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Hustler Turf Diesel Z manual

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Table of contents for the manual

  • Page 1

    ••••••• Hustler Turf Equipment ••••• P .O. Box 7000 ••• Hesston, Kansas • 67062-2097 Hustler Diesel Z Parts Manual[...]

  • Page 2

    t-2 109706 10/08 IMP OR T AN T : T hi s en gine i s no t eq ui p p ed wi th a s p ark arr es ter mu ff le r. It i s a v i o lat i o n o f Cali fo rn ia P u b li c R es o urc e C o d e S ec ti o n 4 442 t o us e o r op er a t e t h is eng ine o n any fo r e s t - c o ver ed , b rus h- co ver e d , o r gras s - co ve re d uni mp ro ved land . O ther [...]

  • Page 3

    109706 10/08 c-1 T able of Content s Chapter 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Chapter 2 Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Ch[...]

  • Page 4

    c-2 109706 10/08 72" Rear Discharge Deck Pulley Assembly . . . . . . . . . . . . . . . . . . 7-24 60" Rear Discharge Deck Assemb ly . . . . . . . . . . . . . . . . . . . . . . . 7-26 60" Rear Discharge Deck Pulley Assembly . . . . . . . . . . . . . . . . . . 7-28 54" Rear Discharge Deck Assemb ly . . . . . . . . . . . . . . . . [...]

  • Page 5

    109706 10/08 1 -1 Chapter 1 General Information This Manual covers Hustler Diesel Z models 928606A/B, 928614A/B, 928622A/B, 928630A/B, 928648, 928655 & 928663. Frequently Ordered Parts Service Literature Note: When ordering p arts, you must use the p art number as shown for each pa rt, not the index number . Always give the model and seria l nu[...]

  • Page 6

    1-2 109 70 6 10/08 Using this manual Illustrations used were current at th e ti me of printing, but subsequent production changes may cause your machine to vary slightly in detail. Excel Industri es, Inc. reserves the right to redesign and ch ange the machine as deemed neces- sary , without notification. If a change has been made to your machine wh[...]

  • Page 7

    109706 10/08 2 -1 Chapter 2 Content s Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4[...]

  • Page 8

    2-2 109 70 6 10/08 Footrest Assembly 5 6 3 4 4 7 7 7 9 4 10 4 11 1 8 3 4 2 1[...]

  • Page 9

    109706 10/08 2 -3 Footrest Assembly NOTES: 1. Do not tighten, Item 5 (109104 Floor Plate) mu st be able to pivot on these bolts. 2. Service part includes Items 1 and 2 (step treads). INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 785485 785485 2 UPPER STEP TREAD 5.00 2 785493 785493 2 LOWER STEP TREAD 9.00 3 056069 056069 2 CS .[...]

  • Page 10

    2-4 109 70 6 10/08 Rivet Nut Installation NOTES: 1. Service part includes Items 2 and 3 and decals. See “T ractor Decals” on page 9-2. INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 549139 109624 1 T RACTOR FRAME (72" SIDE DISCHARGE) 549121 109621 1 T RACT OR FRAME (66" SIDE DISCHARGE) 5491 13 108932 1 T RACT OR FR[...]

  • Page 11

    109706 10/08 3 -1 Chapter 3 Content s Hydraulic Component Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Hydraulic Component Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Hydraulic Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6[...]

  • Page 12

    3-2 109 70 6 10/08 Hydraulic Component Fittings 7 4 3 9 10 2 1 6 5 8 11 12 13 15 14 16 13 20 17 18 19[...]

  • Page 13

    109706 10/08 3 -3 Hydraulic Component Fittings NOTES: 1. Hydraulic system capacity is 7 US quarts. Fill reservoir to within 1" of top of Item 4 (032771 S trainer). 2. Service part includes safety dec al 779280. See “Tra ctor Decals” on page 9-2. INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 601556 601556 1 WHEEL MOTOR [...]

  • Page 14

    3-4 109 70 6 10/08 Hydraulic Component Mounting 7 4 7 3 2 1 5 6 2 6 5 2 8 9 4 11 10 6 5 LEFT WHEEL MOTOR RIGHT WHEEL MOTOR MANIFOLD T ANDEM PUMPS RESERVOIR 12 12 2[...]

  • Page 15

    109706 10/08 3 -5 Hydraulic Component Mounting NOTES: 1. Part of wheel mo tors (601556 and 601557). INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 036236 036236 4 CS .312-18X1.000 HX G5 2 768523 768523 12 FW .343X.687X.051/.080H 3 036244 036244 2 CS .375-16X1.000 HX G5 4 767954 767954 4 FW .406X .812 X.060 SAE 5 767962 767962 10[...]

  • Page 16

    3-6 109 70 6 10/08 Hydraulic Line Connections 14 4 3 11 2 16 1 13 15 5 5 4 3 3 1 2 6 7 8 8 7 12 11 10 10 9 9 3 3 LEFT WHEEL MOTOR RIGHT WHEEL MOTOR MANIFOLD T ANDEM PUMPS RESERVOIR RIGHT WHEEL MOTOR LEFT WHEEL MOT OR T ANDEM PUMPS FIREW ALL & OIL COOLER[...]

  • Page 17

    109706 10/08 3 -7 Hydraulic Line Connections NOTES: 1. See “Hydraulic r outing” on page 10-8. INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 601521 N/A 1 HOSE MANIFOLD BLOCK TO OIL COOLER 2 601583 N/A 1 HOSE MANIFOLD BLOCK 3 601001 601001 7 SPRING CLAMP .75" DIA 4 601522 N/A 1 HOSE RETURN COOLER TO MANIFOLD BLOCK 5 6015[...]

  • Page 18

    3-8 109 70 6 10/08[...]

  • Page 19

    109706 10/08 4 -1 Chapter 4 Content s Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Steering Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Brake System . . [...]

  • Page 20

    4-2 109 70 6 10/08 Deck Lift Assembly TRACTOR FRAME 1 1 1 4 1 3 2 5 5 5 5 5 4 4 5 6 8 8 4 4 4 4 14 13 9 7 10 10 4 10 11 12 8 10 9 9 6 1[...]

  • Page 21

    109706 10/08 4 -3 Deck Lift Assembly NOTES: 1. Apply grease to zer ks (see owner ’s manual). ITEM NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 348318 348318 1 ST OP HANDLE 2 600437 600437 1 DECK HEIGHT 1/2" PIN W/A 3 783001 783001 1 DECK LIFT INDICA TOR SUBASSEMBLY 4 704643 704643 8 NT .437-14 HX FLG ZN 5 781294 781294 7 CLIP E, 1.00[...]

  • Page 22

    4-4 109 70 6 10/08 S teering Sub-Assembly NOTES: 1. Includes Item 1 (7 81260 S teering Bar Grip). INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 781260 N/A 2 S TEERING BAR GRIP 2 109839 109839 2 HANDLE Z W/A 3 767954 767954 16 FW .406X .812 X.060 SAE 4 036244 036244 4 CS .375-16X1.000 HX G5 5 705178 705178 6 CS .375-16X1.750 HX [...]

  • Page 23

    109706 10/08 4 -5 This p age intentionally lef t blank.[...]

  • Page 24

    4-6 109 70 6 10/08 S teering System TRACTOR FRAME 1 1 3 2 5 5 8 7 10 4 4 9 6 7 6 8 11 12 6 6 13 6 14 15 15 6 16 6 14 10 11 6 13 12 6 15 16 15 6 17 6 12 17 6 12 7 7 2 2 3 3 See “S teering Sub-Assembly” on page 4-4. See “S teering Sub-Assembly” on page 4-4.[...]

  • Page 25

    109706 10/08 4 -7 S teering System NOTES: 1. Tube ends to be clean and free of rust. Apply thin coat of grease prior to installing 781 153 Bushing (item 9 on page 4-4). 2. Item 8 (784439 Lock Co llar) to be adjusted su ch that 109259/109260 S teering Box (Item 8 on page 4-4) has no end play . 3. T orque to 180-200 in-lbs. ITEM NO. SERVICE PART NO. [...]

  • Page 26

    4-8 109 70 6 10/08 Brake System 1 TRACTOR FRAME 1 3 2 5 6 5 4 2 10 4 15 4 7 8 9 11 4 12 3 12 13 14 16 WHEEL MOTOR See “S teering Sub-Assembly” on page 4-4.[...]

  • Page 27

    109706 10/08 4 -9 Brake System NOTES: 1. Do not torque this fastener , s hould be snug but allow Item 1 1 (109109/ 1091 10 Brake Bell Crank) to pivot freely . ITEM NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 782979 782979 2 CS .375-16X4.750 HX G5 2 767954 767954 4 FW .406X .812 X.060 SAE 3 023655 023655 4 NT .312-24 HXZY NL 4 768523 768523[...]

  • Page 28

    4-10 109706 10/08[...]

  • Page 29

    109706 10/08 5 -1 Chapter 5 Content s Engine Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Belt Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Firewall & ROPS Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Air Filter Installat[...]

  • Page 30

    5-2 109 70 6 10/08 Engine Sub-Assembly 35 12 6 47 32 33 45 8 10 13 12 6 10 14 5 17 12 10 40 40 6 27 11 22 12 23 1 3 7 6 5 4 2 18 5 21 6 19 12 20 6 12 20 46 44 41 38 39 4 5 24 6 31 30 24 29 25 28 28 25 29 36 1 2 3 32 6 34 48 FUEL FIL TER DET AIL 9 15 16 1 11 12 37 5 37 12 11 42 43 1 7 7 7 26[...]

  • Page 31

    109706 10/08 5 -3 Engine Sub-Assembly INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 601355 601355 1 ENGINE, ISM S773L DIESEL 2 108976 108976 1 MOTOR MNT W/A RS, HDZ 3 601361 601361 1 MUFFLER, ISM S773L HDZ 4 601428 601428 16 CS M12-1.25 X 25 ZN 5 767962 767962 20 FW .531X 1.063X.090 SAE 6 768523 768523 16 FW .343X.687X.051/.080[...]

  • Page 32

    5-4 109 70 6 10/08 NOTES: 1. Supplied with engine. 2. T orque to 33 f t-lbs. 3. T orque to 78 f t-lbs. 4. Engine oil capacity: See engine owner ’s manual. 5. Engine RPM to be set at 2950±50. 6. Included in 601 498 (Hydro Kit). 7. T orque to 64 f t-lbs.[...]

  • Page 33

    109706 10/08 5 -5 This p age intentionally lef t blank.[...]

  • Page 34

    5-6 109 70 6 10/08 Belt Drive System 17 11 16 16 15 15 14 13 2 1 3 4 5 8 7 6 7 9 12 10 11 17 11 34 23 18 19 20 21 22 25 15 26 31 30 28 29 32 27 1 2 DECK BEL T 6 11 15 15 3 17 11 33 4 7 24 5[...]

  • Page 35

    109706 10/08 5 -7 Belt Drive System NOTES: 1. T orque to 41 f t-lbs. 2. T orque to 21 f t-lbs. 3. Apply grease to zerks. 4. T orque to 100 f t-lbs. 5. T ractors with side discharge de cks use 781385; tractors with rear discharge decks use 796714. 6. T orque to 45-48 f t-lb. 7. T orque to 12-15 f t-lb. INDEX NO. SERVICE PA R T N O . MFG . P ART NO. [...]

  • Page 36

    5-8 109 70 6 10/08 8. For mowers with serial numbers prior to 08051277, shims are required between item 32 (pulley) and the engine. Use quantit y (3) of 601662 (Arbor Shim 0.020 Thk).[...]

  • Page 37

    109706 10/08 5 -9 This p age intentionally lef t blank.[...]

  • Page 38

    5-10 109706 10/08 Firewall & ROPS Assembly 12 9 14 2 1 3 4 5 3 5 6 8 9 10 7 12 19 18 19 18 1 2 1 9 11 13 15 9 16 17 4 19 20 FRONT OF FIREW ALL DET AIL[...]

  • Page 39

    109706 10/08 5-11 Firewall & ROPS Assembly NOTES: 1. Assemble Item 6 (ROPS S top) o n right post of ROPS o nly . 2. Service part includes decals. See “T ractor Decals” on page 9-2. INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 601443 601443 1 ROPS DZ FOLDING 2 601470 601470 2 KNOB HAND FOR ROPS 3 601471 601471 2 L YNCH [...]

  • Page 40

    5-12 109706 10/08 Air Filter Installation 7 5 6 1 2 3 4 11 14 8 10 6 13 11 16 15 13 12 3 3 10 9 3 9 3 6 3 9 3 9 17 AIR FIL TER DET AIL 1 1 3 18[...]

  • Page 41

    109706 10/08 5-13 Air Filter Installation NOTES: 1. Orient the hose clamp on the air fi lter to engine hose so that it is accessible for maintenance (See FIG . 4 on page 10-4). Orient the precleaner cap with the vent notch facing downward and away from the operator (See FIG . 5 on page 10-4). 2. For tractors with serial numbers prior to 08070401, u[...]

  • Page 42

    5-14 109706 10/08 Cooling System Installation 2 2 6 RADIA T OR 3 7 5 1 2 2 2 2 13 4 6 8 9 10 11 11 12 12 6 11 11 2 2 13 13 DET A IL 1 1 2 2 2 13 6 2 2 13 13 4 1 14 14 14 15 16 17 18 SEE RADIA T OR DET AIL FOR ASSEMBL Y 20 20 22 22 24 23 24 21 25 13 2 19 2 21 26[...]

  • Page 43

    109706 10/08 5-15 Cooling System Installation NOTES: 1. Coolant capacity: 6.0 US quart s. 2. Service part includes decals. See “T ractor Decals” on page 9-2. 3. For tractors with serial numbers prior to 08070401, use 706531 (Grommet). INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 036236 036236 6 CS .312-18X1.000 HX G5 2 768[...]

  • Page 44

    5-16 109706 10/08 Engine Cover Installation 2 10 21 6 1 8 2 3 17 5 20 22 19 13 12 6 15 16 11 15 14 18 14 23 7 24 26 7 25 23 28 4 31 13 29 30 13 12 9 21 32 32 34 33 35 35 7 27 3[...]

  • Page 45

    109706 10/08 5-17 Engine Cover Installation NOTES: INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 601363 601363 1 HOOD HDZ 2 767954 767954 2 FW .406X .812 X.060 SAE 3 068551 068551 8 NT .250-20 HXZY NL 4 712927 712927 2 FW .344X 1.00X.12 HRD Z 5 601364 601364 2 HINGE 3"X3" ZN W/ HOLES 6 601503 601503 8 CB .250-20 X .62[...]

  • Page 46

    5-18 109706 10/08 Fuel System 9 12 10 11 1 3 5 2 14 1 4 4 6 5 6 7A 8A 4 4 10 11 15 16 16 9 7B 7A 7B 8B 8A 8B 12 13 17 19 3 2 18 4 4[...]

  • Page 47

    109706 10/08 5-19 Fuel System NOTES: 1. Includes Item 6 (601375 O-Ring). 2. Left side fuel sensor termi nal of wire harness connects here. 3. Right side fuel sensor termi nal of wire harne ss connects here. 4. T orque to 20 f t-lbs. 5. Used on tractors with se rial numbers hi gher than 08070401. 6. Used on tractors with se rial numbers prior to 080[...]

  • Page 48

    5-20 109706 10/08 Battery and Electrical Connections 5 7 4 15 6 10 5 3 1 2 TRACT OR FRAME 14 16 18 8 13 12 11 9 1 4 3 3 3 5 3 3 GRN/BLK ORG/GRN 3 PUR 3 YEL/BL K AL TERNA TOR CONNECT OR RED/BLK BLK 3 YEL/WHT 3 WHT/YEL 14 17 18 15 16 POSITIVE BA TT . CABLE DET A IL 19[...]

  • Page 49

    109706 10/08 5-21 Battery and Electrical Connections NOTES: 1. When performing servic e on mower , disconnect battery ground cable and do not reconnect to battery until engi ne is ready to be started. See Owners Manual. 2. Battery is not inst alled in export models. 3. Part of wire harness. 4. Includes 50 amp master fuse. 5. Hardware comes with eng[...]

  • Page 50

    5-22 109706 10/08 Instrument Panel 21 1 2 7 3 13 4 6 7 8 9 10 11 12 15 19 20 22 23 23 24 25 26 27 28 29 30 31 31 32 34 27 35 22 22 36 21 16 17 15 18 1 16 FUSE SIZE & LOCA TION 15A 25A FIREW ALL 1 5 } 5 22 33 14 37 THROTTLE DET AIL 35 27 30 29 37 28 27 26 33 34 20[...]

  • Page 51

    109706 10/08 5-23 Instrument Panel NOTES: 1. Part of wire harness (601367). 2. For wire harness connections see “Instrument panel and wire connections (FIG . 1).” on page 10-3. 3. Service part includes decals. See “T ractor Decals” on page 9-2. INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 109557 109557 1 INSTRUMENT P A[...]

  • Page 52

    5-24 109706 10/08 Electrical Schematic—601367[...]

  • Page 53

    109706 10/08 6 -1 Chapter 6 Content s Front Wheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Front Wheel Breakdown—747782. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Optional Semi-Pneumatic Tire/Wheel—78953 7 . . . . . . . . . . . . . . . . 6-5 Drive Wheel Assembly Installation . . . . . . .[...]

  • Page 54

    6-2 109 70 6 10/08 Front Wheel Assembly 3 1 TRACTOR FRAME 1 2 2 3 4 4 3 5 5 4 4 6 6 7 7 11 11 9 8 10 8 8 9 1 1 2 3 3 3[...]

  • Page 55

    109706 10/08 6 -3 Front Wheel Assembly NOTES: 1. Apply grease to zerks. 2. T orque to 100 ft.-lbs. 3. Assemble with extended inner race toward item 5 (387035 S pacer , 1.07 x 1.312 x 2.793). INDEX NO. SER VICE P ART N O. MFG . P ART NO. QTY . DESCRIPTION 1 705954 705954 2 CS .500-13X1.25 HX G5 Z 2 344267 344267 2 F W .510X 2.15 X.187 SPL 3 712967 7[...]

  • Page 56

    6-4 109 70 6 10/08 Front Wheel Breakdown—747782 NOTES: 1. Inflate tire to 8 -12 psi. ITEM NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 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 SP ACER 5 019521 N/A 1 TIRE V AL VE 6 01551 1 N/A 1 GREASE FITTING 45 DEG 1/4 1 1 1 2 4 3 5 6[...]

  • Page 57

    109706 10/08 6 -5 Optional Semi-Pneumatic T ire/Wheel—789537 NOTES: ITEM NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 039677 N/A 2 WHEEL BEARING 2 789537 N/A 1 T IRE/WHE EL ASSEMBLY 3 01551 1 N/A 1 GREASE FITTING 45 DEG 1/4 4 782771 N/A 1 BEARING SP ACER 1 1 2 4 3[...]

  • Page 58

    6-6 109 70 6 10/08 Drive Wheel Assembly Installation NOTES: 1. T orque to 65-75 ft. lbs. 2. Inflate tire to 8 -12 psi. ITEM NO. SERVICE PART NO. PART N O. QTY DESCRIPTI ON 1 601238 601238 2 WHEEL & TIRE ASSY FOR SD 60", 66" & 72" & 54" RD (QTY PER TRACTOR) 2 781245 N/A TIRE, 12 X 12 X 24 FOR SD 60", 66" &am[...]

  • Page 59

    109706 10/08 6 -7 Anti-Rollover Wheel Assembly NOTES: 1. Do not torque, wh eel must turn freely . ITEM NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 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 .500-13 HX G8 ZY NL TRACTOR FRAME 1 1 4 2 1[...]

  • Page 60

    6-8 109 70 6 10/08[...]

  • Page 61

    109706 10/08 7 -1 Chapter 7 Content s 72" Side Discharge XR7 Deck Assembly . . . . . . . . . . . . . . . . . . . . . 7-2 72" Side Discharge XR7 Deck Pulley Asse mbly . . . . . . . . . . . . . . . . 7-4 66" Side Discharge XR7 Deck Assembly . . . . . . . . . . . . . . . . . . . . . 7-6 66" Side Discharge XR7 Deck Pulley Asse mbly [...]

  • Page 62

    7-2 109 70 6 10/08 72" Side Discharge XR7 Deck Assembly 1 9 7 10 5 4 10 11 7 7 9 11 7 7 9 10 1 4 15 15 14 3 2 3 4 5 6 5 4 13 13 13 17 13 8 8 8 8 8 8 7 9 9 9 10 10 11 11 11 18 10 4 4 4 4 5 5 16 16 12 12[...]

  • Page 63

    109706 10/08 7 -3 72" Side Discharge XR7 Deck Assembly NOTES: 1. Do not torque, Item 2 (798694 Discharge Chut e) must pivot freely . 2. Includes items 7, 8, 9, and 10. 3. Service part deck includes decals (see ‘‘72" Side Discharge XR7 Deck Decals’ ’ on page 9-4 for listing of decals). INDEX NO. SERVICE PA R T N O . MFG. PART NO. Q[...]

  • Page 64

    7-4 109 70 6 10/08 72" Side Discharge XR7 Deck Pulley Assembly 1 4 2 16 16 16 20 19 22 24 23 27 1 2 6 12 11 15 9 8 4 13 17 16 27 5 INDEXING 14 14 6 BEL T GUIDE 72" DECK ASSY 15 15 30 7 10 3 18 21 25 26 28 29 30[...]

  • Page 65

    109706 10/08 7 -5 72" Side Discharge XR 7 Deck Pulley Assembly NOTES: 1. T orque to 1 18 ft . lbs. 2. T orque to 67-75 ft. lbs. 3. Apply grease to ze rk (see owner ’s manual). 4. See ‘‘72", 66" & 54" Side Disch. Deck Belt Routing/T ensioning’’ on p age 8-6 for belt tensioning. 5. See ‘‘S pindle Assembly—79623[...]

  • Page 66

    7-6 109 70 6 10/08 66" Side Discharge XR7 Deck Assembly 1 9 7 10 5 4 10 11 7 7 9 11 7 7 9 10 1 4 14 14 13 3 2 3 4 5 6 5 4 12 12 12 15 12 8 8 8 8 8 8 7 9 9 9 10 10 11 11 11 16 4[...]

  • Page 67

    109706 10/08 7 -7 66" Side Discharge XR7 Deck Assembly NOTES: 1. Do not torque, Item 2 (798694 Discharge Chut e) must pivot freely . 2. Includes items 7, 8, 9, and 10. 3. Service part deck includes decals (see ‘‘66" Side Discharge XR7 Deck Decals’ ’ on page 9-5 for listing of decals). ITEM NO. SERVICE PA R T N O . MFG. PART NO. QT[...]

  • Page 68

    7-8 109 70 6 10/08 66" Side Discharge XR7 Deck Pulley Assembly 1 4 2 16 18 21 22 20 23 25 24 26 29 1 2 6 7 10 11 12 16 8 9 4 13 17 28 30 5 BEL T GUIDE INDEXING 14 14 3 6 66" DECK ASSY 15 19 15 15 15 27 28 16 16[...]

  • Page 69

    109706 10/08 7 -9 66" Side Discharge XR 7 Deck Pulley Assembly NOTES: 1. T orque to 1 18 ft . lbs. 2. T orque to 67-75 ft. lbs. 3. Apply grease to ze rk (see owner ’s manual). 4. See ‘‘72", 66" & 54" Side Disch. Deck Belt Routing/T ensioning’’ on p age 8-6 for belt tensioning. 5. See ‘‘S pindle Assembly—79623[...]

  • Page 70

    7-10 109706 10/08 60" Side Discharge XR7 Deck Assembly 3 4 4 9 10 10 16 7 1 7 7 11 9 9 10 8 7 9 11 11 7 4 5 2 4 6 5 16 15 12 12 18 12 12 1 3 4 4 8 9 10 7 8 9 11 13 4 4 5 14 14 14 4 4 14 4 5 8 10 8 11 8 13 11 17[...]

  • Page 71

    109706 10/08 7-11 60" Side Discharge XR7 Deck Assembly NOTES: 1. Do not torque, Item 2 (798694 Discharge Chut e) must pivot freely . 2. Includes items 7, 8, 9, and 10. 3. Service part deck includes decals (see ‘‘60" Side Discharge XR7 Deck Decals’ ’ on page 9-6 for listing of decals). ITEM NO. SERVICE PA R T N O . MFG. P ART N O. [...]

  • Page 72

    7-12 109706 10/08 60" Side Discharge XR7 Deck Pulley Assembly 1 2 4 BEL T GUIDE INDEXING 11 14 18 20 21 17 24 25 26 27 29 9 8 1 2 7 5 10 16 12 4 6 15 13 13 14 14 16 16 16 19 22 23 30 3 6 60" DECK ASSY 27 15 15 15 28 3[...]

  • Page 73

    109706 10/08 7-13 60" Side Discharge XR 7 Deck Pulley Assembly NOTES: 1. T orque to 1 18 ft . lbs. 2. T orque to 65-75 ft. lbs. 3. Apply grease to ze rk (see owner ’s manual). 4. See ‘‘60" Side Disch. XR7 Deck Belt Routing/T ensioning’’ on p age 8-7 for belt tensioning. 5. See‘‘S pindle Assembly—796235X’ ’ on page 7-34[...]

  • Page 74

    7-14 109706 10/08 54" Side Discharge XR7 Deck Assembly 1 9 10 13 13 4 5 11 12 11 11 10 10 9 9 12 5 7 11 10 9 1 14 15 2 3 4 8 8 8 17 6 12 4 12 4 5 14 4 3 4 5 17 12 4 4 4 16 16 11 10 13 9 9 10 8 11 6 4 4 13 13 13[...]

  • Page 75

    109706 10/08 7-15 54" Side Discharge XR7 Deck Assembly NOTES: 1. Do not torque, Item 2 (798694 Discharge Chut e) must pivot freely . 2. Includes items 9, 10, 1 1, and 13. 3. Service part deck includes decals (see ‘‘54" Side Discharge XR7 Deck Decals’ ’ on p age 9-7 for listing of decals) and item 2 (Discharge Chute). ITEM NO. SERV[...]

  • Page 76

    7-16 109706 10/08 54" Side Discharge XR7 Deck Pulley Assembly BEL T GUIDE POSITIONING 1 4 30 30 30 17 20 19 15 21 22 23 29 24 25 30 5 16 18 1 5 8 7 10 9 3 11 13 14 2 12 26 54" DECK ASSY 4 27 28 2 6 24 6 27[...]

  • Page 77

    109706 10/08 7-17 54" Side Discharge XR 7 Deck Pulley Assembly NOTES: 1. T orque to 1 18 ft . lbs. 2. T orque to 65-75 ft. lbs. 3. Apply grease to zerk. 4. See ‘‘72", 66" & 54" Side Disch. Deck Belt Routing/T ensioning’’ on p age 8-6 for belt tensioning. 5. See‘‘S pindle Assembly—796235X’ ’ on page 7-34 for[...]

  • Page 78

    7-18 109706 10/08 Sid e Discharge Deck—"A" Adaptors 3 DECK ASSEMBL Y 4 4 1 2 2 3[...]

  • Page 79

    109706 10/08 7-19 Side Discharge Deck—"A" Adaptors NOTES: ITEM NO. SERVICE PA R T N O . MFG . P ART N O. QTY . DESCRIPTI ON 1 108661 108661 2 AIR FLOW FLOOR (72" D ECKS) 108531 108531 2 AIR FLOW FLOOR (66" DECK S) 108516 108516 2 AIR FLOW FLOOR (60" DECK S) 108619 108619 2 AIR FLOW FLOOR (54" DECK S) 2 025395 025395 [...]

  • Page 80

    7-20 109706 10/08 Side Discharge Deck—"B" Adaptors 1 4 3 Deck Assembly 4 6 5 7 5 6 4 5 Assembled Detail 2[...]

  • Page 81

    109706 10/08 7-21 Side Discharge Deck—"B" Adaptors NOTES: 1. Service part includes rivet nut s. ITEM NO. SERVICE PA R T N O . MFG . P ART N O. QTY . DESCRIPTI ON 1 108663 108663 1 AIR FLOW BAFFLE, "B" RIGH T SIDE (72" DECKS) 108533 108533 1 AIR FLOW BAFFLE, "B" RIGHT SIDE ( 66" DECKS) 108518 108518 1 AIR FL[...]

  • Page 82

    7-22 109706 10/08 72" Rear Discharge Deck Assembly 1 2 4 5 6 7 5 6 8 32 32 11 11 12 13 6 14 6 13 13 15 15 15 15 16 16 16 16 17 17 18 18 19 19 19 19 10 10 31 31 4 4 20 21 22 23 23 24 24 26 25 27 27 28 28 3 30 30 4 30 18 17 6 29 29 22 30 DEFLECTOR DET AIL 9 5 6 5 6 9[...]

  • Page 83

    109706 10/08 7-23 72" Rear Discharge Deck Assembly NOTES: 1. Factory assembled in t op hole for shipping purposes. 2. Includes Items 15 through 17 and 19. 3. Service part deck includes decal s, see ‘‘72" Rear Discharge Deck Decals’ ’ on page 9-8. 4. When installing Items 22 and 24, Item 24 shoul d be on top of Item 22. ITEM NO. SE[...]

  • Page 84

    7-24 109706 10/08 72" Rear Discharge Deck Pulley Assembly 1 1 2 8 19 18 20 9 9 13 14 4 12 19 22 22 19 9 27 31 32 26 23 23 24 33 23 2 3 28 23 5 22 27 3 5 1 18 6 29 19 10 16 21 25 22 10 11 17 15 5 20 21 5 5 6 24 23 24 30 6 7 2[...]

  • Page 85

    109706 10/08 7-25 72" Rear Discharge Deck Pulley Assembly NOTES: 1. T orque to 1 18 ft . lbs. 2. T orque to 65-75 ft. lbs. 3. See ‘‘72", 60" & 54" Re ar Discharge Deck Belt Ro uting/T ensioning’’ on page 8-8 for belt tensioning. 4. See ‘‘S pindle Assembly—796235X ’’ on p age 7-34 for breakdown. 5. See ‘?[...]

  • Page 86

    7-26 109706 10/08 60" Rear Discharge Deck Assembly 1 2 30 3 4 5 6 4 5 6 25 25 33 5 21 12 5 11 13 13 13 13 14 14 14 14 15 15 15 16 16 16 17 17 17 17 8 7 5 27 20 28 19 3 30 30 28 26 29 24 23 22 32 22 9 11 9 4 DEFLECTOR 21 18 5 DET AIL 7 32 4 20 3 30 10 3 29[...]

  • Page 87

    109706 10/08 7-27 60" Rear Discharge Deck Assembly NOTES: 1. Includes Items 13 through 15 and 17. 2. Factory assembled in t op hole for shipping purposes. 3. Service part deck includes decal s, see ‘‘72" Rear Discharge Deck Decals’ ’ on page 9-8. 4. When installing Items 20 and 22, Item 22 shoul d be on top of Item 20. INDEX NO. S[...]

  • Page 88

    7-28 109706 10/08 60" Rear Discharge Deck Pulley Assembly 1 1 6 2 10 17 5 5 6 19 7 8 9 16 4 5 22 23 19 19 22 23 28 23 22 31 23 2 3 30 26 27 17 29 3 5 1 11 19 20 12 18 20 6 8 22 18 5 6 21 8 24 25 27 24 12 13 14 9 15 18 5 32 33 2[...]

  • Page 89

    109706 10/08 7-29 60" Rear Discharge Deck Pulley Assembly NOTES: 1. T orque to 1 18 ft . lbs. 2. T orque to 65-75 ft. lbs. 3. See ‘‘72", 60" & 54" Re ar Discharge Deck Belt Ro uting/T ensioning’’ on page 8-8 for belt tensioning. 4. See ‘‘S pindle Assembly—796235X ’’ on p age 7-34 for breakdown. 5. See ‘?[...]

  • Page 90

    7-30 109706 10/08 54" Rear Discharge Deck Assembly 1 29 3 5 5 6 6 8 8 32 5 11 5 10 12 12 12 12 13 13 13 13 14 14 15 15 15 16 16 16 16 7 7 7 7 26 3 2 21 21 20 20 28 18 17 19 19 29 10 29 13 13 14 10 5 DEFLECTOR DET AIL 30 4 5 4 22 33 33 31 9 27 29 3 31 3 29 25 27 24 4 5 4 23 24[...]

  • Page 91

    109706 10/08 7-31 54" Rear Discharge Deck Assembly NOTES: 1. Factory assembled in t op hole for shipping purposes. 2. Includes Items 12 through 14 and 16. 3. Service part deck includes decal s, see ‘‘54" Rear Discharge Deck Decals’ ’ on page 9-10. 4. When installing Items 19 and 21, Item 21 shoul d be on top of Item 19. ITEM NO. S[...]

  • Page 92

    7-32 109706 10/08 54" Rear Discharge Deck Pulley Assembly 1 1 10 13 12 9 18 15 11 20 4 2 8 14 22 22 22 19 20 21 19 26 10 27 29 28 32 23 33 24 24 2 3 30 23 23 22 19 10 25 3 1 23 5 6 21 5 17 5 19 27 16 2 31 18 5 6 5 6 7 11[...]

  • Page 93

    109706 10/08 7-33 54" Rear Discharge Deck Pulley Assembly NOTES: 1. T orque to 1 18 ft . lbs. 2. T orque to 65-75 ft. lbs. 3. See ‘‘72", 60" & 54" Re ar Discharge Deck Belt Ro uting/T ensioning’’ on page 8-8 for belt tensioning. 4. See ‘‘S pindle Assembly—796680X ’’ on p age 7-35 for breakdown. 5. See ‘?[...]

  • Page 94

    7-34 109706 10/08 Spindle Assembly—796235X NOTES: 1. Install upper b earing with extended inner race up. 2. Install lower bearing with extended inner race down. ITEM NO. SERVICE PA R T N O . MFG . PA R T N O . QTY . DESCRIPTION 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 [...]

  • Page 95

    109706 10/08 7-35 Spindle Assembly—796680X NOTES: 1. Install upper b earing with extended inner race up. 2. Install lower bearing with extended inner race down. ITEM NO. SERVICE PA R T N O . MFG . P ART N O. QTY . DESCRIPTION 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 [...]

  • Page 96

    7-36 109706 10/08[...]

  • Page 97

    109706 10/08 8 -1 Chapter 8 Content s Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 72", 66" & 54" Side Disch. Deck Belt Ro uting/Tensioning . . . . . . . . . 8-6 60"[...]

  • Page 98

    8-2 109 70 6 10/08 Deck Installation 2 4 3 5 5 1 1[...]

  • Page 99

    109706 10/08 8 -3 Deck Installation NOTES: 1. Install front de ck hanger chains in lower holes only . INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 055749 055749 4 CS .437-14X1.750 HX G5 2 061 101 061 101 2 NT .750- 10 HXZY NL 3 025296 025296 4 FW .760X 1.625X.08 ZNYC 4 051 169 051 169 2 CS .750-10X3.00 0 HX G5 5 704643 704643 [...]

  • Page 100

    8-4 109 70 6 10/08 Seat Installation 1 1 4 3 2 2 3 4 6 5 9 7 8 10 11 13 14 12 16 10 17 10 17 10 17 10 18 15 10 8 10 19 11 TRACTOR FRAME 1 20[...]

  • Page 101

    109706 10/08 8 -5 Seat Installation NOTES: 1. Must pivot freely . 2. Service part number includes decal s; see “T ractor Decals” on page 9-2. INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 792051 792051 1 MICHIGAN SUSPENSION SEAT 2 601444 601444 1 SEAT BELT 3 017129 017129 2 FW .440X 1.000X.083 ZNY 4 797076 797076 2 CS .437-[...]

  • Page 102

    8-6 109 70 6 10/08 72", 66" & 54" Side Disch. Deck Belt R ou t in g/T ensioning NOTES: 1. T ension spring in deck leveling positi on. Measure spring from outside of hook to outside of hook. S pring l ength after tensioning new belt. 2. Route belt as shown.[...]

  • Page 103

    109706 10/08 8 -7 60" Side Disch. XR7 Deck Belt R ou t in g/T ensioning NOTES: 1. S pring length after tensioning belt. Measure spring from out side of hook to outside of hook. 2. Route belt as shown.[...]

  • Page 104

    8-8 109 70 6 10/08 72", 60" & 54" Rear Discharge Deck Belt Routing/T ensioning NOTES: 1. T ension spring in deck leveling positi on. Measure spring from outside of hook to outside of hook. S pring l ength after tensioning new belt. 2. Route belt as shown.[...]

  • Page 105

    109706 10/08 9 -1 Chapter 9 Content s Tractor Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 72" Side Discharge XR7 Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . 9-4 66" Side Discharge XR7 Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . 9-5 60" Side Discharge X[...]

  • Page 106

    9-2 109 70 6 10/08 T ractor Decals 21 15 19 16 20 13 22 9 17 10 11 12 4 7 8 5 TO P OF SEA T P AN BOTT OM OF SEA T P AN 18 6 3 1 2 14[...]

  • Page 107

    109706 10/08 9 -3 T ractor Decals NOTES: INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 763805 763805 1 F AN FINGER WARNING DECAL 2 785121 785121 1 OPERA TION R IGHT DECAL 3 788968 788968 1 ENGINE COMP ARTMENT DECAL 4 601374 601374 1 FUEL GAUGE DECAL 5 601372 601372 1 INSTRUMENT P ANEL DECAL HDZ 6 600899 600899 1 PUMP BEL T WARN[...]

  • Page 108

    9-4 109 70 6 10/08 72" Side Discharge XR7 Deck Decals NOTES: INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 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 &am[...]

  • Page 109

    109706 10/08 9 -5 66" Side Discharge XR7 Deck Decals NOTES: INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 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 &[...]

  • Page 110

    9-6 109 70 6 10/08 60" Side Discharge XR7 Deck Decals NOTES: INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 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 &am[...]

  • Page 111

    109706 10/08 9 -7 54" Side Discharge XR7 Deck Decals NOTES: INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 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 &[...]

  • Page 112

    9-8 109 70 6 10/08 72" Rear Discharge Deck Decals NOTES: INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 786285 786285 1 72" DECK ID DECAL 2 760637 760637 1 MOWER DECK QUICK REFERENCE DECAL 3 727453 727453 4 BELT & PULLEY DECAL 4 727438 727438 2 WHIRLING BLADES DECAL 5 727172 727172 1 “MADE IN U.S.A.” DECAL 6 60[...]

  • Page 113

    109706 10/08 9 -9 60" Rear Dischar ge Deck Decals NOTES: INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 786277 786277 1 60" SIDE DISCHARGE DECK ID DECAL 2 760637 760637 1 MOWER DECK QUICK REFERENCE DECAL 3 727453 727453 4 BELT & PULLEY DECAL 4 727438 727438 2 WHIRLING BLADES DECAL 5 727172 727172 1 “MADE IN U.S.A[...]

  • Page 114

    9-10 109706 10/08 54" Rear Discharge Deck Decals NOTES: ITEM NO. SERVICE PA R T N O . MFG . PA R T N O . QTY . DESCRIPTION 1 799171 799171 1 54" REAR DISCHARGE DECK ID DECAL 2 760637 760637 1 DECAL MOWER DECK QUICK REFERENCE 3 727438 727438 4 DECAL WHIRLING BLADES 4 727453 727453 4 DECAL BEL T & PULLEY 5 727172 727172 1 DECAL 'MA[...]

  • Page 115

    109706 10/08 10-1 Chapter 10 Content s Assembly Pictures and Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 General Information for al l models . . . . . . . . . . . . . . . . . . . . 10-3 Wire harness and cable rout ings . . . . . . . . . . . . . . . . . . . . . 10-4 Fuel lines. . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 116

    10-2 109706 10/08 Belt replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27 Mower blade maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 10-28 Mower blade removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 117

    10-3 109706 10/08 Assembly Pictures and Aids General Information for all models Instrument pane l and wire connections (FIG . 1). FIG . 1 Oil Pressure Light Orange Y ellow w/ Black stripe Glow Plug Light Orange Green w/ Black stripe Coolant T em per at ure Light O ra nge Y ellow w/ Whit e str ipe Charge Light Orange Y ellow w/ Red stripe Hour Meter[...]

  • Page 118

    10-4 109706 10/08 PTO clutch wire routing (FIG . 2 & FIG . 3 ) Orient the hose clamp on the air filter to engine hose so that it is accessible for maintenance (FIG . 4). Orient the pre- cleaner cap with the vent notch fa cing downward and away from the operat or (FIG . 5). Wire harness and cable routings Battery cable connections (FIG . 6 &[...]

  • Page 119

    10-5 109706 10/08 Fuel sensors and wire harness routing ( FIG . 8, FIG . 9 & FIG . 10) Oil cooler and wire harness routing (FIG . 1 1 & FIG . 12). FIG . 8 FIG . 9 FIG . 10 FIG . 1 1 FIG . 12 FUEL SENSOR CONNECTOR THROTTLE CABLE RIGHT SIDE WIRE HARNESS TIE STRAP TIE STRAP FUEL SENSOR CONNECTOR WIRE HARNESS LEFT SIDE TIE STRAP FUEL T ANK FUEL[...]

  • Page 120

    10-6 109706 10/08 Throttle cable conn ection (FIG . 14). Fuel lines Fuel priming b ulb (with ar row facing u p) and right side fuel line routing (FIG . 15 & FIG . 16) FIG . 13 FIG . 14 FIG . 15 THROTTLE CABLE THROTTLE CABLE CLIP FROM RIGHT SIDE FUEL T ANK FUEL LINES HYDRAULIC LINES TIE STRAP FROM PRIMING BULB TO PUMP FUEL LINE AIR HOS E ON ENGI[...]

  • Page 121

    10-7 109706 10/08 Left side fuel line routing (FIG . 17 & FIG . 1 8) FIG . 16 FIG . 17 FIG . 18 PRIMING WIRE HARNESS HYDRAULIC HOSES BULB ARROW UP TIE STRAP TIE STRAP TIE STRAP WIRE HARNESS FUEL LINES TIE STRAP TO F A N SHROUD TIE STRAP FUEL LINES TIED OIL COOLER WITH WIRE HARNESS[...]

  • Page 122

    10-8 109706 10/08 Fuel valve and fuel filte r (F IG . 19 & FIG . 20) Hydraulic routing Hydraulic hose routings (FIG . 21, FIG . 22 & FIG . 23) FIG . 19 FIG . 20 FIG . 21 FIG . 22 FUEL V AL VE RETURN LINE LEFT SIDE FROM ENGINE RETURN LINE TO PRIMING BULB SUPPL Y LINE FROM LEFT T ANK SUPPL Y LINE LEFT LINES SHOWN—RIGHT SIDE SIMILAR ENGINE R[...]

  • Page 123

    10-9 109706 10/08 Engine oil hose routing Route engin e oil hoses be hind the seat latch & thro ugh clamp to remote filter a t rear of t ractor (FIG . 24 & FIG . 25) FIG . 23 FIG . 24 FIG . 25 TIE STRAP SEA T LA TCH ADAPTOR OIL HOSES T O REMOTE FIL TER TIE STRAP CLAMP OIL HOSES TO REMOTE FIL TER FIL TER[...]

  • Page 124

    10-10 109706 10/08 Maintenance & Adjustment Safety This safety alert symbol is used to call attention to a message inte nded to provide a reasonable degree of PER- SONAL SAFETY for operators and other persons dur i ng the normal operation and servicing of this equipment. DANGER — denotes immediate hazards wh ich WILL result in severe pers ona[...]

  • Page 125

    10-11 109706 10/08 ▲ Except when changing or checking belt, always keep belt covers on mower for safety as well as cleanliness. ▲ S top the engine before removing the grass catcher or uncloggin g th e dis c ha r ge chu te . Never clear the discharge chute with the engine runn ing. Turn of f the engine and be sure the blades have sto pped before[...]

  • Page 126

    10-12 109706 10/08 The following illustration s show the various decals that are located on the machine. A brief explanation, for those requiring one, is shown to help the oper at or understand the meanings of these decals. Read Owner ’s Manual an d Quick Reference Decal before attempting to operate this ma chine. Avoid skin cont act with battery[...]

  • Page 127

    10-13 109706 10/08 If you lose steering cont rol while operating the machine, place the ste ering control levers in the park brake pos ition immediat ely . Inspe ct the machine an d involve your Hustler dealer to resolve the problem before co ntinuing to operate. If pump belt fails, s teering control will be lost. Refer to owner ’s manu al for in[...]

  • Page 128

    10-14 109706 10/08 Maintenance FIG . 26 11 V i ewed from top of unit 11 12 11 11 12 9 7 9 6 6 18 5 17 19 3 1 2 1 16 13 13 16 8 4 V iewed from bottom of unit 1. Engine Oil Dipstick 2. Fuel Filter 3. Engine Air Cleaner 4. Engine Oil Drain Plug 5. Battery 6. Fuel T anks 7. Hydraulic Oil Reservoir 8. Hydraulic Oil Filter 9. Gauge Wheel Bearing Zerks (2[...]

  • Page 129

    10-15 109706 10/08 NOTES: 1. Initial oil change is af ter 50 hours of operation. Thereaft er , change oil after every 250 hours operatio n. Change more often un der dusty or dirty conditions and during hot weather periods. 2. T orque initially and after first 2 hours of operation. 3. Perform initial hydraulic f ilter change afte r 50 hours (one wee[...]

  • Page 130

    10-16 109706 10/08 Introduction Regular maintenance is the best preve n tion for costly downtime or expensive, premature rep air . The following pages co nt ain suggested maintenance infor mation and sche du les which the ope ra tor shou ld follo w on a routine b asis. Remain alert for unusual noises, they could be signaling a proble m. Visua lly i[...]

  • Page 131

    10-17 109706 10/08 W ARN ING: Explosive separation of a tire and rim can cau s e serious injury or death. Do not attempt to mount a tire without the proper equ ipment and experience to perform the task. Always maintain the correct tir e pr essure and never over inflate. Never weld or heat a wheel and tire asse mbly as an explosion may occur . Weldi[...]

  • Page 132

    10-18 109706 10/08 Electrical system The electrical system is a 12-volt, ne gative ground. Reco mmended battery size is a garden tractor BCI group 45 with 480 or better cranking AMP rating. A ma inten ance-free battery is recommended. Othe rwise, follow battery manu- facturer ’s mainte nance, safety , storing and charging specific ations.The batt[...]

  • Page 133

    10-19 109706 10/08 Access to engine and hydraulic pump s The hydraulic pump s are accessed by lifting the seat plat form. The seat platform is hinged at the front. T o raise it, release seat latch and tilt seat platform up and forward.The seat platform catch (FIG . 2 9) will prevent the seat from going all the way over . However , if more access is[...]

  • Page 134

    10-20 109706 10/08 1. Smear a light coating of oil on filter ’s o-rings. 2. Insert th e filte r ele m en t into the hyd ra ulic reserv oir hou sin g. Tighten the oil filter 10 ft.- lbs. (13.56 Nm) — DO NOT OVERTIGHTEN. 3. S tart tractor engine and let run at appr oxim ately 2/3 throttle for a few minutes to work any trapped air out of the syste[...]

  • Page 135

    10-21 109706 10/08 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 diesel fuel s pills. Allow engine to cool before st oring machine inside a building. Keep fuel away from open flame or sp ark and store machine away from open flame o[...]

  • Page 136

    10-22 109706 10/08 4. T ry and start the engine. If it will not st ar t after 15 seconds of cranking, repeat S tep 3. 5. If after trying several times and the engine sti ll will not star t, cont act your Hustler Dealer . Hustler Z Diesel tractor s are eq uip p ed with a fu el shu toff va lve located on the lower right of the front en gin e guard (F[...]

  • Page 137

    10-23 109706 10/08 Engine oil and filter Check engine oil daily and af ter every 4 hours of operation . The crankcase dipstick is lo cate d at the front of the engine (FIG . 35) and oil fi ller tu be is locate d o n top of th e engin e (FIG . 36). Tra ctor must be sitting level when checking oil. Refer to engine manual and mainten ance schedule for[...]

  • Page 138

    10-24 109706 10/08 OIL REMOVAL FROM THE ENGI NE BREATHER V ALVE SYSTEM IN THE EVENT THA T OIL ENTERS THE ENGINE BREA THER V AL VE SYSTEM, THE OIL MUST BE REMOVED BEFORE CRANKING THE ENGINE. REFER TO FIG . 39 FOR THIS PROCEDURE. 1. If oil has entered the engine breather valve system, it may be found in the int ake manifold. Remove th e int a ke mani[...]

  • Page 139

    10-25 109706 10/08 W ARN ING: Many engine failures can be attributed to im proper air cleaner servicing. Ingested dust and dirt will cause cylinder , piston and bearing dam age in a few hours. “D usted” engines will result from: 1. Overservicing the air filter element. 2. Improper insta llation. 3. Damaged filter , seals or canister . 4. Incorr[...]

  • Page 140

    10-26 109706 10/08 element slowly , looking for any holes or tea r s in the pape r . Also check gaskets for cut s or tears. Do not attempt to use a damaged element which will allow abrasive particles to enter the engin e . 3. Reinstall the dust cup. Make sure it seals all the way around the air cleaner body , then tighten the clamp s. 4. Chec k all[...]

  • Page 141

    10-27 109706 10/08 Belt replacement FIG . 43, FI G . 44, FIG . 45, FIG . 46 and FI G . 47 show diagrams and descriptions of the unit’s belt drive systems. FIG . 43 FIG . 44 FIG . 45 2 1 2 2 5 5 4 6 3 1. Spindle drive belt 2. Deck blade spindle pulley 3. Spindle belt tension idler 4. Spindle belt tension idler spring (spring 8.4" at operation[...]

  • Page 142

    10-28 109706 10/08 W ARN ING: If the pump belt fails, loss of control will occur especially when operating on a slope. If you lose steering co ntrol while operating the machine, place the st eering control levers in the p ark brake position immediately . Inspect the machine and involve your Hustler dealer to resolve the pr oblem before continuing t[...]

  • Page 143

    10-29 109706 10/08 Mower blade removal Use a 15/16" wrench to remove the 5/8" cap screw ho lding the blade to the spindle shaf t from underneath. Sharpen th e blades on a grinder fo llowing pattern as show n (FIG . 48). T ouch-up sharpening can be done with a file. Check the bl ades for balanc e following gr inding. A commer cia l balanci[...]

  • Page 144

    10-30 109706 10/08 Adjustment Introduction Y our Hus tler Z Diesel was adjusted befo re it left the fa ctory and was checked during pred eliver y setup. However , after st art-up and cont inued use, a certain amount of break-in wear will cause some adjustment s to change. Remain alert for unusual noises, they could be signaling a proble m. Visua ll[...]

  • Page 145

    10-31 109706 10/08 If the tractor creep s in the neutral position the control linkage may be adjusted as follows: 1. Raise and block the tractor up so the drive wheels are of f of the floor . W ARN ING: Never work under the machine or attachment unless it is safely supported with jack stands. M ake certain ma chine is se cure when it is raised and [...]

  • Page 146

    10-32 109706 10/08 T o adjust the stop s for driving st raight when control levers are ag ainst the stops during operation: 1. Determine which drive tire is rotating too fast when both control levers are against the stops. Then stop th e tractor and loosen the lo ck nut on the side which is rotating to o fast and turn the stop (set screw) inward to[...]

  • Page 147

    10-33 109706 10/08 Control lever adjustment The control levers can be adjusted for oper ator comfort. By loosening the cap screws that att aches the upper control lever to the lower lever FIG . 56, the upp er control lever can be pivo ted to fi t the operator ’s personal prefer ence. The control levers should be adjusted so that they align with e[...]

  • Page 148

    10-34 109706 10/08 Hydraulic pump belt adjustment The pump drive belt tension remains const ant by means of a tension idler and spring (FIG . 58). Ther e is no tension adjustment of this belt. NOTE: Replace the belt every 400 hours or every two (2) ye ars whichever comes first. W ARN ING: If the pump belt fails, loss of control will occur especiall[...]

  • Page 149

    10-35 109706 10/08 Engine RPM setting The Hustler Z Diesel is designed so that the engine will run at 2950 rpm static pump load only . At this speed the hydraulic pu mps are running at their max imum rate d speed. Deck leveling and height adjustment The mower deck has three area s that may need to be ch ecked and adjusted periodically . Before cons[...]

  • Page 150

    10-36 109706 10/08 15. Be sure that adjuster is free to move up and down. 16. T ighten the adjuster bolt until the chain just become s tigh t, making sure that the deck stays tight against the 3" block. 17. T ighten the adjuster bolt jam nut to prevent the adjuster bolt from moving (FIG . 65). 18. T ighten the hardware holding th e chain and a[...]

  • Page 151

    10-37 109706 10/08 23. Go to the lef t 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 un til there is slack in the deck lif t chain (FIG . 63). 25. T ighten the appropriate nut until the cha in just becomes tight. 26. T ighten the other nut on the opp osi[...]

  • Page 152

    10-38 109706 10/08[...]

  • Page 153

    109706 10/08 i-1 Numerical Index Part Page No. No. Part Page No. No. Part Page No. No. Index Part Numbers 000323 5 - 1 9 000331 8 - 5 004317 5 - 7 005116 5 - 3 , 7-3 , 7-11 , 7-15 005231 5 - 2 1 008193 3 - 5 008573 5 - 3 010306 5 - 1 7 011510820 5 - 3 011841 5 - 3 012005 7 - 3 4 , 7-35 015495 4 - 3 , 5-7 , 7-3 , 7-7 , 7-11 , 7-15 , 7-23 , 7-27 , 7-[...]

  • Page 154

    Part Page No. No. Part Page No. No. Part Page No. No. i-2 109706 10/08 108607 7 - 1 5 108619 7 - 1 9 108620 7 - 2 1 108621 7 - 2 1 108649 7 - 3 108661 7 - 1 9 108662 7 - 2 1 108663 7 - 2 1 108813 4 - 7 108816 7 - 3 1 108932 2 - 4 108976 5 - 3 108977 5 - 1 5 109073 5 - 1 5 109104 2 - 3 109105 5 - 1 7 109106 8 - 5 109108 5 - 2 1 109109 4 - 9 109110 4[...]

  • Page 155

    109706 10/08 i-3 Part Page No. No. Part Page No. No. Part Page No. No. 601247 3 - 5 601278 5 - 7 601279 5 - 7 601291 5 - 2 1 601295 5 - 1 5 601318 3 - 3 601319 5 - 2 1 601353 5 - 1 5 601354 5 - 1 5 601355 5 - 3 601356 5 - 1 1 601357 5 - 1 1 601358 5 - 1 5 601359 5 - 1 3 601360 5 - 1 3 601361 5 - 3 601362 5 - 2 3 601363 5 - 1 7 601364 5 - 1 7 601365[...]

  • Page 156

    Part Page No. No. Part Page No. No. Part Page No. No. i-4 109706 10/08 767962 3 - 5 , 4-9 , 5-3 , 5-7 , 5-11 , 5-17 , 6-7 , 7-3 , 7-5 , 7-7 , 7- 9 , 7-11 , 7-13 , 7-15 , 7-23 , 7-25 , 7-27 , 7-29 , 7-31 , 7-33 768515 5 - 3 , 5-7 , 5-11 , 5-17 , 5-21 , 5-23 768523 3 - 5 , 4-7 , 4-9 , 5-3 , 5-13 , 5-15 , 5-17 , 5-21 , 5-23 , 7-5 , 7-9 , 7-13 , 7-17 ,[...]