbs.

2. Torque to 65-75 ft. lbs.

3. See “Deck Belt Routing and Tensioning” on page 9-4 for belt tensioning.

4. See “Spindle Assembly–796235” on page 8-10 for breakdown.

107906 6/06 8-5

Page 52

60" Side Discharge Deck Assembly

8-6 107906 6/06

Page 53

60" Side Discharge Deck Assembly

INDEX NO.

1 547745 314021 1 60" DECK CRATED

2 798694 798694 1 RUBBER CHUTE ASSEMBLY

3 052860 052860 8 CS .375-16 X 1.25 HX G5

4 767954 767954 30 FW .406 X .812 X .060 SAE HD ZN

5 086660 086660 24 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 103184 103184 2 REAR ANTI-SCALP BRACKET

14 005116 005116 4 CS .375-16 X 1.375 HX G5 ZNYC

15 314104 314104 1 PUSHER

16 015495 015495 2 STRAIGHT GREASE FITTING

17 025395 025395 6 CB .375-16 X 1.00 STD CD

18 102764 102764 2 60" AIR FLOW FLOOR

19 808493 808493 2 3/8-16 THREAD RIVET NUT

SERVICE

PAR T NO.

788166 788166 4 ANTI SCALP WHEEL ASSY

MFG.

PART NO.

QTY. DESCRIPTION

NOTES:

1. Do not torque, Item 2 (798694 Discharge Chute) must pivot freely.

2. Factory assembled in top hole for shipping purposes.

3. Includes Items 7 through 10.

4. Service part deck included decals, see “72" and 60" Deck Decals” on

page 10-4.

107906 6/06 8-7

Page 54

60" Side Discharge Deck Pulley Assembly

60" DECK ASSY

BELT GUIDE INDEXING

8-8 107906 6/06

Page 55

60" Side Discharge Deck Pulley Assembly

ITEM

NO.

1 797720 797720 1 B-SECTION BELT

2 797910 797910 6 CS .312-18 X 1.50 FLT SH ZNYC

3 600171 600171 1 LS IDLER UHMW SLIDE

4 600189 600189 1 RS IDLER UHMW SLIDE

5 025007 025007 1 CS .625-11 X 1.75 HX G5 ZNYC

6 347443 347443 1 DECK BELT IDLER GUIDE

7 028118 028118 6 FW .62 X 1.00X.134 ZN

8 781856 781856 1 5.00" IDLER PULLEY

9 373191 059931 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. See “Deck Belt Routing and Tensioning” on page 9-4 for belt tensioning.

4. See “Spindle Assembly–796235” on page 8-10 for breakdown.

107906 6/06 8-9

Page 56

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.

8-10 107906 6/06

Page 57

Chapter 9 Contents

Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Deck Belt Routing and Tensioning. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

107906 6/06 9-1

Page 58

Deck Installation

TRACTOR ASSEMBLY

DECK ASSEMBLY

9-2 107906 6/06

Page 59

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. 60" Deck installation is shown, 72" Deck installation is similar.

107906 6/06 9-3

Page 60

Deck Belt Routing and Tensioning

DECK ASSEMBLY

NOTES:

1. Spring length after tensioning new belt. Measured from outside of hook to outside of hook.

2. Route belt as shown.

9-4 107906 6/06

Page 61

Chapter 10 Contents

Tractor Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

72" and 60" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

107906 6/06 10-1

Page 62

Tractor Decals

TOP OF SEAT PAN

BOTTOM OF SEAT PAN

10-2 107906 6/06

Page 63

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

4 727008 727008 1 HYD PRESSURE DECAL

5 791830 791830 1 FUEL INDICATOR DECAL

6 788968 788968 1 ENGINE COMPARTMENT DECAL

7 600899 600899 1 PUMP BELT WARNING DECAL

8 782136 782136 1 Z OPERATION DECAL

9 763177 763177 1 SEAT BELT INSTRUCTIONS DECAL

10 785188 785188 1 Z ARMREST WARNING DECAL

11 782128 782128 1 Z SERVICE DECAL

12 727016 727016 1 BATTERY DECAL

13 771436 771436 1 STABILIZER DECAL

14 N/A 083279 1 TURF PRODUCT SERIAL NO PLATE

15 727172 727172 1 MADE IN USA DECAL

16 782573 782573 1 FIRST ZERO TURN DECAL

17 793588 793588 1 HUSTLER NAME PLATE

18 782615 782615 1 SUPER Z ID DECAL

SERVICE

PAR T NO.

MFG.

PART NO.

QTY. DESCRIPTION

NOTES:

107906 6/06 10-3

Page 64

72" and 60" Deck Decals

INDEX

NO.

1 786285 786285 1 72" 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 (60" DECK ONLY)

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.

786277 786277 1 60" SIDE DISCHARGE DECK ID DECAL

781419 781419 1 BELT ROUTING DECAL (72", 66", & 54" DECKS)

MFG.

PAR T NO.

QTY. DESCRIPTION

NOTES:

10-4 107906 6/06

Page 65

Chapter 11 Contents

Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

107906 6/06 11-1

Page 66

Seat Installation

11-2 107906 6/06

Page 67

Seat Installation

INDEX

NO.

1 792051 792051 1 SUSPENSION SEAT

2 784140 784140 1 SEAT BELT

3 797076 797076 2 CS .437-20 X 1.00 HX G8 ZNYC

4 728147 728147 2 FW .468 X 1.00 X .090 HT T ZNYC

5 746131 746131 4 SPACER, .493 X .675 X .250

6 763391 763391 2 CS .437-20 X 1.75 G5 ZNYC

7 078386 078386 4 FW .510 X 1.750 X .18 ZNYC

8 746081 746081 2 SEAT TETHER

9 000331 000331 2 BLACK CABLE TIE

10 086660 086660 3 NT .375-16 HX LK NY

11 767954 767954 5 FW .406 X .812 X .060 SAE HD ZN

12 724716 724716 1 FIBER WASHER

13 350421 350421 1 SEAT PAN STOP

14 036244 036244 1 CS .375-16 X 1.00 HX G5 ZNYC

15 350041 350041 1 SEAT PAN

16 357384 357384 1 ROPS LATCH

17 768523 768523 4 FW .343 X .687 X .051/.080 HD ZN/Y

18 034272 034272 4 NT .312-18 HX G5 ZN

19 783910 783910 1 ROPS LATCH TORSION SPRING

20 781880 781880 2 BUMPER

21 080358 080358 1 GM .50 X 1.00 X .75 X .12 GROMMET

22 052860 052860 2 CS .375-16 X 1.25 HX G5 ZNYC

23 781617 781617 3 RUBBER BUMPER

24 722199 722199 1 2" WIDE SCOTCH POLYURETHANE 5.55" LONG

SERVICES

PART NO.

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. Must pivot freely.

2. Torque to 48 ft.-lbs.

3. Service parts available for Michigan suspension seat:

PART NO.

793307 SLIDE KIT

793323 KNOB KIT

793281 BACK CUSHION KI

793299 SEAT CUSHION KIT

793315 SEAT SWITCH

793265 MOLDED ARMREST KIT (INCLUDES BOTH ARMRESTS)

793273 ARMREST STOP ASSEMBLY

DESCRIPTION

107906 6/06 11-3

Page 68

Chapter 12 Contents

Maintenance & Adjustments Safety Precautions . . . . . . . . . . . . . . .12-3

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-7

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-17

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This safety alert symbol is used to call attention to a message intended to provide a reasonable degree of PERSONAL SAFETY for operators and other persons during the normal operation and servicing of this equipment.

DANGER – denotes immediate hazards which WILL result in severe personal injury or death.

WARNING - denotes a hazard or unsafe practice which COULD result in severe personal injury or death.

This manual uses two other words to highlight information. IMPORTANT calls attention to special mechanical information and NOTE: emphasizes general information worthy of special attention.

All operators/mechanics should read this manual, or be instructed about safe operating and maintenance procedures. This is the owner’s responsibility.

Improper use or maintenance by the operator, mechanic, or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert ▲ symbol, which means DANGER or WARNING - “personal safety instructions.” Failure to comply with the instructions may result in personal injury or death.

Incorrect usage of this machine may result in severe injury. Personnel operating and maintaining it should be trained in the proper use and should read the manuals completely and thoroughly before attempting to set-up, operate, adjust, or service this machine.

The Quick Reference Decals, located under the right front of the seat, the right front of the deck, and under the seat pan, are designed to give the operator/mechanic brief information needed in the daily operation and service of the machine. These decals are not intended to be used in place of this manual but instead is to be used as an extension of this manual. These decals should not be removed or obliterated. Replace these decals if they become unreadable.

It is the owner’s responsibility to make certain that the operator/mechanic reads and understands this manual and all decals before operating this machine. It is also the owner’s responsibility to make certain that the operator/mechanic is a qualified and physically able individual, properly trained in the operation of this equipment. Local regulations may restrict the age of the operator/mechanic.

The owner should also ensure that the operator/mechanic know that they are responsible for their own safety as well as the safety of other persons within the vicinity. Remember, the operator/mechanic is responsible for accidents or hazards occurring to other people or their property.

Safe Maintenance & Adjustment Practices

This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death.

▲

Unless specifically required, DO NOT have engine running when servicing or making adjustments to tractor. Place control levers in the park brake position, disengage deck clutch, remove ignition switch key and disconnect the negative battery cable. Repairs or maintenance requiring engine power should be performed by trained personnel only. To prevent carbon monoxide poisoning, be sure proper ventilation is available when engine must be operated in an enclosed area.

▲

Follow daily and weekly checklists, making sure hoses are tightly secured and bolts are tightened.

▲

Keep your machine clean and remove any deposits of trash and

clippings, which can cause engine fires and hydraulic overheating as well as excessive belt wear. Clean up oil or fuel spillage. Allow machine to cool before storing.

▲▲

Clean flammable material from machine. Prevent fires by keeping engine compartment, battery, hydraulic lines, fuel line, fuel tank and operator’s station clean of accumulated trash, grass clippings, and other debris. Always clean up spilled fuel and oil.

▲ Always wear adequate ear protection, such as earplugs, when

operating this equipment as prolonged exposure to uncomfortable or loud noises can cause impairment or loss of hearing. Do not wear radios or music headphones while operating the machinery. Safe operation requires your full attention.

▲

Never put hands or feet under any part of the machine while it is running.

▲

Except when changing or checking belt, always keep belt covers on mower for safety as well as cleanliness.

▲

Stop the engine before removing the grass catcher or unclogging the discharge chute. Never clear the discharge chute with the engine running. Turn off the engine and be sure the blades have stopped before cleaning. Use a stick to clear a plugged discharge area.

Never use your hand!

▲

Exercise caution when loading or unloading the machine onto a trailer or truck.

▲

Always wear safety goggles or safety glasses with side shields when operating the mower.

▲

Never leave machine unattended with ignition key in switch, especially with children present.

▲

Be alert and turn the machine off if children enter the area.

▲

Always wear adequate eye protection when servicing the battery, hydraulic system, cooling system or when grinding mower blades and removing accumulated debris.

▲

Use extra caution when handling gasoline and other fuels. They are flammable and vapors are explosive.

▲

Never refuel tractor while engine is running; never refuel near an open flame or near devices which can create a spark. Refuel outdoors preferably, or in well ventilated areas.

▲

Never attempt to start engine when there is a strong odor of gasoline fumes present. Locate and correct cause.

▲

Never run the engine in an enclosed area unless exhaust is vented to the outside. Exhaust gases contain carbon monoxide which is odorless and deadly poison.

▲

Never attempt to make any adjustments or repairs to the tractor drive system, mower deck or any attachment while the tractor engine is running or deck clutch is engaged. Repairs or maintenance requiring engine power should be performed by trained personnel only.

▲

Never work under the machine or attachment unless it is safely supported with jack stands. Make certain machine is secure when it is raised and placed on the jack stands. The jack stands should not allow the machine to move when the engine is running and the drive wheels are rotating. Use only certified jack stands. Use only appropriate jack stands, with a minimum weight rating of 2000 pounds to block the unit up. Use in pairs only. Follow the instructions supplied with the vehicle stands.

▲

Before working on or under the deck, make certain engine cannot be accidentally started. Shut engine off and remove ignition switch key for maximum safety. Repairs or maintenance requiring engine power should be performed by trained personnel only.

▲

Use a stick or similar instrument to clean under the mower making sure that no part of the body, especially arms and hands are under mower.

▲

Exercise caution when working under the deck as the mower blades are extremely sharp. Wearing gloves or wrapping the blade(s) is advisable when working around or with the blades.

▲

Do not touch hot parts of machine.

▲

Keep nuts and bolts tight, especially the blade attachment bolts. Keep equipment in good condition.

▲

Never tamper with safety devices. Check their proper operation

SAFETY PRECAUTIONS

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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.

▲

If a BAC-VAC™ is mounted to the ATZ it will be necessary to remove the BAC-VAC™ and front wheel weights from the tractor and it will be necessary to re-attach the drive wheel weights, frame weights and the front and rear mount legs to the tractor before operating the unit on a slope.

▲

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

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Safety and Instruction Decals

▲▲

Specific safety warning decals are located on the equipment near the immediate areas of potential hazards. These decals should not be removed or obliterated. Replace them if they become non-readable.

The following illustrations show the various safety decals that are located on the machine. A brief explanation is shown to help the operator understand the meanings of these decals.

Read Owner’s Manual and Quick Reference Decals before attempting to operate this machine.

Avoid skin contact with battery acid. Always wear eye protection when checking the battery, acid can cause serious injury to skin and eyes. If contact occurs, flush area with clean water and call physician immediately. Acid will also damage clothing. Do not allow open flame near the battery when charging. Hydrogen gas forms inside the battery. This gas is both toxic and flammable and may cause an explosion if exposed to flame. Always remove the negative ground first and replace it last. Do not overfill battery. Electrolyte may overflow and damage paint, wiring or structure. When cleaning the battery, use soap and water. Be careful not to get soap and water into the battery. Use soda mixed in water to clean corrosion off the terminals.

Do not remove or modify stabilizer wheels or rear engine guard or injury can result.

Never operate the mower deck with side deflector removed or in raised position, except when the grass catcher attachment is being used.

Keep shields or covers in place while machine is in operation. Keep hands away from rotating pulleys and belts.

Whirling blades! Keep hands and feet away. Beware of thrown objects.

Do not smoke while refueling. Do not fill tank with engine running, or while the engine is hot. Allow engine to cool before storing machine inside a building. Store away from open flame or spark if there is fuel in tank. Clean up any gasoline spills. Do not refuel while in enclosed trailer or other enclosed areas

Part Number

727016

Part Number

727420

Part Number

727438

Part Number

727453

Part Number

771436

Keep engine and pump compartment(s) clean (especially in exhaust area) to prevent fire and provide maximum engine and hydraulic cooling.

Part Number

788968

If you loose steering control while

operating the machine, place the steering control levers in the park brake position immediately. Inspect the machine and involve your Hustler dealer to resolve the problem before continuing to operate.

If pump belt fails, steering control will be lost. Refer to owner’s manual for

inspection and replacement intervals and refer to above paragraph for emergency procedures.

Part Number

600899

Hydraulic fluid escaping under pressure can penetrate skin. Hydraulic fluid may also cause infection in a minor cut or opening in the skin; if exposed to hydraulic fluid, see a doctor at once. Before applying pressure to hydraulic system, make sure all connections are tight and all hoses and lines are in good condition. Relieve all pressure in the system before disconnecting or working on hydraulic lines. To find a leak under pressure, use a piece of cardboard or wood – never use your hands. To relieve all pressure in system, turn engine off and lower attachment.

Hot surface!

Part Number

727008

Part Number

779280

Avoid crushing Do not jump if machine tips Use seat belt Seat belt must be fastened while operating this machine. Failure to use seat belt will result in serious injury in the event of a roll over.

Part Number

763177

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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12-7

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MAINTENANCE

MAINTENANCE LOCATOR

CHART

Figure 12-1

1. Engine Oil Fill & Dipstick

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

Viewed from bottom of tractor

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MAINTENANCE LOCATOR

CHART

1. Deck Pusher Arm Zerks (2)

2. Deck Belt

3. Spindle Housing Zerk (3)

4. Blades

72” XR7 deck

60” XR7 deck

Figure 10-1b

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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.

8. More often under dusty or dirty conditions and during hot weather.

9. Do not clean filter element. Replace with a new one.

REFERENCES: a — Refer to Engine Owner’s Manual

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.

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 .............................................290-310 ...........393.2-420.4

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 standard torque chart found elsewhere in this manual.

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.....................................................semi-pneumatic

The bar tread tires are reversed from what is considered the normal operating position. This allows for better traction when backing up a slope.

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. 12-2

Figure 12-2

Hour

meter

WEEKLY MONTHLY ANNUALLY OR

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.

Clean oil heat exchanger (5) Daily or every 4 hrs.

Check & clean engine compartment Daily or every 4 hrs.

Check air cleaner service indicator(8,9) Every 8 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

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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.

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. 12-3

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. 12-4) 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. 12-5

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.

Figure 12-3

Battery

Figure 12-4

Seat platform catch

Control lever

Seat platform

Page 78

Change hydraulic system filter element (Fig. 12-5) 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 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.

The hydraulic oil heat exchanger is designed to keep the hydraulic system oil temperature lower in hot operating conditions or heavy continuous operating conditions.

This hydraulic heat exchanger is located above the engine. Air is drawn across the cooling fins by an electric fan located above the heat exchanger. Fig. 12-6

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.

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. 12-7) 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. 12-8) 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 ATZ tractors are equipped with a fuel shutoff valve located on the right fuel tank mount (Fig. 12-9). Rotate the valve to the middle position (shown) to prevent fuel flow to the fuel pump. The forward

12-11

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Figure 12-7

Fuel tank

Figure 12-5

Hydraulic reservoir

Hydraulic filter

Figure 12-6

Cooling fan

Heat

exchanger

Engine

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position allows fuel to flow from the right fuel tank to the fuel pump. The rear position 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. 12-1). 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.

The oil drain and oil filter are located at the rear of the engine. Fig. 12-

Engine air filter

Perform engine air filter maintenance per the Service Interval chart on

page 12-8.

A specially designed dry filter is standard equipment on the Hustler

ATZ tractors and supplies clean combustion air to the engine. Fig. 12-11

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.

Figure 12-8

Fuel filter

Figure 12-9

Fuel shut-off valve

Closed position

shown

Left tank

position

Right tank

position

Figure 12-10

Engine oil

drain plug

Engine oil filter

Figure 12-11

Pre-cleaner

Canister

Page 80

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 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 engine will have an air restriction indicator

installed in the air cleaner. Fig. 12-12

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, 12-12

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

Figure 12-14

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

54”/66”/72” XR7 deck

Figure 12-13

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

12-13

107906_0606

Figure 12-11

Indicator

Reset

button

Page 81

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 12-13, 12-14 and 12-15 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. 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.

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 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!

Figure 12-16

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

Warped Blade (Replace)

Straight Blade

Comparison of Warped and Straight Blades

Cutting

Plane

Figure 12-17

Figure 12-18

Twisted Blade Edge

(Replace)

Cutting Edge

Straight Blade Edge

End view of blades, comparing

twisted and straighten blades.

Cutting Plane

Cutting Edge

Figure 12-15

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

107906_0606

12-14

Page 82

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. 12-16). 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. 12-17 and 12-18). 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.

12-15

107906_0606

Page 83

107906_0606

12-16

Page 84

ADJUSTMENTS

Introduction

Your Hustler ATZ 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. 12-19). 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. 12-20

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.

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. 12-20 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. 12-20 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

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. 12-21

Control lever stops

The control lever stops (Fig. 12-21) are designed to do two things: First,

and most important, they must keep the pumps from bottoming out

12-17

107906_0606

Figure 12-19

Park brake slot

Control lever in the

neutral position

Control

lever

Figure 12-21

Control

lever

Stop

Jam nut

Figure 12-20

Pump linkage rod

Pump arm

Jam nut

Page 85

internally. Secondly, the stops may be adjusted to help drive straight when 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. 12-22) 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. 12-23), 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. 12-24

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. 12-25), 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

107906_0606

12-18

Figure 12-23

Cap screw

Upper

control

lever

Lower control

lever

Figure 12-22

Spring

housing

Front ball

stud

Figure 12-24

Front brake link

(right side)

Page 86

bypass valves open. There should be no resistance from the brakes at this point.

5. Move the control lever to where it is just inside (1/8”) the park brake slot. Fig. 12-26 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. 12-27

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. 12-26). 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. 12-28). 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

Deck drive belt adjustment

The spindle belt tension remains constant by means of a tension idler and spring (Fig. 12-29). 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. 12-29). Installed spring length should be 9.0" ± .3" (22.8 cm ± .76 cm) originally with adjustments of .60" (15.2mm) per chain link. (Fig. 12-30)

IMPORTANT: Do not over tension the spring to compensate for a badly worn belt or pulley.

Engine RPM setting

The Hustler ATZ 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.

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

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. 10-31). 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. 10-32

5. Clamp the height adjusting stop against the stop handle (10-32). 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.

Figure 12-26

1/8”

Outside edge

Control lever

Park brake

slot

107906_0606

12-19

Figure 12-27

Turnbuckle

Brake linkage

Jam nut

Figure 12-25

Bypass valve

Page 87

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. 10-33, 10-34, 10-35

7. Loosen the two nuts on the front of height indicator so that the foot pedal is free. Fig. 10-36

8. Start the leveling process on the left front of the tractor.

9. Set the amount of threads protruding on the deck lift rod from the lift

block at approximately 1". Fig. 10-37

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. 10-36

13. Go to the right front of the tractor.

14. Loosen the 5/16" jam nut on the adjuster lift chain (10-35), 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. 10-35

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. 10-34

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. 10-37). Typical both sides.

28. When completed, all chains will be tight, and deck cutting height will be set to the deck height indicator.

Figure 12-29

Spring

Tension idler

Chain

Anchor

bracket

Figure 12-28

Spring

Tension

idler

Pump drive

belt

107906_0606

12-20

Figure 12-30

3.0”

Spring Extension

9.0”

6.0”

Normal Spring Length

Figure 12-31

Blocks

Page 88

12-21

107906_0606

Figure 12-34

Deck lift

threaded

rod

Nut

Chains

Figure 12-35

5/16” bolt

Adjuster

Hardware

Jam nut

Figure 12-36

Foot

pedal

Nuts

Figure 12-37

Lift block

1”

Deck lift rod

1”

Deck lift

assist springs

Figure 12-32

Height

adjusting

stop

Stop

handle

Figure 12-33

Deck lift

threaded

rod

Nut

Chains

Page 89

107906_0606

12-22

Page 90

107906_0606

INDEX

PAGE

Access to engine and hydraulic pump............................12-9

Adjustment introduction...............................................12-17

Belt replacement...........................................................12-13

Control lever adjustment ..............................................12-18

Control lever stops .......................................................12-17

Decals.............................................................................12-5

Deck drive belt adjustment...........................................12-19

Deck leveling and height adjustment ...........................12-19

Electrical system ............................................................12-9

Engine air filter ............................................................12-11

Engine oil and filter......................................................12-11

Engine rpm setting .......................................................12-19

Fuel system...................................................................12-10

General engine maintenance ........................................12-12

PAGE

Hour meter .....................................................................12-8

Hydraulic pump belt adjustment ..................................12-19

Hydraulic system............................................................12-9

Lubrication .....................................................................12-9

Maintenance introduction...............................................12-8

Mower blade maintenance ...........................................12-13

Mower blade removal ..................................................12-13

Park brake adjustment ..................................................12-18

Safety precautions ..........................................................12-3

Steering dampener........................................................12-18

Steering linkage............................................................12-17

Tires................................................................................12-8

Torque values .................................................................12-8

12-23

Page 91

107906_0606

12-24

Page 92

11-4 107906 6/06

Page 93

Numerical Index

Part Page No. No.

Index

Part Numbers

000323 5-6 000331 5-6 000398 5-6 000430 5-8 005116 4-7 008193 3-3 008573 7-5 012005 8-10 015495 4-5 015818 5-6 016527 4-11 016642 7-5 016899 5-3 016972 7-5 017616 7-5 019521 6-4 024927 4-3 025007 8-5 025296 4-11 025395 8-3 026237 5-8 027912 1-1 027920 1-1 028118 4-11 029751 5-3 029868 4-3 029876 5-3 029934 8-5 031997 6-5 032763 3-3 032771 3-3 033035 3-3 034272 3-3

034280 5-3 034843 8-10 036236 4-7 036244 4-7 041152 4-7 041475 6-3 044818 5-3 045088 5-6 045765 6-3 045898 5-8 047654 5-3 048876 4-7 051169 9-3 052837 5-3 052860 2-3 053199 4-7 054502 4-7

, 11-3

, 8-3, 8-7 , 4-11, 7-3, 7-5

, 4-11, 8-3, 8-7

, 5-6, 8-5, 8-9

, 8-5, 8-9

, 8-9

, 6-3, 9-3

, 8-7

, 3-3

, 8-5, 8-9

, 8-9 , 8-3, 8-7

, 4-3, 4-5, 4-7,

5-3, 11-3

, 5-3, 7-5 , 5-6, 11-3

, 8-3, 8-7 , 8-3, 8-7

Part Page No. No.

055749 4-5 055822 4-7 055939 4-3 055947 3-3 057661 5-3 058776 4-3 059832 4-7 059931 8-5 061077 6-4 061101 4-11 063198 4-7 068239 6-5 068478 1-1 068551 3-3 072272 8-10 077123 8-10 077859 3-3 078386 7-5 080358 11-3 083022 5-8 083196 4-11 083279 10-3 086660 2-3

089938 7-3 102764 8-7 103010 8-3 103184 8-3 103192 8-9 103200 8-9 107375 8-3 107620 8-5 107621 8-5 107629 8-3 212076 4-11 212472 8-5 259812 8-5 263517 6-3 305615 2-3 314021 8-7 314104 8-3 344267 6-3 347443 8-5 347684 4-7 347989 5-6 348284 4-5 348318 4-5 348391 4-5 348417 4-3 348458 4-5 348714 4-7 348755 4-7

, 9-3 , 5-6 , 5-3 , 5-8

, 8-5, 8-9 , 5-8 , 8-9

, 4-7

, 7-5 , 8-5, 8-9, 11-3

, 4-7, 8-3, 8-7,

11-3

, 8-7 , 8-7

, 8-9

, 8-7

, 8-9

, 6-3, 9-3

Part Page No. No.

348797 4-7 348862 4-7 348888 4-7 348946 4-7 348987 4-7 349266 6-3 349308 5-8 349761 4-11 349944 5-6 350041 11-3 350264 4-7 350330 4-7 350397 4-7 350421 11-3 350884 8-5 354035 4-7 356121 5-3 357384 11-3 357616 3-3 357780 5-3 359547 2-3 366765 4-11 373191 8-9 377994 5-3 381657 7-5 381665 7-5 381673 7-5 381723 7-5 381731 7-5 381749 7-5 381848 2-2 382168 7-5 387035 6-3 391375 7-5 392035 7-3 392191 7-3 392357 7-3 392597 7-3 392605 7-5 392613 7-5 392985 7-5 395533 2-3 397463 1-1 546572 2-2 547745 8-7 547935 8-3 600171 8-5 600189 8-5 600899 10-3 600961 2-2 700484 3-3 704163 4-7

, 8-9

, 10-4

, 8-9 , 8-9

397505 6/06 i-1

Page 94

Part Page No. No.

704643 4-5, 9-3 704932 5-8 705137 5-3 705178 4-7 705608 3-3 705954 6-3 712257 5-8 712919 5-6 712927 4-7 713198 3-3 714998 5-8 722199 11-3 723486 8-5 724716 11-3 727008 10-3 727016 10-3 727172 10-3 727420 10-4 727438 10-4 727453 10-4 728147 11-3 740696 4-3 742684 1-1 744276 4-3 745059 5-6 746081 11-3 746131 11-3 747303 1-1 756270 4-5 760637 10-4 762195 5-8 763318 5-3 763391 11-3 764126 3-3 765339 4-7 766204 8-10 767954 2-3

767962 3-3

768002 7-5 768515 3-3 768523 3-3

768820 4-3 769166 5-8 770842 8-9 771428 4-3 771436 10-3 776476 5-8 778365 5-8 778738 5-3 779280 10-3

, 8-5, 8-9

, 10-4

, 4-7, 5-6, 8-3,

8-7, 11-3

, 4-11, 5-6, 6-5,

7-3, 7-5, 8-3, 8-5, 8-7, 8-9

, 4-7, 5-3, 5-8 , 4-3, 4-7, 5-3,

7-5, 8-5, 8-9, 11-3

779306 5-6 779850 4-3 781153 4-7 781211 4-7 781229 4-5 781260 4-7 781286 4-7 781294 4-5 781302 4-11 781385 8-5 781427 10-3 781443 1-1 781526 3-3 781534 3-3 781567 6-5 781583 4-7 781617 11-3 781658 3-3 781708 8-3 781716 4-7 781831 4-5 781856 4-11 781880 2-3 781922 4-7 782128 10-3 782136 10-3 782441 3-3 782458 3-3 782466 4-11 782474 8-5 782516 1-1 782573 10-3 782615 10-3 782763 5-3 782870 3-3 782880 3-3 782979 4-7 782995 4-5 783001 4-5 783118 4-7 783126 4-7 783563 6-4 783696 4-7 783704 3-3 783712 4-11 783720 3-3 783738 8-5 783761 4-11 783829 4-11 783837 5-3 783852 4-7 783928 3-3 783936 1-1 783977 1-1

, 8-5, 8-9

, 8-9

, 4-11

, 7-3, 8-3, 8-7

, 8-7

, 8-5, 8-9

, 11-3

, 8-9

, 4-8 , 4-8

, 8-9

, 3-3

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Hustler 107906 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

Kohler 27 HP Engine Installation

Fuel System Installation

Instrument Panel Assembly/Installation

Electrical Schematic - Kohler (799320)

Chapter 6 Contents

Front Wheel Assembly

Drive Wheel Assembly Installation

Anti-Rollover Wheel Assembly

Chapter 7 Contents

Weight Installation

ROPS Installation

Chapter 8 Contents

72" Side Discharge Deck Assembly

72" Side Discharge Deck Pulley Assembly

60" Side Discharge Deck Assembly

60" Side Discharge Deck Pulley Assembly

Chapter 9 Contents

Deck Installation

Deck Belt Routing and Tensioning

Chapter 10 Contents

Tractor Decals

72" and 60" Deck Decals

Chapter 11 Contents

Seat Installation

Chapter 12 Contents

MAINTENANCE

ADJUSTMENTS

Index