Hustler Turf 928168 manual

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

t-2 108604 10/08[...]

108602 10/08 c-1 T able of Content s Chapter 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Chapter 2 Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Ch[...]

c-2 108602 10/08 Chapter 10 Tractor Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 72" & 60" Side Discharge Deck Decals(XR7) . . . . . . . . . . . . . . . . . 10-4 60" Rear Discharge Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 Chapter 11 Seat Installation . . .[...]

108604 10/08 1 -1 Chapter 1 General Information This Manual covers Hustler A T Z model 928143, Hustler A TZ model 928150 & Hustler A TZ model 928168 Frequently Ordered Parts Service Literature Note: When ordering p art s, you must use the p art numbe r as shown for each pa rt, not the item number . Always give the model and seria l numb er to y[...]

1-2 108 60 4 10/08 Hardware Description Codes & Abbreviations The following codes are used throu gho ut this par ts manu al. Refer to this list when ordering p arts. St a n d a r d Tor q u e s The following chart list s the standa rd torque values for the threaded fasten ers found in this manual. T orque all cap screws, nuts and set screws to t[...]

108604 10/08 2 -1 Chapter 2 Content s Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3[...]

2-2 108 60 4 10/08 Rivet Nut Installation NOTES: ITEM NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 546572 381848 1 A TZ FRAME 2 N/A 808493 13 RIVET NUT, 3/8-16 THREAD 3 N/A 600961 8 RIVET NUT, 1/2-13 THREAD 1 2 2 2 3 3[...]

108604 10/08 2 -3 Footrest Assembly NOTES: 1. Do not tighten, Floor must be able to pivot on these bolts. ITEM NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 359547 359547 2 STEP TREAD 2 395533 395533 1 FLOOR PLA TE 3 305615 305615 2 STEP TREAD 4 086660 086660 2 NT .375-16 HX LK NY 5 767954 767954 4 FW .406 X .812 X .060 SAE HD ZN 6 0[...]

2-4 108 60 4 10/08[...]

108604 10/08 3 -1 Chapter 3 Content s Hydraulic System Installation—Kawasa ki 31 HP HT Engine . . . . . . . 3-2[...]

3-2 108 60 4 10/08 Hydraulic System Installation—Kawasaki 31 HP HT Engine 11 12 26 14 15 15 15 13 30 28 29 16 17 34 33 37 38 18 19 20 19 39 25 27 21 39 1 2 2 6 5 4 36 7 8 9 2 10 23 35 14 15 13 24 31 32 3 5 27 40 22 28 40[...]

108604 10/08 3 -3 Hydraulic System Installa tion—Kawasaki 31HP HT Engine NOTES: 1. Hydraulic system capacity is 5 US quart s of 20W50 motor oil. Fill reservoir to within 1"of top of Item 8 (032771 S trainer). INDEX NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 705608 705608 4 CS .250-20 X 2.25 HX G5 ZNYC 2 768515 768515 10 FW .281 X .[...]

3-4 108 60 4 10/08 HYDRAULIC SYSTEM CHARGING PROCEDURE 1. Set handles in the neutral position. 2. S tart engine at idle. 3. Let run for a minimum of 30 seconds. 4. S troke handles to forward position. 5. If motors do not turn in 15 seco nds return handles to neutral and repeat step 3 and 4 (one time). 6. If motors do not turn after se cond attempt,[...]

108604 10/08 4 -1 Chapter 4 Content s Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Park Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Steering Assem[...]

4-2 108 60 4 10/08 Battery Installation BLACK WIRE, P ART OF WIRE HARNESS RED WIRE, P AR T OF WIRE HARNESS 1 TRACTOR FRAME 1 1 3 4 5 5 6 7 8 9 9 8 10 11 11 12 2[...]

108604 10/08 4 -3 Battery Installation NOTES: 1. When performing servic e on mower , disconnect battery ground cable and black wire of harness an d do not reconnect to battery until engine is ready to be started. See Owners Manual. ITEM NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 024927 024927 2 NT .250-20 HX GR 5 ZN 2 771428 771428 1 RED [...]

4-4 108 60 4 10/08 Deck Lift Assembly 1 1 1 TRACTOR FRAME 1 2 4 6 3 10 11 7 6 5 7 7 9 9 5 4 7 14 8 13 12 4 5 8 5 4 1 4[...]

108604 10/08 4 -5 Deck Lift Assembly NOTES: 1. Apply grease to zer ks (see owners manual). ITEM NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 348318 348318 1 STOP HANDLE 2 600437 600437 1 HEIGHT ADJUSTMENT S TOP (½" DIA PIN) 3 783001 783001 1 DECK LIFT INDICA TOR 4 704643 704643 8 NT .437-14 HX FLG ZN 5 781294 781294 7 CLIP E, 1.00 X.6[...]

4-6 108 60 4 10/08 Park Brake Assembly 1 6 3 13 12 1 1 8 4 1 9 9 20 18 21 22 17 19 11 5 11 14 1 15 1 16 10 7 SEE “S teering Sub-Assembly” on page 4- 10 2 2 2 1 5 2[...]

108604 10/08 4 -7 Park Brake Assembly NOTES: 1. T orque to 280-310 f t.-lbs. Included with wheel motor . 2. T orque to 24 f t.-lbs. 3. 783126 used on lef t wheel. 4. 7831 18 used on right wheel. ITEM NO. SERVIC E PART NO. MFG. PART NO. QTY DESCRIPTION 1 767954 7 67954 12 FW .406 X .812 X .060 SAE HD ZN 2 768523 7 68523 8 FW .34 3X .687 X .051/.080 [...]

4-8 108 60 4 10/08 S teering Assembly 18 7 5 16 5 17 6 1 2 3 4 8 6 15 14 6 9 10 6 11 12 13 14 6 7 18 6 5 4 6 SEE “S teering Sub-Assembly” on page 4- 10[...]

108604 10/08 4 -9 S teering Assembly NOTES: ITEM NO. SERVIC E PART NO. MFG. PART NO. QTY DESCRIPTION 1 1 10679 1 10679 1 STEERING CONTROL P A NEL 2 781716 7 81716 2 SS .500-13 X 1.75 SH ZN 3 053199 0 53199 2 NT .500-13 HX JAM ZN 4 055822 0 55822 8 CS .375-16 X .750 HX G5 ZN 5 767954 7 67954 8 FW .406 X .812 X .060 SAE HD ZN 6 768523 7 68523 16 FW .[...]

4-10 108604 10/08 S teering Sub-Assembly 2 18 4 7 6 8 9 14 10 12 13 3 5 11 1 17 10 3 7 3 16 15 19 21 20 1 2[...]

108604 10/08 4-11 S teering Sub-Assembly NOTES: 1. Includes Item 1 (7 81260 S teering Bar Grip). 2. Includes Item 15 (601769 Lower Handle Grip ) and Item 16 (601768 End Handle Grip) ITEM NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 781260 N/A 1 STEERING BAR GRIP 2 348755 348755 1 STEERING BAR 3 767954 767954 16 FW .406 X .812 X .060[...]

4-12 108604 10/08 Pump Belt and Pulleys Installation 1 4 3 TRACTOR FRAME 2 1 2 3 4 7 10 11 12 13 15 16 17 18 19 21 5 23 8 7 11 20 9 24 25 26 25 6 11 11 10 14 27 22[...]

108604 10/08 4-13 Pump Belt and Pulleys Installation NOTES: 1. T orque to 45-48 f t-lbs. 2. T orque to 12-15 f t-lbs. 3. Apply grease at zerk (see owners manual). 4. Do not torque Item 18 (NT .750-10 HX NL ZN), Item 15 (349761 Pump Idler Arm) should pivot freely . 5. Electric clutch burnishing procedure: After inst alling a new clutch it is importa[...]

4-14 108604 10/08[...]

108604 10/08 5 -1 Chapter 5 Content s Kawasaki 31 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Fuel System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Instrument Panel Assembly/Ins tallation . . . . . . . . . . . . . . . . . . . . . . . 5-8 Electrical Schematic - Kawa saki ([...]

5-2 108 60 4 10/08 Kawasaki 31 HP Engine Installation PUR RED/BLK 4 5 17 13 14 28 14 16 18 21 22 23 27 19 24 25 30 1 2 4 9 6 9 10 12 15 13 3 8 NEG . BA TTERY CABLE BLK 11 19 7 1 { 4 } 11 31 32 20 19 8 TO S P A D E TERMINAL ON RECT . 3 3 29 2 2 BULLET CONNECTORS POS. BA TTERY CABLE 3 26 YEL/BLK 3 TO SP ADE ON ST ARTER[...]

108604 10/08 5 -3 Kawasaki 31 HP Engine Installation NOTES: 1. Includes mounting hardware. 2. Wires from Item 29 (A TZ 2008 Wire Harness 601555). 3. Wires from Kawasaki 31 HP Wiring Harness (601561). 4. Supplied with engine. 5. Engine oil capacity , Refe r to engine owner ’s manual. 6. Air filter service part s: ITEM NO. SERVICE P ART NO. MFG . P[...]

5-4 108 60 4 10/08 Fuel System Installation TRACTOR 1 1 1 1 1 2 3 4 5 5 7 6 8 9 10 12 15 14 13 18 5 7 17 16 15 17 16 5 7 15 6 9 6 5 11 18 FRAME WITH ENGINE 9 15 2 7[...]

108604 10/08 5 -5 Fuel System Installation NOTES: 1. T orque to 20 f t.-lbs. 2. Supplied with Item 18 (3-way fuel switch.) 3. Included with new fuel tank. 4. Fuel tank service p a rt s not shown: ITEM NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 779306 779306 2 3.5" FUEL CAP 2 793240 793240 1 LEFT SIDE Z FUEL T ANK 3 793232 793232 1 RI[...]

5-6 108 60 4 10/08 Instrument Panel Assembly/Installation RIGHT SIDE FUEL T ANK 1 25a 15a 1 3 11 8 10 7 8 6 12 13 14 13 12 5 5 4 2 FUSE SIZE AND LOCA TION 9 3 15 10 8 18 17 16 BLK ORG 1 1[...]

108604 10/08 5 -7 Instrument Panel Assembly/Installation NOTES: 1. Part of 60 1555 (Wire Harness) ITEM NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 776476 776476 1 PTO SWITCH 2 785808 785808 1 KEY SET 3 045898 045898 1 KEY SWITCH 4 000430 000430 2 SMALL/LONG WIRE TIE 5 785030 785030 1 CHOKE CABLE 6 712257 712257 1 RED INDICA TOR LIGHT 7 714[...]

5-8 108 60 4 10/08 Electrical Schematic - Kawasaki (601555)[...]

108604 10/08 6 -1 Chapter 6 Content s Front Wheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Semi-Pneumatic Tire/Wheel—78953 7 . . . . . . . . . . . . . . . . . . . . . . . 6-4 Drive Wheel Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Anti-Rollover Wheel Assembly . . . . . .[...]

6-2 108 60 4 10/08 Front Wheel Assembly TRACTOR FRAME 1 1 2 3 3 3 1 2 4 3 6 5 8 9 10 10 12 11 1 2 4 3 6 5 7 10 12 5 7 9 8 5[...]

108604 10/08 6 -3 Front Wheel Assembly NOTES: 1. Apply grease to zer ks (see owners manual). 2. T orque to 100 f t.-lbs. 3. Assemble with extended inner race toward item 6 (387035 S p acer , 1.07 x 1.312 x 2.793). ITEM NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 705954 705954 2 CS .500-13 X 1.25 HX G5 ZN 2 344267 344267 2 FW .510 X 2.15 X [...]

6-4 108 60 4 10/08 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/WHEEL 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[...]

108604 10/08 6 -5 Drive Wheel Assembly Installation NOTES: 1. T orque to 65-75 f t. lbs. 2. Inflate tire to 8-12 psi. ITEM NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 789529 789529 1 LH TIRE/WHEEL ASSEMBLY 789420 789420 1 RH TIRE/WHEEL ASSEMBLY 2 783563 N/A TIRE 24 X 12-12 A T101 3 784066 N/A WHEEL ASSY 12 X 8.50 (A TZ) 4 019521 N/A TIRE V[...]

6-6 108 60 4 10/08 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 .50-13 HX LK NY TRACTOR FRAME 1 1 4 2 1 3 [...]

108604 10/08 7 -1 Chapter 7 Content s Weight Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 ROPS Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4[...]

7-2 108 60 4 10/08 W eight Installation TIRE/WHEEL ASSEMBL Y TRACTOR FRAME 1 2 3 4 5 6 2 7 8 2 10 9[...]

108604 10/08 7 -3 W eight Installation NOTES: ITEM NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 008193 008193 8 NT .500-13 HX G5 ZNYC 2 767962 767962 16 FW .531 X 1.063 X .090 SAE HD ZN 3 789214 789214 2 MMZ WHEEL WEIGHT 4 392597 392597 2 WHEEL WEIGHT BACKING PLA TE 5 792077 792077 8 CB .50-13 X 6 STD ZN 6 781567 781567 4 NT .50-13 [...]

7-4 108 60 4 10/08 ROPS Installation 1 2 2 1 1 2 2 1 2 11 12 13 7 9 15 6 20 21 22 23 24 16 18 17 18 19 1 1 2 3 4 5 2 2 1 2 6 7 16 8 10 2 7 14 25 1 1 2 12 26 2 27 28 29 30[...]

108604 10/08 7 -5 ROPS Installation NOTES: 1. T orque to 73 f t.-lbs. (8 places). 2. T orque to 145 f t.- lbs. (2 places). ITEM NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 008193 008193 18 NT .500-13 HX G5 ZNYC 2 767962 767962 26 FW .531 X 1.063 X .090 SAE HD ZN 3 391375 391375 1 A TZ ROOF 4 381657 381657 1 A TZ FRONT R.S. ROPS 5 3[...]

7-6 108 60 4 10/08[...]

108604 10/08 8 -1 Chapter 8 Content s 72" Side Discharge Deck Assembly (XR7) . . . . . . . . . . . . . . . . . . . . 8-2 72" Side Discharge Deck Pulley Assembly (XR7) . . . . . . . . . . . . . . . 8-4 60" Side Discharge Deck Assemb ly . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 60" Side Discharge Deck Pulley Assembly ([...]

8-2 108 60 4 10/08 72" Side Discharge Deck Assembly (XR7) 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[...]

108604 10/08 8 -3 72" Side Discharge 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" & 60" Side Discharge Deck Decals(XR7)” on page 10-4 for listing of decals). ITEM NO. SERVICE PA R T N O . MFG. PART [...]

8-4 108 60 4 10/08 72" Side Discharge Deck Pulley Assembly (XR7) 1 3 2 16 16 16 18 21 24 20 25 27 26 28 29 19 1 2 7 9 11 12 8 10 5 13 15 15 27 23 INDEXING 14 14 4 3 BEL T GUIDE 72" DECK ASSY 17 16 22 6 15 30[...]

108604 10/08 8 -5 72" Side Discharge Deck Pulley Assembly (XR7) NOTES: 1. T orque to 1 18 ft. lbs. 2. T orque to 67-75 f t. lbs. 3. See “72" Side Discharge Belt R outing and T ensioning” on page 9-4 for belt tensioning. 4. See “S pindle Assembly–796235 ” on page 8-16 for breakdown. ITEM NO. SERVICE PA R T N O . MFG. PART NO. QTY[...]

8-6 108 60 4 10/08 60" Side Discharge 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[...]

108604 10/08 8 -7 60" Side Discharge 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" & 60" Side Discharge Deck Decals(XR7)” on page 10-4 for listing of decals). ITEM NO. SERVICE PA R T N O . MFG. P ART[...]

8-8 108 60 4 10/08 60" Side Discharge Deck Pulley Assembly (XR7) 1 2 3 BEL T GUIDE INDEXING 11 14 18 20 21 17 24 25 26 27 29 10 8 1 2 4 9 16 12 5 7 15 13 13 14 14 16 16 16 19 22 23 30 3 60" DECK ASSY 27 15 15 15 28 6[...]

108604 10/08 8 -9 60" Side Discharge Deck Pulley Assembly (XR7) NOTES: 1. T orque to 1 18 ft. lbs. 2. T orque to 65-75 f t. lbs. 3. See “60" Side Discharge Belt R outing and T ensioning” on page 9-5 for belt tensioning. 4. See“S pindle Assembly–796235” on page 8-16 for breakdown. ITEM NO. SERVICE PA R T N O . MFG. PART NO. QTY D[...]

8-10 108604 10/08 Side Discharge Deck—"A" Adaptors 3 Deck Assembl y 4 4 1 2 2 3[...]

108604 10/08 8-11 Side Discharge Deck—"A" Adaptors NOTES: ITEM NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 108661 108661 2 AIR FLOW FLOOR ( 72" DECKS) 108516 108516 2 AIR FLOW FLOOR ( 60" DECKS) 2 025395 025395 4 CB .375-16X 1.00 STD CD 3 767954 767954 4 FW .406X .812 X.060 SAE 4 086660 086660 4 NT .375-16 HXZ[...]

8-12 108604 10/08 60" Rear Discharge Deck Assembly 1 2 3 27 4 5 22 4 5 22 6 6 26 28 29 11 5 5 10 10 12 12 12 12 13 13 13 13 14 14 14 15 15 15 15 16 16 16 16 7 30 7 7 5 9 18 27 3 25 23 24 8 27 17 21 21 20 20 28 27 10 25 19 DEFLECTOR DET AIL 26 3 3 19[...]

108604 10/08 8-13 60" 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 decals, see “72" & 60" Side Discharge Deck Decals(XR7)” on page 10-4. ITEM NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 549576[...]

8-14 108604 10/08 60" Rear Discharge Deck Pulley Assembly 1 1 6 2 10 21 5 5 6 19 7 8 9 16 5 4 22 32 19 19 22 23 28 23 22 31 2 3 30 26 27 17 3 5 1 12 19 20 13 18 20 6 8 22 18 5 6 21 8 24 27 24 6 5 25 29 2 9 15 23 33 11 14[...]

108604 10/08 8-15 60" Rear Discharge Deck Pulley Assembly NOTES: 1. T orque to 1 18 ft. lbs. 2. T orque to 65-75 f t. lbs. 3. See “60" Rear Disc harge Belt Routing and T ens ioning” on page 9-6 for belt tensioning. 4. See “S pindle Assembly–796235 ” on page 8-16 for breakdown. 5. See “S pindle Assembly–796680 ” on page 8-1[...]

8-16 108604 10/08 Spindle Assembly–796235 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 1[...]

108604 10/08 8-17 Spindle Assembly–796680 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 NO. 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 GR[...]

8-18 108604 10/08[...]

108604 10/08 9 -1 Chapter 9 Content s Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 72" Side Discharge Belt Routing and Tensi oning . . . . . . . . . . . . . . . 9-4 60" Side Discharge Belt Routing and Tensi oning . . . . . . . . . . . . . . . 9-5 60" Rear Discharge Belt Routing[...]

9-2 108 60 4 10/08 Deck Installation TRACTOR ASSEMBL Y DECK ASSEMBL Y 1 2 3 4 5 5[...]

108604 10/08 9 -3 Deck Installation NOTES: 1. 60" Side Discharge Deck installati on is shown, 72" Side Discharge Deck and 60" Rear Discharge Deck installation are similar . ITEM NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 055749 055749 4 CS .437-14 X 1.750 HX G5 ZN 2 061 101 061 101 2 NT .750-10 HX NL ZN 3 025296 025296 4 FW[...]

9-4 108 60 4 10/08 72" Side Discharge Belt Routing and T ensioning NOTES: 1. S pring length af ter tensioning belt. Measure spring from out side of hook to outside of hook. 2. Route belt as shown. DECK ASSEMBL Y 1[...]

108604 10/08 9 -5 60" Side Discharge Belt Routing and T ensioning NOTES: 1. S pring length af ter tensioning belt. Measure spring from out side of hook to outside of hook. 2. Route belt as shown. DECK ASSEMBL Y 1[...]

9-6 108 60 4 10/08 60" Rear Discharge Belt Routing and T ensioning NOTES: 1. S pring length af ter tensioning belt. Measure spring from out side of hook to outside of hook. 2. Route belt as shown. DECK ASSEMBL Y 1[...]

108604 10/08 10-1 Chapter 10 Content s Tractor Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 72" & 60" Side Discharge Deck Decals(XR7) . . . . . . . . . . . . . . . . . 10-4 60" Rear Discharge Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5[...]

10-2 108604 10/08 T ractor Decals TO P O F SEA T P AN BOTT OM OF S E AT PA N 1 2 5 9 11 12 10 3 4 13 8 6 14 7 15 16[...]

108604 10/08 10-3 T ractor Decals NOTES: ITEM NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 781427 781427 1 DECK HEIGHT INDICA T OR DECAL 2 779280 779280 1 HOT & HYDRAULIC OIL DECAL 3 601980 601980 1 INSTRUMENT P ANEL DECAL 4 601968 601968 1 HYD PRESSURE DECAL 5 791830 791830 1 FUEL INDICA TOR DECAL 6 601967 601967 1 ENGINE COMP [...]

10-4 108604 10/08 72" & 60" Side Discharge Deck Decals(XR7) INDEX NO. SERVICE PA R T N O . MFG . PA R T N O . QTY . DESCRIPTION 1 786285 786285 1 72" SIDE DISCHARGE DECK ID DECAL 786277 786277 1 60" SIDE DISCHARGE DECK ID D ECAL 2 760637 760637 1 MOWER DECK QUICK REFERENCE DECAL 3 727420 727420 1 DEFLECTOR SHIELD DECAL 4 727[...]

108604 10/08 10-5 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" DECK ID DECAL 2 760637 760637 1 MOWER DECK QUICK REFERENCE DECAL 3 727438 727438 4 WHIRLING BLADES DECAL 4 727453 727453 4 BEL T & PULLEY DECAL 5 727172 727172 1 "MADE IN U.S.A." DEC[...]

10-6 108604 10/08[...]

108604 10/08 11-1 Chapter 1 1 Content s Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2[...]

11-2 108604 10/08 Seat Installation 1 1 20 17 14 7 10 12 13 9 11 15 16 18 22 11 21 19 6 1 2 23 26 24 5 2 10 3 4 34 35 29 30 31 37 36 17 8 25 38 27 28 38 28 3 32 38 38 23 33 18 17[...]

108604 10/08 11-3 Seat Installation NOTES: 1. Must pivot freely . 2. T orque to 48 f t.-lbs. 3. Service part s available for Michigan suspension seat: ITEM NO. SERVICES PART NO. MFG. PART NO. QTY DESCRIPTION 1 792051 792051 1 SUSPENSION SEA T 2 784140 784140 1 SEA T BEL T 3 797076 797076 4 CS .437-20 X 1.00 HX G8 ZNYC 4 728147 728147 2 FW .468 X 1.[...]

11-4 108604 10/08 793299 SEA T CU SHION KIT 793315 SEAT SWITCH 793265 MOLDED ARMREST KIT (INCLUDES BOTH ARMRESTS) 793273 ARMREST STOP ASSEMBLY PART NO. DESCRIPTION[...]

108604 10/08 12-1 Chapter 12 Content s Maintenance & Adjustment Safety. . . . . . . . . . . . . . . . . . . . . . . . . . 12-2 Safe Maintenance & Adjustment Practi ces . . . . . . . . . . . . . . 12-2 Using a ramp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4 Safety and Instruction Decals . . . . . . . . . . [...]

12-2 108604 10/08 Control lever stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22 Steering dampener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-23 Control lever adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 12-23 Park brake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

108604 10/08 12-3 Maintenance & Adjustment Safety This safety alert symbol is used to call attention to a messa ge intended to provide a reasonable d eg ree of PERSONAL SAFETY for operators and other person s dur ing the normal operati on and servicing of this equipment. DANGER – denotes immediate hazar ds which WILL result in severe personal[...]

12-4 108604 10/08 Clean flammable material from machine. Prevent fires by keeping engine comp artment, battery , hydr aulic lines, fuel line, fuel t ank and operat or ’ s st atio n clean of accumulated t rash, grass clippings, and other debris. Always clean up spilled fuel and oil. Always wear adequate ear protection, such as earp lugs, when oper[...]

108604 10/08 12-5 Using a ramp Use extreme c aution when loading an d unloading a unit with a ramp. Use only a single, full width ramp; do not use indi vidual ramps for each side of the unit. Having a full width ramp provides a surfa ce for the tractor frame to cont act if the unit start s to tip backwards. It also reduces the risk of a wheel going[...]

12-6 108604 10/08 Maintenance FIG . 1 3 2 16 8 11 11 10 6 6 12 7 12 9 4 1. E ngine Oil Fill & Dipstick 2. Fuel Filter 3. Engine Air Cleaner 4. Engine Oil Drain Plug 5. Battery 6. Fuel T anks 7. H ydraulic Oil Reservoir 8. H ydraulic Oil Filter 9. G auge Wheel Bearing Zerks (2) 10. Engine Oil Filter 1 1. D eck Height Pivot Zerks (4) 12. Park Bra[...]

108604 10/08 12-7 FIG . 2 1 3 2 4 1. D eck Pusher Arm Zerks (2) 2. Deck Belt 3. Spindle Housing Zerk (3) 4. Blades MAINTENANCE LOCATOR CHART 72" XR-7 deck 1 3 3 4 2 4 4 60" XR-7 deck 3 3 3 1 1 1 1 2 3 3 3 4 4 60" Rear Discharge deck[...]

12-8 108604 10/08 NOTES: 1. Initial oil change is after 5 hours of operation. Thereaf ter , change oil after every 40 hours operation. Change more of ten under dusty or dirty conditions and du ring hot weather periods. 2. T orque initially and after first 2 hours of operation. 3. Perform initial hydraulic filte r change after 50 hours (one week) of[...]

108604 10/08 12-9 REFERENCES: a --- Refer to Engine Owner ’s Manual NOTE: After completing maint enance cycle (300 hours), repeat cycle. INTRODUCTION Regular maintenance is the best pr even tion for costly downtime or expensive, prematur e repair . The following p age s contain sug gested maintenance info rma tion and schedules wh ich the operato[...]

12-10 108604 10/08 Solid fill tires are not recommended for Hustler turf equipment. On an y machine, with solid filled tires, the warranty claim will be denied. W ARNING: Explosive separation of a tire an d rim can caus e se rio us inju r y or de at h. Do not attempt to mount a tire without the proper equ ipment and experience to perform the t ask.[...]

108604 10 /08 1 2-11 The battery is located under the seat plat form "FIG . 4". W ARNING: Batt ery posts, terminals, and related accesso ries conta in lead and lea d compounds, chemicals known to the S tate of California to caus e cancer and reproductive h arm. W ash hands af ter handling. W ARNING: Avoid skin and clothing contact with ba[...]

12-12 108604 10/08 Before attempting any failu re diagnosis of the electrical system, use a test light or voltmeter to check the battery voltage. If the battery volt age is satisfactory , check the cleanliness and tightness of the terminals and ground connections. A gener al underst anding of el ectrical servicing and use of basic test equipment is[...]

108604 10 /08 1 2-13 The system filter is located directly in front of the hydraulic reservoir . A standard oil filter wrench is used to change filter , threads are right h anded. Use a Hu stler approve d filter elem ent only . IMPORT ANT : Prefill the filter element with cl ean oil, before inst alling, to prevent drawing air into the system pump. [...]

12-14 108604 10/08 FUEL SYSTEM DANGER: Observe usu al fu el ha nd lin g preca u tio ns : Do not smoke while refueling. Do not fill tank with engine ru nning or while engine is hot. Clean up any gasoline spills. 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 f[...]

108604 10 /08 1 2-15 The fuel tanks are located in the tractor ’s fender s. ("FI G . 8") T otal capacity for the fuel tanks is 15 U.S. gallon (56.8 lit er ) Use regular unleaded gasoline with an octane rating of 87 or higher . The fuel filter ("FIG . 9") is installe d in the fuel line between fuel t anks and engine fuel pu mp.[...]

12-16 108604 10/08 The oil drain and oil filter are locate d at th e rear of the engine "FIG . 1 1". ENGINE AIR FILTER Perform engine air filte r maintenance per th e sch eduled maintenance chart. See ‘ ‘SER VICE A T INTERV ALS INDICA TE D’’ on p age 12-8. A specially designed dry filte r is standard eq uip ment on the Hustler A T[...]

108604 10 /08 1 2-17 Air cleaner servicing is an inexpensive mainten anc e check that can prevent costly no n-warrant able premature engine damage. OVERSERVIC ING Overservicing occurs when an air filter element is remove d for cleaning or replace ment before it is necessary . Ea ch time the filte r is removed a sm all amount of dir t and dust cou l[...]

12-18 108604 10/08 Owners should be reminded th at failure to use original equipment replacement pa rts is an “alteration ” and will not be considered for warranty in the ev ent of engine damage. RECOMMENDED SERVICE PROCEDURE 1. Release clamps and r emove element. Clean the ca nister with a damp cloth. 2. Before installing a new elemen t, ins p[...]

108604 10 /08 1 2-19 Inspect these belt s frequently for wear and serv iceabilit y . Replace a be lt that sh ows signs of severe cuts, tears, separation, weath er checking and cracking, or burns caused by slipping. Slight raveling of belt covering does not indicate fa ilure , trim ravelings with a sharp knif e. NOTE: Replace the belt every 400 hour[...]

12-20 108604 10/08 run against the bottom of the gro ove. Replace the pu lley 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 belt s, and never use belt dressings. Any of these wi ll destroy t[...]

108604 10 /08 1 2-21 FIG . 19 FIG . 20 FIG . 18 Resharpening pat t er n Do not sharpen to original patte rn (below). It is easier to get a straight cutting edge following the resharpening pa ttern shown above. Original edge Warped Blade (Replace ) Straight Blade (Repl ace) Comparison of W arped and Straight Blades Cutting plane Cutting edge Cutting[...]

12-22 108604 10/08 Adjustment INTRODUCTION Y our Hustler A TZ was adjusted before it left the factory and was checked during pr edelivery setup. However , after start-up and continu ed use, a cert ain amount of break-in wear will cause some adjustments to change. Remain alert for unusual noises, they could be signalin g a problem. Visually insp ect[...]

108604 10 /08 1 2-23 If the tractor creeps in the neut ral position the control linkage may be adjusted as follows: 1. Raise and block the tractor up so the dr ive wheels are of f of the floor . W ARNING: 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 p[...]

12-24 108604 10/08 correspond in g side an d turn the sto p (set scre w) inw ard to stop the cont ro l leve rs slightly before the pump bottoms out. Lock in place when the adjustm ent is correct by re-tightening the jam nut. 3. Do this for each side. T o adjust the stop s for driving st raight when control levers are against the stop s during opera[...]

108604 10 /08 1 2-25 W ARNING: 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 place d on the jack stand s. The jack stands sh ould not allow the machine to move when the engine is runn ing and the drive wheels are rotating. Use only ce rtified jack st a[...]

12-26 108604 10/08 8. Rotate the tire and at the same time rotate the turnbuckle to sh or te n th e len gt h of th e brake linkage to incre a se the br ak e pr es sure. When you feel th e br ak e be gin to engage, stop adjusting th e turnbuckle. Re-tighten the jam nut s on the turnbuckle. 9. Place the control lever in the park brake slot "FIG [...]

108604 10 /08 1 2-27 ENGINE RPM SETTING The Hustler A TZ is designed so that the engine will run at 3600 rpm static pump load only . At this speed the hydraulic pumps ar e running at their maximum rated spe ed. DECK LEVELING AND HEIGHT ADJUSTMENT The mower deck has three area s that may need to be checked and adjusted peri odically . Before conside[...]

12-28 108604 10/08 3. Raise deck and place 3.25” block under th e back of the deck and a 4” block under the front of the deck "FIG . 33". This will set the cutting hei ght at 3-1/2 ". NOTE: Back of deck will automatically be set approximately ¼" higher . 4. Set cutting height at 3-1/2" in the height indicator by placin[...]

108604 10 /08 1 2-29 7. Loosen the two nut s on the front of heig ht indicato r so that the foot pedal is free "FIG . 38". 8. S t art the leveling proc ess on th e left front of the tractor . 9. Set the amount of threads protrudin g on the deck lift rod from the lif t block at approximately 1" "FIG . 39". 10. Jam both nuts [...]

12-30 108604 10/08 height indicato r . FIG . 38 FIG . 39 FOOT PEDAL NUTS 1" DECK LIFT ROD 1" LIFT BLOCK[...]

108604 10/08 i-1 Numerical Index Part Page No. No. Part Page No. No. Part Page No. No. Index Part Numbers 000323 5 - 5 000331 5 - 5 , 11 -3 000398 5 - 5 000430 5 - 7 005116 4 - 7 , 8- 3 , 8-7 008193 3 - 3 , 4- 13 , 7-3 , 7-5 008573 7 - 5 012005 8 - 1 6 , 8-17 015495 4 - 5 , 4- 13 , 8-3 , 8-7 , 8-13 015511 6 - 4 015818 5 - 5 016253 8 - 1 3 016527 4 [...]

Part Page No. No. Part Page No. No. Part Page No. No. i-2 108604 10/08 377994 5 - 3 381657 7 - 5 381665 7 - 5 381673 7 - 5 381723 7 - 5 381731 7 - 5 381749 7 - 5 381848 2 - 2 387035 6 - 3 391375 7 - 5 392035 7 - 3 392191 7 - 3 392357 7 - 3 392597 7 - 3 392605 7 - 5 392613 7 - 5 392985 7 - 5 395533 2 - 3 538850 8 - 5 546572 2 - 2 548438 8 - 7 548453[...]

108604 10/08 i-3 Part Page No. No. Part Page No. No. Part Page No. No. 782615 1 0 - 3 782664 5 - 3 782771 6 - 4 782979 4 - 7 782995 4 - 5 783001 4 - 5 783118 4 - 7 783126 4 - 7 783563 6 - 5 783704 3 - 3 783712 4 - 1 3 783738 8 - 5 , 8- 9 , 8-15 783829 4 - 1 3 783837 5 - 3 783928 3 - 3 783936 1 - 1 , 3- 3 783993 3 - 3 784025 3 - 3 784066 6 - 5 78408[...]

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