Hustler Turf Z XR7 User Manual

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Hustler Z XR7

Parts Manual

•••••••

Hustler Turf Equipment

•••••

P.O. Box 7000

•••

Hesston, Kansas

•

67062-2097

WARNING:

The engine exhaust from this product

contains chemicals known to the State

of Calif orn ia to cau se c an cer, birt h

defects or other reproductive harm.

IMPORTANT: This engine is not equipped with a spark arr ester muffler. It is a violation of California Public Resource Code Section 4442 to use o r operate this eng i ne on any fo rest-co vered, brush-cover ed, or grass-co ver ed unimproved land . Other states or federal areas may have similar laws.

This spark ign i tion sy stem c ompli es with Can adian ICES -002.

The Eng ine Owne r’s Ma nual provide s info rma tion regarding the U.S. E nvironmenta l Protection Agency (EP A) a nd the California Emission Control Regulation of emission systems, maintenance and warranty.

Keep E ng ine Owner’s Manual with your unit. Sho uld the E ngine Owner’s Manual become damaged or illeg ible, replace i mmediately. Re pl acements may be o rd ered per the information found in th e Produc t In f ormation section of th e

owner’s manual.

Chapter 1

Chapter 2

Chapter 3

Chapter 4

Chapter 5

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

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

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

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

Battery Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Steering and Park Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Pump Belt and Pulleys Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Kawasaki Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Honda Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Kohler Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Fuel System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Instrument Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Electrical Schematic (799320) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Chapter 6

Chapter 7

Chapter 8

Chapter 9

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

Front Wheel Breakdown—747782 . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Optional Semi-Pneumatic Tire/Wheel—789537 . . . . . . . . . . . . . . . 6-5

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

Anti-Rollover Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

66" Deck Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

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

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

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

54" Deck Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

54" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Spindle Assembly–796235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

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

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

Seat Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

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

66" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

60" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

54" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

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Chapter 10

Maintenance & Adjustment Safety . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

Safe Maintenance & Adjustment Practices . . . . . . . . . . . . . . . . . . 10-4

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25

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

c-2 106567 4/07

Chapter 1

General Information

This Manual covers Hustler XR7 Z models 927723, 927731, 927749, 927756, 927772, 927798, 927806, 927814 with serial numbers prior to 07020000.

Frequently Ordered Parts

PART NO. DESCRIPTION

027912 Lubrizol 7 oz. Bottle 027920 Lubrizol 10 oz. Bottle 768341 Hydraulic Oil Filter 781443 Pump Drive Belt 797696 Blade, F18.50"-H-F-CW (54" Deck) 794685 Blade, F20.50"-H-F-CW (60" Deck) 798496 Blade, F22.50"-H-F-CW (66" Deck) 797928 Belt, B-Section (54" Deck) 797720 Belt, B-Section (60" Deck) 797936 Belt, B-Section (66" Deck) 068478 Fuel Filter 785261 Main Air Filter Element 785279 Safety Air Filter Element 772079 Kawasaki Engine Oil Filter 785634 Honda Engine Oil Filter 747303 Kohler Engine Oil Filter

Service Literature

PART NO. DESCRIPTION

600876 Owner’s Manual 785642 Honda 18/20/24 Engine Owner’s Manual 778423 Kawasaki 19–25 hp Engine Owner’s Manual 742684 Kohler Engine Owner’s Manual

Note: When ordering parts, yo u 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 represen tative.

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 nece ssary, without notification. If a change has been made to your machine which is not reflected in this parts manual, see

106567 4/07 1-1

your Hustler dealer for current information and parts.

Hardware Description Codes & Abbreviations

The following codes are used throughout this parts manual. Refer to this list when ordering parts.

ABBREVIATION DESCRIPTION

CB Carriage Bolt CE Clevis Pin CP Cotter Pin CS Cap Screw

CW Cup Washer

FDRW Fender Washer

FW Flat Washer

HX Hex Head LW Lock Washer MB Machine Bushing MS Machine Screw NT Nut SC Self Tapping Cap Screw SH Socket Head SB Shoulder Bolt SS Set Screw OD Outside Diameter

ID Inside Diameter

Standard Torques

The following chart lists the standard torque va lues 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 se ction next to the fastener .

SIZE FT-LBS NM SIZE FT-LBS NM

.250 8.2 11.1 M3 1 1.3 .312 17 23 M4 2.2 3 .375 30 40 M5 4.5 6.1 .438 48 65 M6 7.7 10.4 .500 73 99 M8 18.5 25 .562 105 143 M10 37 50 .625 145 200 M12 64 87 .750 260 350 M14 80 108.5 .875 420 565 M16 160 215

1.00 625 850 M20 320 435 M24 555 750

NOTE:

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

1-2 106567 4/07

Chapter 2 Contents

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

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

106567 4/07 2-1

Rivet Nut Installation

INDEX NO.

1 548032 107701 1 TRACTOR FRAME (54")

2 N/A 808493 15 3/8-16 THREAD RIVET NUT 3 N/A 600961 8 1/2-13 THREAD RIVET NUT 4 N/A 808477 2 1/4-20 THREAD RIVET NUT (KAW ONLY) 5 547950 106732 1 XR7 MMZ SEAT SUPPORT

SERVICE

PART NO.

547760 106211 1 TRACTOR FRAME (60") 547752 106039 1 TRACTOR FRAME (66")

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Seat support 547950 includes rivet nuts.

2-2 106567 4/07

Footrest Assembly

INDEX

NO.

1 359547 359547 2 STEP TREAD 2 395533 395533 1 FLOOR 3 305615 305615 2 PLATFORM STEP TREAD 4 086660 086660 2 NT .375-16 HX LK NY 5 767954 767954 4 FW .406 X .812 X .060 SAE HD ZN 6 781880 781880 2 RUBBER BUMPER 7 052860 052860 2 CS .375-16 X 1.250 HX G5 ZN

SERVICE

PART NO.

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. Do not tighten, Item 2 (348276 Floor) must be able to pivot on these bolts.

106567 4/07 2-3

2-4 106567 4/07

Chapter 3 Contents

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

106567 4/07 3-1

Hydraulic System Installation

FRONT

17 10

3-2 106567 4/07

Hydraulic System Installation

ITEM

NO.

1 768515 768515 2 FW .281 X .625 X .051/.080 HD ZN/YL 2 055947 055947 2 CS .250-20 X .500 HX G5 ZN 3 032771 032771 1 STRAINER 4 032763 032763 1 BREATHER CAP 5 349860 349860 1 RESERVOIR 6 034272 034272 4 NT .312-18 HX G5 ZN 7 768523 768523 4 FW .343 X .687 X .051/.080 HD ZN/YL 8 781062 781062 1 HYDRO-GEAR PUMP, BDP-10A-300

9 781047 781047 1 HYDRO-GEAR PUMP BDP-10A-400 10 041707 041707 4 NT .437-14 HX G5 ZN 11 704742 704742 8 FW .453 X .812 X .060 ZN 12 781054 781054 2 ROSS/PARKER WHEEL MOTOR, MB-15 13 705186 705186 4 CS .437-14 X 1.375 HX G5 ZN 14 768341 768341 1 FILTER ELEMENT 15 768333 768333 1 FILTER HEAD 16 781575 N/A 1 -6STR -6 90°, PUSHLOC HOSE 4.75" 17 763946 N/A 3 90°, -6 O-RING/-6 JIC FITTING 18 778985 N/A 2 -6STR -6 90°, PUSHLOC HOSE, 13.00" 19 781591 N/A 1 -6STR -6 90°, PUSHLOC HOSE, 15.00" 20 779132 N/A 2 STR-6MORB/-6JIC FITTING 21 781559 N/A 1 45°, -8MORB/-8MSL FITTING 22 781542 N/A 1 90°,-8MORB/-8MSL FITTING 23 781658 N/A 1 STR-8-MORB/HEX PLUG 24 781526 N/A 4 90°, -10MORB/-8MSL FITTING 25 781500 N/A 1 RIGHT LOOP/RP-BM HYDRO TUBE 26 781492 N/A 1 RIGHT LOOP/LP-TM HYDRO TUBE 27 781484 N/A 1 LEFT LOOP/RP-BM HYDRO TUBE 28 781476 N/A 1 LEFT LOOP/LP-TM HYDRO TUBE 29 781534 N/A 2 STR-8MORB/-8MSL FITTING 30 781518 N/A 1 -6STR -6STR PUSHLOC HOSE, 9.00" 31 763953 N/A 1 -6 O-RING/-6JIC/6JIC T FITTING

SERVICE

PART NO.

N/A 781469 1 MMZ HYDRAULIC KIT (INCLUDES 16-31)

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. Add 3.5 oz. Lubrizol® (027912) when hydraulic oil is changed (see Owner’s Manual).

2. Hydraulic system capacity is 5 US quarts. Fill reservoir to within 1" of top of Item 3 (032771 Strainer)

106567 4/07 3-3

Note:

HYDRAULIC SYSTEM CHARGING PROCEDURE

1. Set handles in the neutral position.

2. Start engine at idle.

3. Let run for a minimum of 30 seconds.

4. Stroke handles to forward position.

5. If motors do not turn in 15 seconds return handles to neutral and repeat step 3 and 4 (one time).

6. If motors do not turn after second attempt, shut off the engine and check for oil at the pump.

7. Increase throttle to half speed and work handles through forward and reverse position until the motor operates smoothly throughout the entire speed range.

Seal Kit for hydraulic pump; 727756 (BDP10 Overhaul Seal Kit)

3-4 106567 4/07

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

106567 4/07 4-1

Battery Installation

TRACTOR FRAME

4-2 106567 4/07

Battery Installation

INDEX

NO.

1 024927 024927 2 NT .250-20 HX GR.5 ZN 2 771428 771428 1 RED BATTERY CABLE BOOT 3 796219 796219 1 36" NEGATIVE BATTERY CABLE 4 744276 744276 1 POSITIVE BATTERY CABLE 5 768523 768523 3 FW .343 X .687 X .051/.080 HD ZN/YL 6 058776 058776 2 NT .312-18 HX NL ZN 7 348417 348417 1 BATTERY CLAMP STRAP 8 055939 055939 2 CS .250-20 X .750 HX G5 ZN

9 029868 029868 4 LW .250 INT-EXT TOOTH ZN 10 740696 740696 1 BATTERY 11 034272 034272 2 NT .312-18 HX G5 ZN 12 779850 779850 2 CB .312-18 X 3.00 FUL ZN

SERVICE

PART NO.

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. When performing service on mower, disconnect battery ground cable and do not reconnect to battery until engine is ready to be started. See Owners Manual.

1065674/07 4-3

Deck Lift Assembly

TRACTOR FRAME

4-4 106567 4/07

Deck Lift Assembly

ITEM

NO.

1 348318 348318 1 STOP HANDLE 2 600437 600437 1 DECK HEIGHT 1/2" PIN W/A

{

3 783001 783001 1 DECK LIFT INDICATOR SUBASSEMBLY 4 704643 704643 8 NT .437-14 HX FLG ZN 5 781294 781294 7 CLIP E, 1.00 X .625 X .050 6 782995 782995 2 DECK LIFT SPRING SUBASSEMBLY 7 781229 781229 1 CE .750 X 2.25 X 1.75 HEADLESS 8 055749 055749 3 CS .437-14 X 1.750 HX G5 ZN

9 348391 018846 4 DECK LIFT CHAIN 10 015495 015495 4 STRAIGHT GREASE FITTING 11 034272 034272 1 NT .312-18 HX G5 ZN 12 756270 756270 1 CS .312-18 X 1.50 FUL THR GR5 ZN 13 348458 348458 1 DECK LEVELER YOKE 14 781831 781831 1 CS .437-14 X 1.750 FUL THD G5 ZN

SERVICE

PART NO.

348284 N/A 1 HEIGHT ADJUSTMENT STOP 3/8"

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. Apply grease to zerks (see owner’s manual).

2. Verify pin diameter prior to ordering replacement part. For mowers with 3/8" diameter pins, order 348284; for mowers with 1/2" pins, order

600437. Item 3 includes 600437 (1/2" pin).

1065674/07 4-5

Steering and Park Brake Assembly

TRACTOR FRAME

4-6 106567 4/07

Steering and Park Brake Assembly

ITEM

NO.

1 781260 N/A 2 STEERING BAR GRIP 2 348755 348755 2 STEERING BAR 3 767954 767954 48 FW .406 X .812 X .060 SAE HD ZN 4 036244 036244 10 CS .375-16 X 1.000 HX G5 ZN 5 705178 705178 6 CS .375-16 X 1.750 HX G5 ZN 6 041152 041152 8 NT .312-24 HX ZN 7 768523 768523 18 FW .343X .687 X .051/.080 HD ZN/YL 8 348946 348946 2 STEERING ARM MOUNT 9 348888 348888 1 STEERLEVER SUPPORT LH

10 055822 055822 8 CS .375-16 X .750 HX G5 ZN 11 781716 781716 4 SS .500-13 X 1.75 SH ZN 12 053199 053199 2 NT .500-13 HX JAM ZN 13 348987 348987 1 STEERING CONTROL PANEL 14 348862 348862 4 STEERLEVER BUSHING 15 086660 086660 8 NT .375-16 HX LK NY 16 781583 781583 2 BRAKE ROD ASSEMBLY 17 063198 063198 4 CS 10-24 X .750 HXFLK ZN 18 781211 781211 2 PUSH BUTTON SWITCH 19 781286 781286 2 PUMP ROD ADJUSTER ASSEMBLY 20 600221 600221 2 CENTERING DAMPER

21 781922 781922 4 DAMPER BALL STUD 22 704163 704163 2 CS .250-20 X 2.00 HX G5 ZN 23 768515 768515 4 FW .281 X .625 X .051/.080 HD ZN/YL 24 068551 068551 2 NT .250-20 HX NL ZN 25 367557 367557 2 PUMP ARM 26 348797 348797 2 ADJUSTABLE PIVOT 27 781153 781153 4 BUSHING 28 005116 005116 4 CS .375-16 X 1.375 HX G5 ZN 29 054502 054502 4 NT .375-16 HX GRD 5 ZN 30 034272 034272 8 NT .312-18 HX G5 ZN 31 781765 781765 2 BRAKE DRUM-HUB ASSEMBLY 32 781112 781112 1 BRAKE ASSEMBLY

3 4

33 036236 036236 4 CS .312-18 X 1.000 HX G5 ZN 34 350272 350272 2 BRAKE ARM EXTENSION 35 350330 350330 1 L.S. BRAKE PIVOT ARM

36 765339 765339 4 BUSHING 37 059832 059832 4 NT #10-24 HX NL ZN 38 782979 782979 2 CS .375-16 X 4.75 HX G5 ZN 39 065516 N/A 2 ROSS CASTLE NUT 40 350397 350397 2 BRAKE LINK TURNBUCKLE 41 064337 N/A 2 ROSS KEY

SERVICE

PART NO.

348714 348714 1 STEERLEVER SUPPORT RH

783696 783696 2 CENTERING DAMPER

781351 781351 1 BRAKE ASSEMBLY

350264 350264 1 R.S. BRAKE PIVOT ARM

MFG.

PART NO.

QTY DESCRIPTION

1065674/07 4-7

NOTES:

1. Torque to 350-375 ft.-lbs. Included with wheel motor.

2. Torque brake assembly mounting bolts to 100 ft.-lbs.

3. 781112 used on left wheel.

4. 781351 used on right wheel.

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

6. Use 783696 on mowers with serial numbers prior to 06071499.

4-8 106567 4/07

This page intentionally left blank.

1065674/07 4-9

Pump Belt and Pulleys Installation

TRACTOR FRAME

25 26

4-10 106567 4/07

Pump Belt and Pulleys Installation

INDEX

NO.

1 779876 779876 1 ENGINE SC SINGLE PULLEY 2 212076 212076 1 KEY 1/4 SQ X 1.50 LONG 3 787366 787366 1 WARNER CLUTCH 4 783829 783829 1 FW .460 X 1.750 X .250 ZNYC 5 785659 785659 1 CS .437-20 X 2.50 HX G5 ZNYC 6 083196 083196 4 SS .312-18 X .750 SQ-HD ZN 7 768127 768127 2 KEY 5MM X 30MM RADIUS ENDS 8 325308 325308 2 PULLEY & FAN

9 008193 008193 2 NT .500-13 HX G5 ZNYC 10 767962 767962 4 FW .531 X 1.063 X .090 SAE HD ZN 11 016527 016527 2 CS .500-13 X 1.00 HX G5 ZNYC 12 366765 366765 1 CLUTCH ANCHOR ANGLE 13 784918 784918 2 RUBBER BUMPER 14 349761 349761 1 PUMP IDLER ARM 15 015495 015495 1 STRAIGHT GREASE FITTING 16 025296 025296 1 FW .760 X 1.625 X .08 ZN 17 061101 061101 1 NT .750-10 HX NL ZN 18 781856 781856 1 IDLER PULLEY 19 028118 028118 1 FW .62 X 1.00 X.134 ZN 20 794446 794446 1 CS .625-11 X 1.50 HX G5 ZN 21 781302 781302 1 IDLER SPRING 22 781443 781443 1 A-SEC PUMP IDLER BELT 23 791251 791251 1 HARNESS, CLUTCH PIGTAIL(DIODE) 24 036236 036236 1 CS .312-18X1.000 HX G5 ZNYC 25 768523 768523 1 FW .343 X .687 X .051/.080 HD ZNYC 26 034272 034272 1 NT .312-18 HX G5 ZNYC

SERVICE

PART NO.

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. Torque to 45-48 ft-lbs.

2. Torque to 12-15 ft-lbs.

3. Apply grease at zerk (see owner’s manual).

4. Included with Honda 24 HP engine (785014).

5. Electric clutch burnishing procedure: After installing a new clutch it is important to burnish the clutch to insure maximum deck clutch life. In an open area with no bystanders set the engine speed to half throttle. Cycle the deck clutch on for 15 seconds, and then off for 15 seconds. Repeat this operation 10 times, it will require about 5 minutes to complete.

1065674/07 4-11

4-12 106567 4/07

Chapter 5 Contents

Kawasaki Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Honda Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Kohler Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Fuel System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Instrument Panel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Electrical Schematic (799320). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

106657 4/07 5-1

Kawasaki Engine Installation

TO ENGINE SENSOR

ELLOW

TO SPADE

TERMINAL

TO BULLET

TERMINALS

RED/BLK

PART OF ENGINE

STARTER SOLENOID GROUND

NEGATIVE BATTERY CABLE

POSITIVE BATTERY CABLE

PURPLE

TRACTOR FRAME

PART OF COMMON WIRE HARNESS

5-2 106567 4/07

Kawasaki Engine Installation

ITEM

NO.

1 777656 777656 1 KAWASAKI 23 HP ENGINE

5 6

2 058776 058776 4 NT .312-18 HXZY NL 3 768523 768523 22 FW .343 X .687 X .051/.080 HD ZN/YL 4 029876 029876 1 LW .312 INT-EXT TOOTH ZN 5 792762 792762 1 BATTERY CABLE 6 768515 768515 5 FW .281 X .625 X .051/.080 HD ZN/YL 7 024927 024927 3 NT .250-20 HX GR.5 ZN 8 799312 799312 1 WIRE HARNESS ADAPTER

9 799320 799320 1 COMMON WIRE HARNESS 10 044255 044255 1 NT #10-32 HX ZN 11 030817 030817 1 STARTER SOLENOID 12 055947 055947 2 CS .250-20 X .500 HX G5 ZN 13 792192 792192 1 STARTER RELAY GROUND WIRE 14 771428 771428 1 RED BATTERY CABLE BOOT 15 050161 050161 4 CS .312-18 X 1.75 HX G5 16 786673 786673 1 DONALDSON AIR CLEANER CAP

17 057661 057661 3 HOSE CLAMP 18 788943 788943 1 AIR FILTER INDICATOR 19 785741 785741 1 MOUNTING BAND 20 034272 034272 6 NT .312-18 HX G5 ZN 21 782763 782763 1 AIR CLEANER 22 366443 366443 1 REMOTE AIR CLEAN MOUNT BRACKET 23 036236 036236 6 CS .312-18 X 1.00 HX G5 ZNYC 24 786038 786038 1 REMOTE AIR FILTER HOSE 25 796524 796524 1 OIL DRAIN M20 X 2.5 VALVE 26 350371 350371 1 MUFFLER GUARD 27 349704 349704 1 ENGINE CAGE MOUNT PLATE 28 767962 767962 6 FW .531 X 1.063 X .090 SAE HD ZN 29 016527 016527 6 CS .500-13 X 1.00 HX G5 ZN 30 064006 064006 2 CS .312-18 X .625 HX G5 ZN 31 781732 781732 1 MUFFLER MANIFOLD 32 781724 781724 1 MUFFLER 33 720177 720177 2 CS M 8-1.25 X 20 10.9 HXFL ZN 34 782649 782649 1 KAW (23) EXHAUST PIPE CLAMP 35 782664 782664 4 NT M8-1.25 HX STAINLESS STEEL 36 017004 017004 4 LW .312 MED SPRING ZN 37 360693 360693 1 HEAT SHIELD 38 780841 780841 2 KAW (23) MUFFLER GASKET 39 789131 789131 1 HUSTLER Z FAN CONNECTOR CAP

SERVICE

PART NO.

782318 782318 1 KAWASAKI 25 HP ENGINE (FH721V, 3600 RMP)

MFG.

PART NO.

QTY DESCRIPTION

106567 4/07 5-3

NOTES:

1. Includes mounting hardware.

2. Part of Item 8 (799312 Wire Harness Adapter).

3. Engine oil capacity; 2 US quarts (w/filter).

4. Engine RPM to be set at 3600± 50.

5. 23 HP engine used in 927723 and 927731 only.

6. 25 HP engine used in 927772 and 927798 only.

7. Includes one (1) of Item 17 (057661 Hose Clamp).

8. When installing lower hose clamp on air cleaner hose, install as low as possible (against carburetor inlet).

9. This connector used for optional hydraulic oil cooler fan.

10. Air filter service parts:

785261 MAIN AIR FILTER ELEMENT 763318 VACUATOR VALVE

5-4 106567 4/07

This page intentionally left blank.

106567 4/07 5-5

Honda Engine Installation

YEL

BLK

NEGATIVE BATTERY CABLE

RED/BLK

PART OF COMMON WIRE HARNESS

PART OF ENGINE

ORG

BRN

GRA/PUR

PUR

POSITIVE BATTERY CABLE

TRACTOR FRAME

5-6 106567 4/07

Honda Engine Installation

ITEM

NO.

1 785014 785014 1 HONDA 24HP ENGINE

2 058776 058776 4 NT .312-18 HXZY NL 3 768523 768523 23 FW .343 X .687 X .051/.080 HD ZN/YL 4 799320 799320 1 COMMON WIRE HARNESS 5 029876 029876 1 LW .312 INT-EXT TOOTH ZN 6 077545 N/A 1 NT M8-1.25 X 10 HX ZNYC 7 017004 N/A 5 LW .312 MED SPRING ZN 8 799304 799304 1 WIRE HARNESS ADAPTER

9 050161 050161 4 CS .312-18 X 1.75 HX G5 10 775353 775353 1 DONALDSON AIR CLEANER CAP 11 057661 057661 3 HOSE CLAMP 12 785741 785741 1 MOUNTING BAND 13 034272 034272 6 NT .312-18 HX G5 ZN 14 782763 782763 1 AIR CLEANER 15 366443 366443 1 REMOTE AIR CLEANER MOUNT BRACKET 16 036236 036236 9 CS .312-18 X 1. HX G5 ZNYC 17 785675 785675 1 REMOTE AIR FILTER HOSE 18 787689 787689 1 HONDA OIL DRAIN VALVE 19 787713 787713 1 0.50" LOW PRESSURE HOSE, 3.00" LONG 20 382168 382168 1 MUFFLER GUARD 21 377994 377994 1 MMZ ROLLER HEAT SHIELD 22 365742 365742 1 ENGINE CAGE MOUNT PLATE 23 767962 767962 6 FW .531 X 1.063 X .090 SAE HD ZN 24 016527 016527 6 CS .500-13 X 1.00 HX G5 ZNYC 25 017038 017038 2 LW .250 MED SPRING ZNYC 26 024927 024927 2 NT .250-20 HX GR.5 ZNYC 27 785477 N/A 1 HONDA 20 AMP RECTIFIER 28 768515 768515 2 FW .281 X .625 X .051/.080HD ZNYC 29 056077 056077 2 CS .250-20 X 1.00 HX G5 ZNYC 30 784843 784843 1 MUFFLER 31 720177 720177 2 CS M 8-1.25 X 20 10.9 HXFL ZN 32 785378 785378 1 1.50" MUFFLER CLAMP 33 785543 N/A 2 HONDA (20) MUFFLER GASKET 34 782664 N/A 4 NT M8-1.25 HX STAINLESS STEEL 35 784959 784959 1 MUFFLER MANIFOLD 36 789131 789131 1 HUSTLER Z FAN CONNECTION CAP

SERVICE

PART NO.

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. Includes mounting hardware.

2. Part of Item 4 (799320 Tractor Common Wire Harness).

3. Part of 8 (799304 Wire Harness Adapter).

4. Engine oil capacity; 2.3 US quarts (with filter).

5. Engine RPM to be set at 3600± 50.

6. Used on 927756 only.

106567 4/07 5-7

7. Includes one (1) of Item 14 (057661 Hose Clamp).

8. Supplied with engine.

9. When installing lower hose clamp on air cleaner hose, install as low as possible (against carburetor inlet).

10. This connector used for optional hydraulic oil cooler fan.

11. Air filter service parts:

785261 MAIN AIR FILTER ELEMENT 763318 VACUATOR VALVE

5-8 106567 4/07

This page intentionally left blank.

106567 4/07 5-9

Kohler Engine Installation

POSITIVE BATTERY CABLE

TRACTOR FRAME

PUR (P/O ENGINE)

RED/BLK

BLK

NEGATIVE BATTERY CABLE

PART OF COMMON WIRE HARNESS

5-10 106567 4/07

Kohler Engine Installation

ITEM

NO.

1 788216 788216 1 KOHLER 27HP ENGINE

2 799320 799320 1 COMMON WIRE HARNESS 3 058776 058776 4 NT .312-18 HXZY NL 4 768523 768523 29 FW .343 X .687 X .051/.080 HD ZN/YL 5 029876 029876 1 LW .312 INT-EXT TOOTH ZN 6 050161 050161 4 CS .312-18 X 1.75 HX G5 7 786673 786673 1 DONALDSON AIR CLEANER CAP 8 057661 057661 3 HOSE CLAMP

9 788943 788943 AIR FILTER INDICATOR 10 782763 782763 1 AIR CLEANER 11 785741 785741 1 MOUNTING BAND 12 034272 034272 6 NT .312-18 HX G5 ZN 13 366443 366443 1 REMOTE AIR CLEANER MOUNT BRACKET 14 036236 036236 9 CS .312-18 X 1.00 HX G5 ZNYC 15 795310 795310 1 REMOTE AIR FILTER HOSE (STRAIGHT) 16 796672 796672 1 3/8-18 OIL DRAIN VALVE 17 787713 787713 1 0.50" LOW PRESSURE HOSE 18 382168 382168 1 MUFFLER GUARD 19 365742 365742 1 ENGINE CAGE MOUNT PLATE 20 377994 377994 1 MMZ ROLLER HEAT SHIELD 21 016527 016527 6 CS .500-13 X 1.00 HX G5 ZNYC 22 767962 767962 6 FW .531 X 1.063 X .090 SAE HD ZN 23 029751 029751 2 CS .375-16 X 1.00 HXFLK ZNYC 24 705137 705137 4 FW .391 X 1.250 X .060 ZNYC 25 788018 788018 1 MUFFLER 26 788026 788026 1 MUFFLER MANIFOLD 27 785378 785378 1 1.50" MUFFLER CLAMP 28 016899 016899 2 NT .375-16 HXFLK ZNYC 29 789131 789131 1 HUSTLER Z FAN CONNECTION CAP

SERVICE

PART NO.

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. Includes mounting hardware.

2. Part of Item 2 (799320 Common Wire Harness).

3. Engine oil capacity; 1.9 US quarts (w/filter).

4. Engine RPM to be set at 3600± 50.

5. Used on 927806, and 927814 only.

6. Supplied with engine.

7. Air filter service parts:

785261 MAIN AIR FILTER ELEMENT 763318 VACUATOR VALVE

106567 4/07 5-11

Fuel System Installation

5-12 106567 4/07

Fuel System Installation

ITEM

NO.

1 779306 779306 2 3.5" FUEL CAP 2 793240 793240 1 LEFT SIDE FUEL TANK 3 793232 793232 1 RIGHT SIDE FUEL TANK 4 000323 000323 6 CLIP 5 106732 N/A 1 REAR SEAT SUPPORT 6 055822 055822 12 CS .375-16 X .750 HX G5 ZN 7 712919 712919 11 FW .406 X 1.00 X .12 HRD ZN 8 036244 036244 2 CS .375-16 X 1.000 HX G5 ZN

9 767954 767954 3 FW .406 X .812 X .060 SAE HD ZN 10 045088 045088 1 HOSE CLAMP 1" 11 797084 797084 1 3-WAY NYLON FUEL VALVE 12 347989 347989 1 FUEL SHUT-OFF BRACKET 13 016527 016527 8 CS .500-13 X 1.00 HX G5 ZN 14 767962 767962 8 FW .531 X 1.063 X .090 SAE HD ZN 15 015818 015818 1 FUEL LINE 45.5" 16 015818 015818 1 FUEL LINE 26.5" 17 015818 015818 1 FUEL LINE 22.5"KAWASAKI

SERVICE

PART NO.

015818 015818 1 FUEL LINE 36”"HONDA 015818 015818 1 FUEL LINE 38"KOHLER 000331 000331 3 BLACK CABLE TIE (NOT SHOWN)

MFG.

PART NO.

QTY DESCRIPTION

1. Torque to 20 ft.-lbs.

2. Supplied with new fuel tank.

3. Fuel tank service part not shown:

PN DESCRIPTION

799197 SZ HOSE ASSY, SUCTION

NOTES:

106567 4/07 5-13

Instrument Panel Assembly

FUSE SIZE AND LOCATION

10a

15a

RIGHT SIDE FUEL TANK

5-14 106567 4/07

Instrument Panel Assembly

ITEM

NO.

1 776476 776476 1 PTO SWITCH

2 785808 785808 1 IGNITION KEY SET

3 045898 045898 1 KEY SWITCH

4 785030 785030 1 Z CHOKE CABLE (KAWASAKI)

5 712257 712257 1 RED INDICATOR LIGHT

6 000430 000430 2 TIE STRAP

7 704932 704932 4 FW .219 X .500 X .048 ZN

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

9 059832 059832 2 NT #10-24 HX NL ZN 10 769166 769166 1 HOUR METER 11 778365 778365 1 THROTTLE/CHOKE CABLE 12 055947 055947 3 CS .250-20 X .500 HX G5 ZN 13 768515 768515 3 FW .281 X .625 X .051 /.080 HD ZN/YL 14 106633 106633 1 INSTRUMENT PANEL

SERVICE

PART NO.

786657 786657 1 Z CHOKE CABLE (HONDA & KOHLER)

026237 N/A 6 RELAY (NOT SHOWN) 762195 N/A 1 DELAY MODULE (NOT SHOWN)

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. Part of 799320 (Common Wire Harness)

106567 4/07 5-15

Electrical Schematic (799320)

5-16 106567 4/07

Chapter 6 Contents

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

Front Wheel Breakdown—747782. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Optional Semi-Pneumatic Tire/Wheel—789537 . . . . . . . . . . . . . . . . 6-5

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

Anti-Rollover Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

106567 4/07 6-1

Front Wheel Assembly

TRACTOR FRAME

6-2 106567 4/07

Front Wheel Assembly

INDEX

NO.

1 705954 705954 2 CS .500-13 X 1.25 HX G5 ZN 2 344267 344267 2 FW .510 X 2.15 X .187 SPL ZN 3 712976 712976 2 FW .531X 1.375X.125 ZNY 4 784223 784223 4 BEARING W/O COLLAR 5 387035 387035 2 SPACER, 1.07 X 1.312 X 2.793 6 045765 045765 2 FW 1.030 X 1.500 X.134 ZN 7 349266 349266 2 FORK 8 041475 041475 2 CS .750-10 X 9.50 HX ZN

9 025296 025296 4 FW .760 X 1.625 X .08 ZN 10 061101 061101 2 NT .750-10 HX NL ZN 11 747782 747782 2 WHEEL & TIRE ASSY

SERVICE

PART NO.

789537 N/A 2 OPTIONAL SEMI-PNEUMATIC WHEEL/TIRE ASSEMBLY

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. Apply grease to zerks.

2. Torque to 100 ft.-lbs.

3. Assemble with extended inner race toward item 5 (387035 Spacer, 1.07 x 1.312 x 2.793).

1065674/07 6-3

Front Wheel Breakdown—747782

ITEM

NO.

1 039677 N/A 2 WHEEL BEARING 2 747741 N/A 1 13 X 6.50 TIRE 3 747832 N/A 1 6 X 4.5 WHEEL 4 782771 N/A 1 BEARING SPACER 5 019521 N/A 1 TIRE VALVE 6 015511 N/A 1 GREASE FITTING 45 DEG 1/4

SERVICE

PART NO.

1. Inflate tire to 8-10 psi.

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

6-4 106567 4/07

Optional Semi-Pneumatic Tire/Wheel—789537

ITEM

NO.

1 039677 N/A 2 WHEEL BEARING 2 789537 N/A 1 TIRE/WHEEL ASSEMBLY 3 015511 N/A 1 GREASE FITTING 45 DEG 1/4 4 782771 N/A 1 BEARING SPACER

SERVICE

PART NO.

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1065674/07 6-5

Drive Wheel Assembly Installation

INDEX

NO.

1 784058 784058 2 WHEEL & TIRE ASSY FOR 66" (QTY PER TRACTOR) 2 781245 N/A TIRE, 12 X 12 X 24 FOR 66" 3 784066 N/A WHEEL ASSEMBLY 12 X 8.50 FOR 66" 4 019521 N/A TIRE VALVE 5 061077 061077 10 WHEEL NUT (QTY PER TRACTOR) 6 770859 N/A 10 1/2" WHEEL LUG STUD

1 781237 781237 2 WHEEL & TIRE ASSY FOR 60" & 54" (QTY PER TRACTOR) 2 781245 N/A TIRE, 12 X 12 X 24 FOR 60" & 54" 3 781252 N/A 2 WHEEL ASSEMBLY 12 X 8.50 FOR 60" & 54" 4 019521 N/A 2 TIRE VALVE 5 061077 061077 10 WHEEL NUT (QTY PER TRACTOR) 6 770859 N/A 10 1/2" WHEEL LUG STUD

SERVICE

PART NO.

PART NO. QTY DESCRIPTION

NOTES:

1. Torque to 65-75 ft. lbs.

2. Inflate tire to 8-10 psi.

6-6 106567 4/07

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.

1065674/07 6-7

6-8 106567 4/07

Chapter 7 Contents

66" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

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

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

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

54" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

54" Deck Pulley Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Spindle Assembly–796235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

106567 4/07 7-1

66" Deck Assembly

}

Optional Anti-Scalp Wheels

7-2 106567 4/07

66" Deck Assembly

INDEX

NO.

1 547737 103929 1 66" DECK CRATED

2 798694 798694 1 RUBBER CHUTE ASSEMBLY 3 052860 052860 2 CS .375-19 X 1.250 HX G5 ZN 4 767954 767954 22 FW .406 X .812 .060 SAE HD ZN 5 086660 086660 8 NT .375-16 HX LK NY 6 103010 103010 1 DISCHARGE CHUTE MOUNT BRACKET 7 781708 N/A 6 CS .500-13 X 4.25 HX G5 ZN 8 767962 N/A 12 FW .531 X 1.063 X .090 SAE HD ZN

9 031997 N/A 6 ANTI-SCALP WHEEL 10 053199 N/A 6 NT .500-13 HX JAM ZN 11 781567 781567 6 NT .50-13 HX LK NY 12 808485 808485 4 5/16-18 THREAD RIVET NUT 13 314104 314104 1 PUSHER 14 015495 015495 2 STRAIGHT GREASE FITTING 15 052860 052860 6 CS .375-16 X 1.25 HX G5 16 025395 025395 6 CB .375-16 X 1.00 STD CD 17 103713 103713 2 66, AIR FLOW FLOOR 18 N/A 808493 2 RIVET NUT, 3/8-16 THREAD

SERVICE

PART NO.

788166 788166 4 ANTI SCALP WHEEL ASSY

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. Do not torque, Item 2 (349324 Discharge Chute) must pivot freely.

2. Includes 6 each of items 7 through 10.

3. Service part deck includes decals (see ’’66" Deck Decals” in on page 4 for listing of decals).

4. For optional anti-scalp wheels order:

INDEX NO.

19 788166 788166 2 ANTI-SCALP WHEEL ASSEMBLY

20 781567 781567 2 NT .500-13 H8ZY NL

SERVICE

PART NO.

MFG.

PART NO.

QTY. DESCRIPTION

106567 4/07 7-3

66" Deck Pulley Assembly

BELT GUIDE INDEXING

7-4 106567 4/07

66" Deck Pulley Assembly

ITEM

NO.

1 797936 797936 1 B-SECTION BELT 2 025007 025007 1 CS .625-11 X 1.75 HX G5 ZNYC 3 347443 347443 1 DECK BELT IDLER GUIDE 4 028118 028118 5 FW .62 X 1.00X.134 ZN 5 781856 781856 1 5.00" IDLER PULLEY 6 797910 797910 6 CS .312-18 X 1.50 FLT SH ZNYC 7 600189 600189 1 RS UHMW IDLER SLIDE 8 600171 600171 1 LS UHMW IDLER SLIDE

9 373191 059961 1 SIDE MOUNT CHAIN (21 LINKS) 10 781302 781302 1 IDLER SPRING 11 350884 350884 1 DECK IDLER 12 786335 786335 1 .03 THICK UHMW 13 103721 103721 1 RS 66" XR7 PULLEY COVER 14 103739 103739 1 LS 66" XR7 PULLEY COVER 15 016972 016972 2 NT .625-11 HX G5 ZNYC 16 781385 781385 2 6.00" IDLER PULLEY, 17 792002 792002 4 5/16-18 X 3/4"MALE KNOB 18 016527 016527 3 CS .500-13 X 1.00 HX G5 ZN 19 752386 752386 3 CW .515X 2.25X .204 ZN 20 798975 798975 3 B-SEC 6.32 EOD PULLEY 21 705954 705954 12 CS .500-13 X 1.25 HX G5 ZNYC 22 767962 767962 12 FW .531 X 1.063 X .090 SAE HD ZN 23 768523 768523 6 FW .343 X .687 X .051/.080 HD ZN 24 058776 058776 6 NT .312-18 HXZY NL 25 212472 212472 3 KEY 1/4 SQ X 1.00 LONG 26 796235 796235 3 SPINDLE HOUSING ASSEMBLY 27 798496 798496 3 BLADE, F22.50"-H-F-CW

28 782474 782474 5 CW .631 2.250 X .187 PNT 29 029934 029934 3 CS .625-11 X 3.00 HX G5 ZNYC 30 783738 783738 2 CS .625-11 X 3.00 FULL HX G5 ZN

SERVICE

PART NO.

798512 N/A 3 OPTIONAL BLADE, F24.50"-H-F-CW 798504 N/A 3 OPTIONAL BLADE, 22.50"-MUL-F-CW

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. Torque to 118 ft. lbs.

2. Torque to 67-75 ft. lbs.

3. Apply grease to zerk (see owner’s manual).

4. See ’’Deck Belt Routing and Tensioning” in on page -4 for belt tensioning.

5. See ’’Spindle Assembly–796235” in on page -14 for breakdown.

106567 4/07 7-5

60" Side Discharge Deck Assembly

7-6 106567 4/07

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 808493 808493 2 3/8-16 THREAD RIVET NUT

SERVICE

PART 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. Includes items 7, 8, 9, and 10.

3. Service part deck includes decals (see ’’60" Deck Decals” in on page 5 for listing of decals).

4. For optional anti-scalp wheels order:

INDEX NO.

21 788166 788166 2 ANTI-SCALP WHEEL ASSEMBLY

22 781567 781567 2 NT .500-13 H8ZY NL

SERVICE

PART NO.

MFG.

PART NO.

QTY. DESCRIPTION

106567 4/07 7-7

60" Deck Pulley Assembly

60" DECK

15 4

23 24

BELT GUIDE INDEXING

7-8 106567 4/07

60" Deck Pulley Assembly

ITEM

NO.

1 797720 797720 1 B-SECTION BELT 2 025007 025007 1 CS .625-11 X 1.75 HX G5 ZNYC 3 347443 347443 1 DECK BELT IDLER GUIDE 4 028118 028118 5 FW .62 X 1.00X.134 ZN 5 781856 781856 1 5.00" IDLER PULLEY 6 797910 797910 6 CS .312-18 X 1.50 FLT SH ZNYC 7 600189 600189 1 RS UHMW IDLER SLIDE 8 600171 600171 1 LS UHMW IDLER SLIDE

9 373191 059961 1 SIDE MOUNT CHAIN (21 LINKS) 10 781302 781302 1 IDLER SPRING 11 350884 350884 1 DECK IDLER 12 786335 786335 1 .03 THICK UHMW 13 103192 103192 1 RS 60" XR7 PULLEY COVER 14 103200 103200 1 LS 60" XR7 PULLEY COVER 15 016972 016972 3 NT .625-11 HX G5 ZNYC 16 781385 781385 3 6.00" IDLER PULLEY, 17 792002 792002 4 5/16-18 X 3/4"MALE KNOB 18 016527 016527 3 CS .500-13 X 1.00 HX G5 ZN 19 752386 752386 3 CW .515X 2.25X .204 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

PART NO.

794230 N/A 3 OPTIONAL BLADE, 20.50" GAT-F-CW 794214 N/A 3 OPTIONAL BLADE, 20.50"-MUL-F-CW

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. Torque to 118 ft. lbs.

2. Torque to 65-75 ft. lbs.

3. Apply grease to zerk (see owner’s manual).

4. See ’’Deck Belt Routing and Tensioning” in on page -4 for belt tensioning.

5. See ’’Spindle Assembly–796235” in on page -14 for breakdown.

106567 4/07 7-9

54" Deck Assembly

}

7-10 106567 4/07

Optional Anti-Scalp Wheels

54" Deck Assembly

INDEX NO.

1 548008 103317 1 54" DECK CRATED 2 798694 798694 1 54" DISCHARGE CHUTE 3 052860 052860 8 CS .375-16 X 1.25 HX G5 ZN 4 767954 767954 30 FW .406 X .812 X .060 SAE HD ZN 5 086660 086660 18 NT .375-16 HX LK NY 6 N/A 808493 2 3/8-16 THREAD RIVET NUT 7 103010 103010 1 DISCHARGE CHUTE MOUNT BRACKET 8 N/A 808485 4 5/16-18 THREAD RIVET NUT

9 781708 N/A 6 CS .500-13 X 4.25 HX G5 ZN 10 767962 N/A 12 FW .531 X 1.063 X.090 SAE HD ZN 11 053199 N/A 6 NT .500-13 HX JAM ZN 12 781567 781567 6 NT .50-13 HX LK NY 13 031997 N/A 6 ANTI-SCALP WHEEL 14 015495 015495 2 STRAIGHT GREASE FITTING 15 314104 314104 1 PUSHER 16 005116 005116 4 CS .375-16X1.375 HX G5 17 103184 103184 2 REAR ANTI-SCALP BRACKET 18 025395 025395 6 CB .375-16X 1.00 STD CD 19 103572 103572 2 54" AIR FLOW BAFFLE

SERVICE

PART NO.

788166 788166 6 ANTI-SCALP WHEEL ASSEMBLY

MFG.

PART NO.

QTY. DESCRIPTION

NOTES:

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

2. Includes items 9, 10, 11, and 13.

3. Secure Item 11 (053199 Jam Nut) to bolt with a drop of Loctite® (271 Red). Tighten Item 11 to shank of Item 9 (781708 Cs .500-13 X 4.25 Hx G5 Zn). Anti-scalp wheel must turn freely.

4. Assemble in top hole for shipping purposes.

5. Item 15 (314104 Pusher) installed as shown with zerks pointing upward, apply grease to zerks.

6. Service part deck includes decals (see ’’66" Deck Decals” in on page 4 for listing of decals) and item 2 (Discharge Chute).

7. For optional anti-scalp wheels order:

INDEX NO.

20 788166 788166 2 ANTI-SCALP WHEEL ASSEMBLY

21 781567 781567 2 NT .500-13 H8ZY NL

SERVICE

PART NO.

MFG.

PART NO.

QTY. DESCRIPTION

106567 4/07 7-11

54" Deck Pulley Assembly

54" DECK ASSY

BELT GUIDE POSITIONING

7-12 106567 4/07

54" Deck Pulley Assembly

INDEX

NO.

1 797928 797928 1 B-SECTION BELT 2 016972 016972 2 NT .625-11 HX G5 ZNYC 3 025007 025007 1 CS .625-11 X 1.50 HX G5 ZN 4 028118 028118 5 FW .62 X 1.00 X .134 ZN 5 781385 781385 2 6.00" IDLER PULLEY 6 797910 797910 6 CS .312-18X1.50FLT SH ZY 7 600189 600189 1 IDLER SLIDE UHMW RS 8 600171 600171 1 IDLER SLIDE UHMW LS

9 347443 347443 1 DECK BELT IDLER TOP GUIDE 10 781856 781856 1 5.00" IDLER PULLEY 11 350884 350884 1 DECK IDLER 12 373191 059931 1 SIDE MOUNT CHAIN 21 LINKS 13 781302 781302 1 IDLER SPRING 14 786335 786335 1 UHMW .03 THICK 15 103986 103986 1 RS 54" PULLEY COVER 16 103994 103994 1 LS 54" PULLEY COVER 17 016527 016527 3 CS .500-13 X 1.00 HX G5 ZN 18 752386 752386 3 CW .515X 2.25X .204 ZN 19 798967 798967 3 DECK DRIVE PULLEY 20 705954 705954 12 CS .500-13X1.25 HX G5 ZY 21 767962 767962 12 FW .531X 1.063X.090 SAE 22 212472 212472 3 KEY 1/4 SQ X 1.00 LONG 23 796235 796235 3 DECK SPINDLE ASSY 24 797696 797696 3 BLADE, F18.50"-H-F-CW

25 782474 782474 5 CW .631 X 2.250 X .187 PNT 26 768523 768523 6 FW .343X.687X.051/.080H 27 058776 058776 6 NT .312-18 HXZY NL 28 783738 783738 2 CS .625-11X3.00 FULL HX G5 ZN 29 769257 769257 1 FW .656X 1.250X.250 ZNY 30 029934 029934 3 CS .625-11 X 3.00 HX G5 ZNYC 31 792002 792002 4 5/16-18 X 3/4"MALE KNOB

SERVICE

PART NO.

797712 N/A 3 OPTIONAL BLADE, 18.50"-GAT-F-CW 797704 N/A 3 OPTIONAL BLADE, 18.50"-MUL-F-CW

MFG.

PART NO.

QTY. DESCRIPTION

NOTES:

1. Torque to 118 ft. lbs.

2. Torque to 65-75 ft. lbs.

3. Apply grease to zerk.

4. See ’’Deck Belt Routing and Tensioning” in on page -4 for belt tensioning.

5. See ’’Spindle Assembly–796235” in on page -14 for breakdown.

106567 4/07 7-13

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 600893 N/A 1 BEARING DUST COVER 6 796227 N/A 1 SADDLELESS SPINDLE SHAFT

SERVICE

PART NO.

MFG.

PART NO.

QTY. DESCRIPTION

NOTES:

1. Install upper bearing with extended inner race up.

2. Install lower bearing with extended inner race down.

7-14 106567 4/07

Chapter 8 Contents

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

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

Seat Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

106567 4/07 8-1

Deck Installation

TRACTOR ASSEMBLY

DECK ASSEMBLY

8-2 106567 4/07

Deck Installation

ITEM

NO.

1 055749 055749 4 CS .437-14 X 1.750 HX G5 ZN 2 061101 061101 2 NT .750-10 HX NL ZN 3 025296 025296 4 FW .760 X 1.625 X.08 ZN 4 051169 051169 2 CS .750-10 X 3.000 HX G5 ZN 5 704643 704643 8 NT .437-14 HX FLG ZN

SERVICE

PART NO.

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. 66" Deck installation is shown, 54" and 60" Deck installations are similar.

106567 4/07 8-3

Deck Belt Routing and Tensioning

DECK ASSEMBLY

8-4 106567 4/07

NOTES:

1. Spring length after tensioning belt. Measure spring from outside of hook to outside of hook.

2. Route belt as shown.

106567 4/07 8-5

Seat Installation

8-6 106567 4/07

Seat Installation

INDEX

NO.

1 793661 793661 1 MICHIGAN SEAT 2 350041 350041 1 SEAT PAN 3 000331 000331 3 BLACK CABLE TIE 4 086660 086660 3 NT .375-16 HX LK NY 5 767954 767954 7 FW .406 X .812 X .060 SAE HD ZN 6 724716 724716 1 FIBER WASHER 7 350421 350421 1 SEAT PAN STOP 8 036244 036244 3 CS .375-16 X 1.000 HX G5 ZN

9 052860 052860 2 CS .375-16 X1.250 HX G5 ZN 10 768523 768523 4 FW .343 X .687 X .051/.080 HD ZN/Y 11 034272 034272 4 NT .312-18 HX G5 ZN 12 781880 781880 2 BUMPER 13 080358 080358 1 GM .50 X 1.00 X .75 X .12 GROMMET 14 748756 748756 1 LATCH SPRING PLUNGER 15 350462 350462 1 SEAT LATCH BRACKET 16 781617 781617 3 RUBBER BUMPER 17 722199 722199 1 2" WIDE SCOTCH POLYURETHANE 5.55" LONG

SERVICES

PART NO.

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. Must pivot freely.

2. Service parts available for Michigan Standard seat;

PART NO.

793307 SLIDE KIT 793315 SEAT SWITCH 793331 ARMREST KIT (OPTIONAL SQUARE STYLE) 793349 L.H. ARMREST ASSMBLY (SQUARE STYLE W/ BRACKETS) 793356 R.H. ARMREST ASSMBLY (SQUARE STYLE W/ BRACKETS) 797456 ARMREST KIT (OPTIONAL ROUND STYLE) 767464 L.H. ARMREST ASSMBLY (ROUND STYLE W/ BRACKETS) 797472 R.H. ARMREST ASSMBLY (ROUND STYLE W/ BRACKETS) 797480 ONE ARMREST ONLY (ROUND STYLE W/O BRACKET) 793273 ARMREST STOP ASSY

DESCRIPTION

106567 4/07 8-7

8-8 106567 4/07

Chapter 9 Contents

Tractor Decals–US Version. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Tractor Decals–CE Version. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

66" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

60" Deck Decals–US Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

60" Deck Decals–CE Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

54" Deck Decals–US Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

54" Deck Decals –CE Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

106567 4/07 9-1

Tractor Decals

TOP OF SEAT PAN

BOTTOM OF SEAT PAN

9-2 106567 4/07

Tractor Decals

INDEX

NO.

1 781427 781427 1 DECK HEIGHT INDICATOR DECAL

2 779280 779280 1 HOT & HYDRAULIC OIL DECAL

3 784702 784702 1 INSTRUMENT PANEL DECAL (SEPARATE CHOKE)

4 727008 727008 1 HYD PRESSURE DECAL

5 791830 791830 1 FUEL INDICATOR DECAL

6 782136 782136 1 Z OPERATION DECAL

7 788968 788968 1 ENGINE COMPARTMENT DECAL

8 785188 785188 1 Z ARMREST WARNING DECAL

9 782128 782128 1 Z SERVICE DECAL 10 727016 727016 1 BATTERY DECAL 11 771436 771436 1 STABILIZER DECAL 12 727172 727172 1 MADE IN USA DECAL 13 N/A 083279 1 TURF PROD SERIAL NO PLATE 14 782573 782573 1 FIRST ZERO TURN DECAL 15 793588 793588 1 HUSTLER NAME PLATE 16 786426 786426 1 HUSTLER Z ID DECAL 17 600899 600899 1 PUMP BELT WARNING DECAL

SERVICE

PART NO.

MFG.

PART NO.

QTY. DESCRIPTION

NOTES:

106567 4/07 9-3

66" Deck Decals

INDEX

NO.

1 799189 799189 1 66" SIDE DISCHARGE DECK ID DECAL 2 760637 760637 1 MOWER DECK QUICK REFERENCE DECAL 3 727420 727420 1 DEFLECTOR SHIELD DECAL 4 727172 727172 1 "MADE IN U.S.A." DECAL 5 727453 727453 2 BELT & PULLEY DECAL 6 727438 727438 2 WHIRLING BLADES DECAL 7 781419 781419 1 BELT ROUTING DECAL 8 799353 799353 2 DECK XR7 ID DECAL 9 359547 359547 1 5.00 X 9.00 STEP TREAD

10 797845 797845 1 FUSION DECAL

SERVICE

PART NO.

MFG.

PART NO.

QTY. DESCRIPTION

NOTES:

9-4 106567 4/07

60" Deck Decals

INDEX

NO.

1 786277 786277 1 60" SIDE DISCHARGE DECK ID DECAL 2 760637 760637 1 MOWER DECK QUICK REFERENCE DECAL 3 727420 727420 1 DEFLECTOR SHIELD DECAL 4 727172 727172 1 "MADE IN U.S.A." DECAL 5 727453 727453 2 BELT & PULLEY DECAL 6 727438 727438 2 WHIRLING BLADES DECAL 7 799395 799395 1 BELT ROUTING DECAL 8 799353 799353 2 DECK XR7 ID DECAL 9 359547 359547 1 5.00 X 9.00 STEP TREAD

10 797845 797845 1 FUSION DECAL

SERVICE

PART NO.

MFG.

PART NO.

QTY. DESCRIPTION

NOTES:

106567 4/07 9-5

54" Deck Decals

INDEX

NO.

1 799171 799171 1 54" SIDE DISCHARGE DECK ID DECAL 2 760637 760637 1 MOWER DECK QUICK REFERENCE DECAL 3 727420 727420 1 DEFLECTOR SHIELD DECAL 4 727172 727172 1 "MADE IN U.S.A." DECAL 5 727453 727453 2 BELT & PULLEY DECAL 6 727438 727438 2 WHIRLING BLADES DECAL 7 781419 781419 1 BELT ROUTING DECAL 8 799353 799353 2 DECK XR7 ID DECAL 9 359547 359547 1 5.00 X 9.00 STEP TREAD

10 797845 797845 1 FUSION DECAL

SERVICE

PART NO.

MFG.

PART NO.

QTY. DESCRIPTION

NOTES:

9-6 106567 4/07

Chapter 10 Contents

Maintenance & Adjustment Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

Safe Maintenance & Adjustment Practices . . . . . . . . . . . . . . . . . . . . . . .10-2

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-6

Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-23

106567 4/07 10-1

10-2 1065674/07

Maintenance & Adjustment Safety

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 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 p ay at tention 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 comp letely and thoroughly befor e attempting to set-up, operate, adjust, or service this machine.

The Quick Reference Decals, located in front of and to the right of the seat, 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 ma nu al but in stead i s to be used as an extension o f 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 responsib ility to make certain that the operator/mechanic is a qualified and physically able ind ivid ual , p roper ly trained in the oper ation of this equipment. Local regulations may restrict the age of the operator/mechanic.

The owner should also ensure that the operator/mechanic knows 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.

10-3 106567 4/07

Safe Maintenance & Adjustment Practices

▲ This product is capable of amputating hands and f eet 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 le vers in the park brake position, disengage deck clutch, remove ignition switch key and disconnect the negative battery cable. Repairs or maintenance re quiring 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 e ngine before removing the grass catcher or unclogg ing 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 traine d 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 st a nds 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 cert ain engine cannot b e accidenta lly started. Shut eng ine

10-4 106567 4/07

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 regularly. ▲ Grass collection system components are subject to wear, damage and deterioration, which could

expose moving parts or allow objects to be thrown. Frequently check components and replace with manufacturer’s recommended parts, when necessary.

▲ Use only genuine Hustler replacement parts to en sure that original standards are maintained

Using a ramp

▲ Use extreme caution when loading and unloading a unit with a ramp. ▲ Use only a single, full width ramp; do not use individual ramps for each side of the unit. Having a full

width ramp provides a surface for the tractor frame to contact if the unit starts to tip backwards. It also reduces the risk of a wheel going off and the machine tipping over.

▲ Do not exceed a 15 degree angle between the ramp and the ground or between the ramp and the

trailer or truck.

▲ When on a ramp avoid sudden acceleration

10-5 106567 4/07

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 nonreadable.

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

Part Number

727016

Read Owner’s Manual and Quick Reference Decal 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.

Part Number

727420

Part Number

727438

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.

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

Whirling blades! Keep hands and feet away.

Beware of thrown objects.

10-6 106567 4/07

Part Number

771436

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

Keep shields or covers in place while machine is in operation.

Keep hands away from rotating pulleys and belts.

Part Number

727453

Part Number

788968

Part Number

727008

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

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.

Part Number

600899

Part Number

779280

If you lose steering control while operating the machine,

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

If pump belt fails, steering control will be lost. Refer to

owner’s manual for inspection and replacement intervals and refer to above paragraph for emergency procedures.

Hot surface!

10-7 106567 4/07

Maintenance

Maintenance Locator Chart

1a. Engine Oil Fill & Dipstick (Kawasaki & Honda) 1b. Engine Oil Fill & Dipstick (Kohler) 2a. Fuel Filter (Honda & Kawasaki) 2b. Fuel Filter (Kohler)

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 (2)

13. Drive Tire

14. Pump Idler Ze rk (1)

15. Pump Belt

Viewed from bottom of tractor

FIG. 1

10-8 106567 4/07

Maintenance Locator Chart

54" & 66" XR7 deck

60" XR7 deck

1. Deck Pusher Arm Zerks (2)

2. Deck Belt

3. Spindle Housing Zerk (3)

4. Blades

FIG. 2

10-9 106567 4/07

SERVICE AT INTERVALS INDICATED

Verify safety start interlock system Visually inspect unit for loose hardware and/or

damaged parts Visually inspect ti res Check oil level, engine (1) Clean air intake screen (5) Check fuel level Blades - sharpen & securely fastened Discharge chute - securely in place & in lowest

position Clean engine and pump compartment Replace air cleaner paper element (5) Grease deck idler Grease deck pusher arms Grease pump idler Grease deck height pivots Grease gauge wheel bearings Change engine oil and filter (1) (4) Clean cylinder and head fins(a) Check battery connections Check tire pressure with a gauge Check hydraulic oil level Clean engine exterior (a) Clean & regap spark plugs (a) Check pump and deck belt tension and condition (6) Check fuel and hydraulic lines (7) Check fuel valve and grommet (7) Tighten lug nuts on wheels (2) Change fuel filter Clean or replace hydraulic fill cap Change hydraulic oil and filter (3) Grease deck spindle housings Replace spark plugs

WEEKLY OR 50

HOURS

X X X X X X X X X X X

MONTHLY OR 100

HOURS

Daily Daily

Daily Daily or every 4 hours Daily or every 4 hours

Daily

As needed

X X X X X

ANNUALLY OR 500

HOURS

X X X X X

NOTES:

1. Initial oil change is after 5 hours of operation. Thereafter, change oil after every 40 hours operation. Change more often under dusty or dirty conditions and during hot weather periods.

2. Torque initially and after first 2 hours of operation.

3. Perform initial hydraulic filter change after 50 hours (one week) of ope ra tio n.

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 grommets for any cracks or leaks

REFERENCES:

a-- Refer to Engine Owner’s Manual

NOTE:

After completing maintenance cycle (500 hours), repeat cycle.

10-10 106567 4/07

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 areas; minute dust particles 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, using jack stands or blocks, 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 are 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.................160.01

It is recommended that these be checked after the first 2 hours of operation initially, every 50 hours, and following removal for repair or replacement. For all other torques refer to the various tractor parts manuals for standard torque charts.

NOTE: For engine torque values, see engine owner’s manual.

10-11 106567 4/07

Tires

It is important for level mowing that the tires have the same amount of air pressure. The recommended pressures are:

Drive wheels...........................8-12 psi (55-69 KPa)

Gauge wheels.........................8-12 psi (55-69 KPa)

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. 3

HOUR METER

FIG. 3

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 ar m pi vots 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 into grease zerks. Bearings are sealed and do not require much lubricant.

10-12 106567 4/07

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 specificat ions.

The battery is located under the seat platform FIG. 4.

BATTERY

FIG. 4

WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds,

chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

WARNING: Avoid skin and clothing 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 drink the battery electrolyte. 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. Clean the battery terminal s with a solution of four parts water and one part baking soda when they become corroded.

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.

10-13 106567 4/07

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. Always connect the positive (red) battery cable before connecting the negative (black) 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 charging system should be performed by trained technicians only.

Access to engine and hydraulic pumps

The hydraulic pumps are accessed by lifting the seat pla tfo rm. The seat platfor m is hinged at the front. To raise it, release seat latch and tilt seat platform up and forward.The seat platform catch (FIG. 5) 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 f ull 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.

SEAT PLATFORM CHECK

SEAT PLA TFORM

CONTROL LEVER

FIG. 5

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 lo cate d in front of the engine an d under the operator’s platform FIG. 6.

10-14 106567 4/07

Check oil level in hydraulic system after every 50 hours of operation or weekly, whichever occurs first. Check more often if system appears to be leaking or otherwise malfunctioning.

Fluid level should be 1” from top of reservoir. Use only SAE 10W40 SG, SF/CC, CD service motor oil. Change hydraulic system filter element (FIG. 6) 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 st an dar d oi l filter wrench is used to change filter, threads are right handed. Use a Hustler approved filter element o n ly.

HYDRAULIC RESERVOIR

HYDRAULIC FILTER

FIG. 6

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. St art tractor engine and let run at approximately 2/3 throttle for a few minutes to work any trapp ed 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.

10-15 106567 4/07

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 gaso line in an approved cont a iner and keep it out of th e reach of childre n. Never buy more tha n

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 carpet s 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 eq uipment with its wheels o n

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 no zzle. If a gasoline disp enser 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.

FUEL FILTER

FUEL TANK

Kawasaki Engine Shown

FIG. 7 FIG. 8

The fuel tanks are located in the tractor’s fenders. (FIG. 7) Tot al capacity for the fuel tanks is 15 U.S. gallon (56.8 liter)

10-16 106567 4/07

Use regular unleaded gasoline with an octane rating of 87 or higher. The fuel filter (FIG. 8) is installed in the fuel line between fuel tanks and engine fuel pump. Replace filter

annually or after every 500 hours of operation, wh ichever occurs first. When replacing the fuel filter, check the fuel line hoses and fuel shut-off valve grommet for any cracks or

leaks. Replace as needed. Hustler Z tractors are equipped with a fuel shutoff valve located on the right fuel tank mount (FIG. 9).

Rotate the valve to the middle position (shown) to prevent fuel flow to the fuel pump. The forward position allows fuel to flow from the right fuel tank to the fuel pump. The rear position 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.

RIGHT TANK

POSITION

LEFT TANK

POSITION

FUEL SHUT-OFF

VALVE CLOSED

POSITION SHOWN

FIG. 9

Engine oil and filter

Check engine oil daily and after every 4 hours of operation. Crankcase dipstick and oil filler tube are located at the rear of the machine (FIG. 10). Tractor must be sitting level when checking oil. Refer to engine manual and maintenance schedule for oil recommendation and capacities.

Change the engine oil and filter after the first 5 hours of operation, per the engine manufacturer’s recommendations after that. If tractor is being operated in extremely dirty conditions, then it is recommended oil be changed more frequently.

10-17 106567 4/07

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

ENGINE OIL FILLER TUBE

ENGINE OIL DRAIN PLUG

ENGINE OIL FILTER

Kawasaki Engine Shown

FIG. 10

Engine air filter

Perform engine air filter maintenance per the scheduled maintenance chart. See “SERVICE AT INTERVALS INDICATED” on page 10.

A specially designed dry filter is standard equipment on the Hustler Z and Super Z tractors and supplies clean combustion air to the engine FIG. 11.

PRE-CLEANER

ENGINE OIL FILTER

Kawasaki Engine Shown

FIG. 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 elem ent.

2. Improper installation.

3. Damaged filter, seals or canister.

4. Incorrect air filter element size.

5. Use of poorly designed aftermarket air filter elements.

10-18 106567 4/07

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 an d a c tu ally acts as part of the filter media. When the next round of dirt enters, the first dirt helps filter out even smaller particles making the filter more efficient at stopping dirt from entering the engine. This is referred to as barrier filtration.

Of course, at some point the filter media becomes too clogged to allow air to pass. The mowing conditions will determine the frequency of air filter element changing.

Improper installation of an air filter element

Dust must not leak past the seals on each end of the air filter element. The filter must be aligned with in the canister and properly seated for an effective seal so that no dirt can enter the en gine.

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 expen sive air filter elem ents used on gasoline engines may cause some individuals to opt for a less expensive part.

The filter element must be sufficient size and construc tion 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 T u rf Equipment and the engine man ufacturers ha ve 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.

10-19 106567 4/07

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 d ust cup . Make sure it se als all the way around th e air cleaner bod y, then tighten the clamps.

4. Check all fittings and clamps periodically for tightness and inspect hoses for holes or cracks.

5. Periodically check the inta ke hose for signs of ingeste d dust. Locate a nd rep a ir the source of ingested dirt.

6. Never operate a machine without an air filter installed.

Air restriction indicator

Any unit with a Kohler or Kawasaki engine will have an air restriction indicator installed in the air cleaner FIG. 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 A restriction indicator takes the guesswork out of air cleaner servicing and allows you to safely benefit from

the filter’s optimum performance.

RESET BUTTON

INDICATOR

FIG. 12

General engine maintenance

Detailed instructions and recommendations for break-in and regular maintenance are specified in the Engine Owner’s manual. Please refer to this manual for engine servicing, lubricating oil levels with quality and viscosity recommendations, bolt torques, etc. The engine warranty is backed by the manufacturer. Special attention should be paid to applicable data which will not be duplicated here.

Belt replacement

FIG. 13, FIG. 14 & FIG. 15 show diagram s an d de sc rip tio ns of the unit’s belt drive system s. 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.

10-20 106567 4/07

1. Pump belt

2. Engine pulley

3. Pump idler pulley

4. Pump idler arm

5. Pump pulley

6. Electric deck clutch

7. Pump idler sprin g

2,6

VIEWED FROM

BOTTOM OF UNIT

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

FIG. 13 FIG. 14

54" & 66" XR7 DECK

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

FIG. 15

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.

10-21 106567 4/07

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: INever attempt to straighten a bent blade by heating, or weld a cracked or broken blade

as the blade may break and cause serious inju ry.

DANGER: INever work with blades while engine is running or deck clutch switch is engaged (on).

Always place deck clutch switch in the disengaged position, place control levers in the park brake position and turn engine off and disconnect negative battery cable. Block up mower when you must work under it. Wear gloves when handling blades. Always check for blade damage if mower strikes rock,

branch or other foreign object during mowing!

WARNING: IAlways 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 undern eath. Sharpen the blades on a grinder following pattern as shown FIG. 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. 17 and FIG. 18. Replace any distorted blade. Do not re-use spindle bolts which have stripped, worn or und ercut 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.

10-22 106567 4/07

Hustler Turf Z XR7 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

Chapter 1

General Information

Chapter 2 Contents

Rivet Nut Installation

Footrest Assembly

Chapter 3 Contents

Hydraulic System Installation

Chapter 4 Contents

Battery Installation

Deck Lift Assembly

Steering and Park Brake Assembly

Pump Belt and Pulleys Installation

Chapter 5 Contents

Kawasaki Engine Installation

Honda Engine Installation

Kohler Engine Installation

Fuel System Installation

Instrument Panel Assembly

Electrical Schematic (799320)

Chapter 6 Contents

Front Wheel Assembly

Drive Wheel Assembly Installation

Anti-Rollover Wheel Assembly

Chapter 7 Contents

66" Deck Assembly

66" Deck Pulley Assembly

60" Side Discharge Deck Assembly

60" Deck Pulley Assembly

54" Deck Assembly

54" Deck Pulley Assembly

Chapter 8 Contents

Deck Installation

Deck Belt Routing and Tensioning

Seat Installation

Chapter 9 Contents

Tractor Decals

66" Deck Decals

60" Deck Decals

54" Deck Decals

Chapter 10 Contents

Maintenance & Adjustment Safety

Safe Maintenance & Adjustment Practices

Maintenance