HUSTLER Honda Engine Z manual

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

t-2 108602 10/08 IMP OR T AN T : Th i s e n gi ne i s n o t e q u i pped w i t h a s par k a r r est e r m u ffl er . I t i s a vi ola t i on of Ca li for nia Publ i c Re sour c e C od e S ec t i o n 4442 to us e o r op erate th i s eng ine o n an y fo res t-c o v ered , b rus h-co vered , o r grass -co ver ed uni mp r o ved l and . O t her sta te [...]

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 54" Rear Discharge Deck Assy—S /N 08010000—08100000 . . . . 7-20 54" Rear Discharge Deck Assy–S/N Prio r to 08010000 . . . . . . . . . 7-22 54" Rear Discharge Deck Pulley Assy—S/N 08100000 & Higher . 7-24 54" Rear Discharge Deck Pulley A ssy—S/N Prior to 08100000 . . 7-26 Spindle Assembly–796235 [...]

108602 10/08 1 -1 Chapter 1 General Information This Manual covers Hustler Z models 927723A/B, 927749A/ B, 927756A/B, 927772A/B, 927798A/ B, 927806A/B, 927814A/B, 928432, 928853A/B, and 928861A/B, with serial numbers higher than 07020000. Frequently Ordered Parts Service Literature Note: When ordering p arts, yo u must use the part numbe r as shown[...]

1-2 108 60 2 10/08 Using this manual Illustrations used were current at th e ti me of printing, but subsequent produ ction chang es 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 nece s- sary , without notification. If a ch ange has been made to your machin[...]

108602 10/08 1 -3 St an d a r d T o r qu e s The following chart list s the standard torque values for the threaded fasteners found in this manual. T orq ue all cap screws, nuts and set screws to these values unless a dif fer ent to rque is shown in the Notes sectio n next to the fastener . NOTE: Loctite® 592 to be used on all pipe thr eads. Lubri[...]

1-4 108 60 2 10/08[...]

108602 10/08 2 -1 Chapter 2 Content s Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3[...]

2-2 108 60 2 10/08 Rivet Nut Installation NOTES: 1. Seat supports 547950 a nd 549303 include rivet nut s. 2. Mowers with serial numbers pr ior to 08010000 requ ire (2) of 808493 (Rivet Nut 3/8-16 thread). ITEM NO. SERVICE P ART NO. MFG . P ART NO. QTY . DESCRIPTION 1 548032 107701 1 TRACTOR FRAME (54" SIDE DISCHARGE) 547760 10621 1 1 TRACTOR F[...]

108602 10/08 2 -3 Footrest Assembly NOTES: 1. Do not tighten, It em 2 (348276 Floor) must be able to pivot on these bolts. ITEM NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 359547 359547 2 STEP TREAD 2 395533 395533 1 FLOOR 3 305615 305615 2 PLA TFORM STEP TREAD 4 086660 086660 2 NT .375-16 HX LK NY 5 767954 767954 4 FW .406 X .812 X .060 S[...]

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

108602 10/08 3 -1 Chapter 3 Content s Hydraulic System Installation—S/N 07120009 and higher . . . . . . . . 3-2 Hydraulic System Installa tion—S/N prior to 07120009 . . . . . . . . . . . 3-6[...]

3-2 108 60 2 10/08 Hydraulic System Installation —S/N 07120009 and higher FRONT 18 1 32 2 3 4 19 20 5 6 7 22 21 19 10 11 24 12 25 26 27 9 30 11 10 20 22 14 31 15 19 11 13 28 25 12 29 8 17 16 16 17 23[...]

108602 10/08 3 -3 Hydraulic System Installation —S/N 07120009 and higher NOTES: 1. Hydraulic system capacity is 5 US quart s of 20W50 motor oil. Fill reservoir to within 1" of top of Item 3 (032771 S trai ner). See “Hydraulic system” on page 10-24. ITEM NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 768515 768515 2 FW .281 X .625 X[...]

3-4 108 60 2 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,[...]

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3-6 108 60 2 10/08 Hydraulic System Installation—S/N prior to 07120009 8 22 FRONT 16 1 31 2 3 4 17 18 5 6 7 20 19 17 21 10 11 23 12 24 25 26 9 29 11 10 18 20 14 30 15 17 11 13 27 24 12 28[...]

108602 10/08 3 -7 Hydraulic System Installation—S/N prior to 07120009 NOTES: 1. Hydraulic system capacity is 5 US quart s of 20W50 motor oil. Fill reservoir to within 1" of top of Item 3 (032771 S trai ner). See “Hydraulic system” on page 10-24. ITEM NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 768515 768515 2 FW .281 X .625 X .0[...]

3-8 108 60 2 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,[...]

108602 10/08 4 -1 Chapter 4 Content s Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Steering and Park Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Steering Sub-Assembly[...]

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

108602 10/08 4 -3 Battery Installation 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. ITEM NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 024927 024927 2 NT .250-20 HX GR.5 ZN 2[...]

4-4 108 60 2 10/08 Deck Lift Assembly 1 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 6 9 9[...]

108602 10/08 4 -5 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 STOP 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 [...]

4-6 108 60 2 10/08 S teering and Park Brake Assembly TRACTOR FRAME 1 2 20 6 19 4 5 23 5 25 25 26 29 7 28 6 6 21 28 24 5 23 32 30 31 34 5 27 5 35 6 7 16 17 18 6 8 6 11 5 10 22 9 4 5 2 3 1 6 10 6 12 13 14 14 15 6 7 22 6 5 22 SEE STEERING SUB-ASSEMBL Y pag e 4-9 6 33 4[...]

108602 10/08 4 -7 S teering and Park Brake Assembly NOTES: 1. For units with serial number 07120009 and higher: T orque to 180-210 ft.-lbs. Included with wheel motor . ITEM NO. SERVIC E PART NO. MFG. PART NO. QTY DESCRIPTION 1 348987 348987 1 STEERING CONTROL P ANEL 2 781716 781716 2 SS .500-13 X 1.7 5 SH ZN 3 053199 053199 2 NT .500 -13 HX JAM ZN [...]

4-8 108 60 2 10/08 2. For units with serial number 07120009 and higher: T or que to 17 f t.-lbs. 3. For units with serial number 07120009 and higher : 600925 used on left wheel. 600924 used on right wheel. 4. For units with serial numbers pr ior to 07120009: T orque to 350-375 ft.- lbs. Included with wheel motor . 5. For unit s with serial numbers [...]

108602 10/08 4 -9 S teering Sub-Assembly NOTES: 1. Includes Item 1 (7 81260 S teering Bar Grip). ITEM NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 781260 N/A 2 STEERING BAR GRIP 2 348755 348755 2 STEERING BAR 3 767954 767954 16 FW .406 X .812 X .060 SAE HD ZN 4 036244 036244 4 CS .375-16 X 1.000 HX G5 ZN 5 705178 705178 6 CS .375-16[...]

4-10 108602 10/08 Pump Belt and Pulleys Installation 3 2 TRACTOR FRAME 1 2 2 1 6 7 11 6 4 14 16 17 15 18 19 20 12 10 21 22 2 5 13 8 7 3 10 10 8 9 23 24 25 26 13 5 6 27 7 7[...]

108602 10/08 4-11 Pump Belt and Pulleys Installation NOTES: 1. T orque to 45-48 ft-lbs. 2. T orque to 12-15 ft-lbs. 3. Apply grease at ze rk (see owner ’s manual). 4. Included with Honda 24 HP engine (785014). 5. For mowers with serial numbers prior to 07060569 order clutch 787366. 6. For mowers with serial numbers prior to 07120009 use 325308 (p[...]

4-12 108602 10/08[...]

108602 10/08 5 -1 Chapter 5 Content s Kawasaki Engine Installation (Remote Ai r Cleaner) . . . . . . . . . . . . . 5-2 Kawasaki 25 HP Engine Installation (With HD Air Cleaner) . . . . . . . 5-6 Kawasaki 26 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Kawasaki 29 HP Engine Installation (With HD Air Cleaner) . . . . . [...]

5-2 108 60 2 10/08 Kawasaki Engine Installation (Remote Air Cleaner) RED TO ENGINE SENSOR TO BULLET TERMINALS TO S P AD E TERMINAL YELLOW 16 2 RED/BLK 2 2 TRACTOR FRAME POSITIVE BA TTER Y CABLE 2 1 6 2 7 5 18 25 11 16 17 27 3 31 33 30 29 20 3 19 26 39 32 8 4 17 7 7 6 6 NEGA TIVE BA TTERY CABLE 9 ST ARTER SOLENOID GROUND 10 6 12 13 14 3 15 15 3 3 2 [...]

108602 10/08 5 -3 Kawasaki Engine Installation (Remote Air Cleaner) ITEM NO. SERVICE P ART NO. MFG . P ART NO. QTY DESCRIPTION 1 777656 777656 1 KA W ASAKI 23 HP ENGINE 782318 782318 1 KAWASAKI 25 HP ENGINE (FH721V , 3600 RPM) 2 058776 058776 4 NT .312-18 HXZY NL 3 768523 768523 24 FW .343 X .687 X .051/.080 HD ZN/YL 4 029876 029876 1 L W .312 INT [...]

5-4 108 60 2 10/08 NOTES: 1. Includes mounting hardware. 2. Part of Item 8 (7993 12 Wire Harness Adapter). 3. Engine oil capacity: Refe r to engine owner ’ s manual. 4. Engine RPM to be set at 3600± 50. 5. Includes one (1) of Item 17 (057661 Hose Clamp). 6. When installing lower hose clamp on air cleaner hose, in stall as low as possible (agains[...]

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5-6 108 60 2 10/08 Kawasaki 25 HP Engine Inst allation (W ith HD Air Cleaner) 1 34 2 3 4 5 7 5 6 8 9 5 10 12 13 14 15 16 17 18 19 20 4 5 22 21 2 24 23 2 TO E NG INE SENSOR YELLO W PA R T O F ENGINE ST ARTER SOLENOID GROUND 26 TO BULLET TERMINALS 2 TO SP ADE TERMINAL 2 25 28 23 24 29 31 24 23 30 24 6 5 32 PURPLE 2 27 33 RED/BLK 11 5 1 P AR T OF COMM[...]

108602 10/08 5 -7 Kawasaki Engine Installation (With HD Air Cleaner) NOTES: 1. Includes mounting hardware. 2. Part of Item 27 (799 312 Wire Harness Adapter). 3. Engine oil capacity: Refe r to engine owner ’ s manual. 4. Engine RPM to be set at 3600± 50. 5. This connector used for optional electrical equipment. 6. Air filter service part s: ITEM [...]

5-8 108 60 2 10/08 Kawasaki 26 HP Engine Installation P AR T OF WIRE HARNESS 7 30 1 2 3 4 5 6 { 1 } 6 7 8 9 8 10 KA W ASAKI ENGINE SCREEN PA R T O F ENGINE PA R T O F ENGINE 11 11 12 12 12 13 14 17 12 15 16 20 21 22 23 29 24 25 26 9 8 19 18 30 27 28 POSITIVE BA TTER Y CABLE NEGA TIVE BA TTERY CABLE PUR 2 BLK 2 31 BLK 2 } 6[...]

108602 10/08 5 -9 Kawasaki 26 HP Engine Installation NOTES: 1. Includes mounting hardware. 2. Part of Item 31 (799 338 T r actor Wire Harness). 3. Engine oil capacity: Refe r to engine owner ’ s manual. 4. Engine coolant capa city , 2.9 US quarts. 5. Engine RPM to be set at 3600±50. 6. Supplied with engine. 7. This connector used for optional el[...]

5-10 108602 10/08 Kawasaki 29 HP Engine Inst allation (W ith HD Air Cleaner) 1 2 3 4 { 5 1 6 9 8 7 10 11 11 12 13 14 15 16 17 18 19 9 8 21 20 15 22 24 25 3 26 28 YEL/BL K 3 4 RED/BLK 2 TO SP ADE TERMINAL BULLET 3 CONNECT ORS BLK 2 PUR 3 TO SP ADE TERMINAL NEGA TIVE BA TTERY CABLE POSITIVE BA TTERY CABLE ON RECT . ON ST ARTER PUR 3 (2 WIRES) P AR T [...]

108602 10/08 5-11 Kawasaki 29 HP Engine Inst allation (W ith HD Air Cleaner) NOTES: 1. Includes mounting hardware. 2. Wires from Item 27—XR7 Common Wire Ha rness (799320). 3. Wires from Item 28—Kawasa ki 29,31 Wiring Ha rness (601561). 4. Supplied with engine. 5. Engine oil capacity: Refe r to engine owner ’ s manual. 6. Engine RPM to be set [...]

5-12 108602 10/08 Honda Engine Installation 3 1 BRN ORG RED/BLK PUR POSITIVE BA TTERY CABLE GRA/PUR 3 3 3 2 7 30 3 10 13 11 12 29 18 1 13 16 21 22 16 24 32 3 2 14 3 25 7 20 3 3 5 15 NEGA TIVE BA TTERY CABLE 8 4 2 BLK 2 YEL 2 6 9 11 11 3 16 3 17 28 3 9 35 19 26 PA R T O F ENGINE 3 23 31 34 27 7 7 33 7 6 TRACTOR FRAME P ART OF COMMON WIRE HARNESS 9 3[...]

108602 10/08 5-13 Honda Engine Installation NOTES: 1. Includes mounting hardware. 2. Part of Item 4 (799320 T r actor Common Wire Harness). 3. Part of Item 8 (7993 04 Wire Harness Adapter). 4. Engine oil capacity: Refe r to engine owner ’ s manual. 5. Engine RPM to be set at 3600± 50. 6. Includes one (1) of Item 1 1 (057661 Hose Clamp). ITEM NO.[...]

5-14 108602 10/08 7. Supplied with engine. 8. When installing lower hose clamp on air cleaner hose, in stall as low as possible (against carburetor inlet). 9. This connector used for optional electrical equipment. 10. Air filter service part s: 785261 MAIN AIR FIL TER ELEMENT 763318 V ACUA TOR V AL VE[...]

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5-16 108602 10/08 Kohler Engine Installation 4 15 21 22 23 1 POSITIVE BA TTERY CABLE RED/BLK 2 PUR (P/O ENGINE) 5 5 28 1 7 6 4 BLK 2 2 3 4 5 TRACTOR FRAME 8 8 8 9 11 12 13 4 14 4 4 15 13 16 3 4 4 17 18 6 19 20 4 15 24 25 25 26 27 29 NEGATIVE BA TTER Y CABLE P ART OF COMMON WIRE HARNESS 2 30 6 10[...]

108602 10/08 5-17 Kohler Engine Installation NOTES: 1. Includes mounting hardware. 2. Part of Item 2 (7993 20 Common Wire Harness). 3. Engine oil capacity: Refe r to engine owner ’ s manual. 4. Engine RPM to be set at 3600± 50. 5. Supplied with engine. 6. Includes one (1) of It em 8 (057661 Ho se Clamp). 7. Air filter service part s: ITEM NO. SE[...]

5-18 108602 10/08 Fuel System Installation (Air Cooled Engines) 1 1 1 2 3 4 4 4 4 5 6 7 1 6 7 1 6 7 8 8 9 10 9 9 1 6 11 11 12 13 14 14 13 15 17 16[...]

108602 10/08 5-19 Fuel System Installation (Air Cooled Engines) NOTES: 1. T orque to 20 ft.-lbs. 2. Fuel tank service p art 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 FUEL T ANK 3 793232 793232 1 RIGHT SIDE FUEL T ANK 4 000323 000323 6 CLIP 5 106732 N/A 1 REAR [...]

5-20 108602 10/08 Fuel System Installation (Liquid Cooled Engines) 1 1 1 2 3 4 5 5 5 5 6 6 6 6 6 6 7 7 7 7 7 8 9 10 10 11 11 12 13 13 14 14 15 16 17 18 19 20 1 1 1[...]

108602 10/08 5-21 Fuel System Installation (Liquid Cooled Engines) NOTES: 1. T orque to 20 ft.-lbs. 2. Fuel tank service p art not shown: ITEM NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 779306 779306 2 3.5" FUEL T ANK CAP 2 793240 793240 1 LEFT SIDE Z FUEL T ANK 3 793232 793232 1 RIGHT SIDE Z FUEL T ANK 4 109678 N/A 1 REAR SEA T SUPP[...]

5-22 108602 10/08 Instrument Panel Assembly (Air Cooled) RIGHT SIDE FUEL T ANK 1 10a FUSE SIZE AND LOCA TION 15a 1 2 4 6 10 12 7 9 5 13 14 15 3 4 14 13 15a 3 11 18 8 7 9 7 16 17 WIRE HARNESS RELA YS RELA Y ASSEMBL Y[...]

108602 10/08 5-23 Instrument Panel Assembly (Air Cooled) NOTES: 1. Part of 799320 (C ommon 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 785030 785030 1 Z CHOKE CABLE (KAWASAKI) 786657 786657 1 Z CHOKE CABLE (HONDA & KOHLER) 5 712257 71[...]

5-24 108602 10/08 Instrument Panel Assembly (Liquid Cooled) RIGHT SIDE FUEL T ANK 1 10a FUSE SIZE AND LOCA TION 15a 1 2 10 8 13 7 6 5 17 18 19 3 4 18 17 15a 3 9 11 14 7 8 7 15 16 WIRE HARNESS RELA YS RELA Y ASSEMBL Y 10 12[...]

108602 10/08 5-25 Instrument Panel Assembly (Liquid Cooled) NOTES: 1. Fuses are part of the wiring 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 785030 785030 1 Z CHOKE CABLE 5 712257 712257 3 RED INDICA TOR LIGHT 6 601098 601098 2 CB 10-24 X .50[...]

5-26 108602 10/08 Electrical Schematic (799320)[...]

108602 10/08 5-27 Electrical Schematic— Kawasaki LC (799338)[...]

5-28 108602 10/08[...]

108602 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 . . . . . . .[...]

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

108602 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). 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 .187 SPL ZN 3 712976 71[...]

6-4 108 60 2 10/08 Front Wheel Breakdown—747782 NOTES: 1. Inflate tire to 8 -12 p si. 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[...]

108602 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/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[...]

6-6 108 60 2 10/08 Drive Wheel Assembly Installation NOTES: 1. T orque to 65-75 ft. lbs. 2. Inflate tire to 8 -12 p si. 3. For mowers with serial numbers prior to 07120009, use 781237 for the wheel and tire assembly , and 781252 for the wheel assembly . ITEM NO. SERVICE PART NO. PART NO. QTY DESCRIPTION 1 784058 784058 2 WHEEL & TIRE ASSY FOR 6[...]

108602 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 .50-13 HX LK NY TRACTOR FRAME 1 1 4 2 1 2 3[...]

6-8 108 60 2 10/08[...]

108602 10/08 7 -1 Chapter 7 Content s 66" Side Discharge XR7 Deck Assembly . . . . . . . . . . . . . . . . . . . . . 7-2 66" Side Discharge XR7 Deck Pulley Asse mbly . . . . . . . . . . . . . . . . 7-4 60" Side Discharge XR7 Deck Assembly . . . . . . . . . . . . . . . . . . . . . 7-6 60" Side Discharge XR7 Deck Pulley Asse mbly [...]

7-2 108 60 2 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[...]

108602 10/08 7 -3 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 9-4 for listing of decals). ITEM NO. SERVICE PA R T N O . MFG. PART NO. QT[...]

7-4 108 60 2 10/08 66" Side Discharge XR7 Deck Pulley Assembly 1 3 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[...]

108602 10/08 7 -5 66" Side Discharge XR7 Deck Pulley Assembly NOTES: 1. T orque to 1 18 f t. lbs. 2. T orque to 67-75 ft. lbs. 3. See ‘‘66" & 54" Side Discharge De ck Belt Routing and T ensioning’ ’ on page 8-4 for belt tensioning. 4. See ‘‘S pindle Assembly–796235’ ’ on page 7-28 for breakdown. 5. Item 3 (60143[...]

7-6 108 60 2 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[...]

108602 10/08 7 -7 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 9-5 for listing of decals). ITEM NO. SERVICE PA R T N O . MFG. P ART NO. Q[...]

7-8 108 60 2 10/08 60" Side Discharge XR7 Deck Pulley Assembly 1 2 3 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[...]

108602 10/08 7 -9 60" Side Discharge XR 7 Deck Pulley Assembly NOTES: 1. T orque to 1 18 f t. lbs. 2. T orque to 65-75 ft. lbs. 3. See ‘ ‘60" Side Discharge Deck Belt Routing and T ensioning’’ on p age 8- 5 for belt tensioning. 4. See‘‘S pindle Assembly–796235’ ’ on page 7-28 for breakdown. 5. Item 3 (601434) replaces id[...]

7-10 108602 10/08 54" Side Discharge XR7 Deck Assembly 1 9 10 13 13 4 5 11 12 11 11 10 10 9 9 12 13 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 13 4 4 13[...]

108602 10/08 7-11 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. Secure Item 1 1 (053199 Jam Nut) to bolt with a dr op of Loctite® (271 Red). T ighten Item 1 1 to shank of Item 9 (781708 Cs .500-13 X 4.25 Hx G5 Zn). Anti-scalp w heel m[...]

7-12 108602 10/08 54" Side Discharge XR7 Deck Pulley Assembly BEL T GUIDE POSITIONING 1 3 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[...]

108602 10/08 7-13 54" Side Discharge XR 7 Deck Pulley Assembly NOTES: 1. T orque to 1 18 f t. lbs. 2. T orque to 65-75 ft. lbs. 3. See ‘‘66" & 54" Side Discharge De ck Belt Routing and T ensioning’ ’ on page 8-4 for belt tensioning. 4. See‘‘S pindle Assembly–796235’ ’ on page 7-28 for breakdown. 5. Item 8 (60143[...]

7-14 108602 10/08 Side Discharge Deck—"A" Adaptors 3 Deck Assembl y 4 4 1 2 2 3[...]

108602 10/08 7-15 Side Discharge Deck—"A" Adaptors NOTES: ITEM NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 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 4 CB .375-16X 1.00 STD CD 3 767954 767954 4 FW .406[...]

7-16 108602 10/08 Side Discharge Deck—"B" Adaptors 1 4 3 Deck Assembly 4 6 5 7 5 6 4 5 Assembled Detail 2[...]

108602 10/08 7-17 Side Discharge Deck—"B" Adaptors NOTES: 1. Service part includes rivet nut s. ITEM NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 108533 108533 1 AIR FLOW BAFFLE, "B" RIGHT SIDE ( 66" DECKS) 108518 108518 1 AIR FLOW BAFFLE, "B" RIGHT SIDE ( 60" DECKS) 108621 108621 1 AIR FLOW[...]

7-18 108602 10/08 54" Rear Discharge Deck Assy —S/N 08100000 & Higher 1 27 3 22 5 6 6 8 8 30 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 24 3 2 21 21 20 20 26 18 17 19 19 27 10 26 13 13 14 10 5 DEFLECTOR DET AIL 28 4 5 4 22 31 31 29 9 25 27 3 29 3 27 23 25[...]

108602 10/08 7-19 54" Rear Discharge Deck Assy —S/N 08100000 & Higher 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 9-7. ITEM NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPT[...]

7-20 108602 10/08 54" Rear Discharge Deck Assy—S/N 08010000—08100000 1 27 3 22 5 6 6 8 8 30 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 24 3 2 21 21 20 20 26 18 17 19 19 27 10 26 13 13 14 10 5 DEFLECTOR DET AIL 28 4 5 4 22 31 31 29 9 25 27 3 29 3 27 23 25[...]

108602 10/08 7-21 54" Rear Discharge Deck Assy—S/N 08010000—08100000 NOTES: 1. Includes Items 12 through 14 and 16. 2. Service part deck includes decal s, see ‘‘54" Rear Discharge Deck Decals’ ’ on page 9-7. ITEM NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 548644 107933 1 54" REAR DISCHARGE DECK W/A 2 109[...]

7-22 108602 10/08 54" Rear Discharge Deck Assy–S/N Prior to 08010000 1 2 26 3 22 5 6 6 8 8 9 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 23 23 26 3 24 25 21 21 20 20 25 18 17 19 19 24 26 3 10 25 13 13 14 10 5 DEFLECTOR DET AIL 27 4 5 4 22 28 28[...]

108602 10/08 7-23 54" Rear Discharge Deck Assy–S/N Prior to 08010000 NOTES: 1. Includes Items 12 through 14 and 16. 2. Service part deck includes decal s, see ‘‘54" Rear Discharge Deck Decals’ ’ on page 9-7. ITEM NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 548644 107933 1 54" REAR DISCHARGE DECK W/A 2 10806[...]

7-24 108602 10/08 54" Rear Disch arge Deck Pulley Assy —S/N 08100000 & Higher 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 11 6 5 6 7[...]

108602 10/08 7-25 54" Rear Disch arge Deck Pulley Assy —S/N 08100000 & Higher NOTES: 1. T orque to 1 18 f t. lbs. 2. T orque to 65-75 ft. lbs. 3. See ‘‘54" Rear Discharge Deck Belt Routing and T ens ioning’’ on page 8-6 for belt tensioning. 4. See ‘‘S pindle Assembly–796680’ ’ on page 7-29 for breakdown. 5. See ‘[...]

7-26 108602 10/08 54" Rear Discharge Deck Pull ey Assy—S/N Prior to 08100000 1 1 5 2 5 6 4 4 7 15 8 9 10 12 13 13 13 13 14 15 16 14 18 17 20 21 22 23 23 24 27 27 2 3 28 23 26 25 14 17 19 3 1 23 5 7 16 5 7 5 14 20 11 4 5 7 2[...]

108602 10/08 7-27 54" Rear Discharge Deck Pull ey Assy—S/N Prior to 08100000 NOTES: 1. T orque to 1 18 f t. lbs. 2. T orque to 65-75 ft. lbs. 3. See ‘‘54" Rear Discharge Deck Belt Routing and T ens ioning’’ on page 8-6 for belt tensioning. 4. See ‘‘S pindle Assembly–796235’ ’ on page 7-28 for breakdown. 5. See ‘‘S [...]

7-28 108602 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. 3. Apply grease to zerk. ITEM NO. SERVICE PA R T N O . MFG . PA R T N O . QT Y . DESCRIPTION 1 077123 N/A 2 BEARING W/O COLLAR 2 766204 N/A 1 BLADE SPINDLE BUSHING 3 034843 N/A 1 CAST SPIN[...]

108602 10/08 7-29 Spindle Assembly–796680 NOTES: 1. Install upper b earing with extended inner race up. 2. Install lower bearing with extended inner race down. 3. Apply grease to zerk. 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 [...]

7-30 108602 10/08[...]

108602 10/08 8 -1 Chapter 8 Content s Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 66" & 54" Side Discharge Deck Belt Routing and Tensioning . . . . . . 8-4 60" Side Discharge Deck Belt Routing and Tensioning . . . . . . . . . . . 8-5 54" Rear Discharge Deck Belt Routi[...]

8-2 108 60 2 10/08 Deck Installation TRACTOR ASSEMBL Y DECK ASSEMBL Y 1 2 3 4 5 5[...]

108602 10/08 8 -3 Deck Installation NOTES: 1. 66" Deck installation is shown, 60" and 54" Side Di scharge Decks, and 54" Rear Discharge Decks 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 .760 X 1.62[...]

8-4 108 60 2 10/08 66" & 54" Side Discharge Deck 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[...]

108602 10/08 8 -5 60" Side Discharge Deck 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[...]

8-6 108 60 2 10/08 54" Rear Discharge Deck 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[...]

108602 10/08 8 -7 This p age intentionally lef t blank.[...]

8-8 108 60 2 10/08 Seat Installation—S/N 08010000 & Higher 1 10 12 19 14 5 6 16 4 3 17 5 5 7 8 9 13 4 11 5 4 23 15 4 20 19 21 22 2 21 18 1 20 LA TCH W/A DET AIL 14 2 1 10 10 25 24 21 21[...]

108602 10/08 8 -9 Seat Installation —S/N 08010000 & Higher NOTES: 1. Must pivot freely . 2. Part of seat. 3. Seat stop is used on mowers with 29 HP Kawasaki engines only . 4. Service part s available for Michigan S tandard seat; ITEM NO. SERVICES PART NO. MFG. PART NO. QTY DESCRIPTION 1 793661 793661 1 MICHIGAN SEAT 2 109307 109307 1 SEA T P [...]

8-10 108602 10/08 Seat Installation—S/N Prior to 08010000 1 1 10 12 15 1 2 5 5 6 14 16 4 3 17 3 8 5 5 7 8 9 13 4 11[...]

108602 10/08 8-11 Seat Installation—S/N Prior to 08010000 NOTES: 1. Must pivot freely . 2. Service part s available for Michigan S tandard seat; ITEM NO. SERVICES PART NO. MFG. PART NO. QTY DESCRIPTION 1 793661 793661 1 MICHIGAN SEAT 2 350041 350041 1 SEA T P AN 3 000331 000331 3 BLACK CABLE TIE 4 086660 086660 3 NT .375-16 HX LK NY 5 767954 7679[...]

8-12 108602 10/08 ROPS Installation 5 6 7 8 9 11 1 2 3 3 9 10 7 5 6 2 1 4[...]

108602 10/08 8-13 ROPS Installation NOTES: 3. ROPS come standard on all Hustle r Z unit s with serial numbers 08010000 and higher . Prior to this seri al number , ROPS were optional for Hustler Z mowers. ITEM NO. SERVICES PART NO. MFG. PART NO. QTY DESCRIPTION 1 601440 N/A 1 ROPS 2 601471 N/A 2 L YNCH PIN W/ LANY ARD 3 601470 N/A 2 KNOB 4 601560 N/[...]

8-14 108602 10/08[...]

108602 10/08 9 -1 Chapter 9 Content s Tractor Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 66" Side Discharge XR7 Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . 9-4 60" Side Discharge XR7 Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . 9-5 54" Side Discharge X[...]

9-2 108 60 2 10/08 T ractor Decals TOP OF S E AT PA N BOTTOM OF S E AT PA N 1 2 6 9 10 13 12 11 3 4 14 5 15 7 A A 8 17 18 7 BB VIEW B-B 1 2[...]

108602 10/08 9 -3 T ractor Decals NOTES: 1. Location for item 7 (788968-Engi ne Compartment Decal) for mowers with HD air cleaners only . 2. Location for item 7 ( 788968-Engine Compartment Decal) for all mowers except those with HD air cleaners. ITEM NO. SERVICE PA R T N O . MFG . PA R T N O . QT Y . DESCRIPTION 1 781427 781427 1 DECK HEIGHT INDICA[...]

9-4 108 60 2 10/08 66" Side Discharge XR7 Deck Decals NOTES: ITEM NO. SERVICE PA R T N O . MFG . PA R T N O . QT Y . 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[...]

108602 10/08 9 -5 60" Side Discharge XR7 Deck Decals NOTES: ITEM 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 BEL [...]

9-6 108 60 2 10/08 54" Side Discharge XR7 Deck Decals NOTES: ITEM NO. SERVICE PA R T N O . MFG . PA R T N O . QT Y . 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[...]

108602 10/08 9 -7 54" Rear Dischar ge Deck Decals NOTES: ITEM NO. SERVICE PA R T N O . MFG . P ART NO. 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 'MADE[...]

9-8 108 60 2 10/08[...]

10-1 108602 10/08 Chapter 10 Content s Assembly Pictures and Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 General information for a ll models: . . . . . . . . . . . . . . . . . . . . 10-3 Hustler Z’s with Kawasaki engines: . . . . . . . . . . . . . . . . . . . 10-4 Hustler Zs with Kawasaki 29 HP engi nes: . . . . . . . . [...]

10-2 108602 10/08 Recommended service procedure . . . . . . . . . . . . . . . . . . . 10-29 Air restriction indi cator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29 General engine maintenance . . . . . . . . . . . . . . . . . . . . . . . 10-30 Belt replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30 Mow[...]

10-3 108602 10/08 Assembly Pictures and Aids General information for all models: PTO clutch wire routing "FIG . 1". PTO clutch switch installa tion (Instrument Panel) "FIG . 2" & "FIG . 3". FIG . 1 FIG . 2 FIG . 3 TIE STRAP CLUTCH PIGT AIL WIRE PTO SWITCH TIE STRAP[...]

10-4 108602 10/08 Hustler Z’ s with Kawasaki engines: Does not include machines with 29 HP or 26 HP engines. Throttle cable routing "FIG . 4". Choke cable routing, front and rear tie straps "FIG . 5 " & "FIG . 6". FIG . 4 FIG . 5 FIG . 6 THROTTLE HYDRAULIC RESER VOIR CABLE ROUTED THROUGH TUBE TIE STRAP CHOKE CABL[...]

10-5 108602 10/08 Fuel line routing "FIG . 7 " & "FIG . 8". FIG . 7 FIG . 8 WIRE HARNESS FUEL LINE TIE STRAP POS. BA TT ER Y CABLE TIE STRAP TIE STRAP FUEL LINE NEG . BA TTER Y CABLE THROTTLE CABLE LEFT FUEL RIGHT FUEL TO ENGINE TA N K TA N K WIRE HARNES S[...]

10-6 108602 10/08 Hustler Zs with Kawasaki 29 HP engines: Routings "FIG . 9". Route fuel lines, battery cabl es, and choke an d throttle cables and tie as shown, "FIG . 1 0". T ie fuel lines to seat support as shown in "FIG . 1 1" (r ight side shown, left side similar). Choke and throttle cable routed aroun d engine, s[...]

10-7 108602 10/08 Choke and throttle cable co nnections to eng ine, see "FIG . 13". THROTTLE AND CHOKE CABLE INSTALLATION TO ENGI NE (SEE " FIG . 13" & "FIG . 14"). 1. Clamp Instrument Panel to side of seat support in inst alled orientation 2. Make sure throttle lever is in the full throttle détente position . 3. [...]

10-8 108602 10/08 Throttle and choke cable connectio ns to engine: "FIG . 17" and "FIG . 18". Hustler Z’ s with Honda engines: Choke/Throttle cable r outing "FIG . 19". T ie throttle and choke cables t o hydro hose as s hown.Fuel line routing "FIG . 20" & "FIG . 21". FIG . 17 FIG . 18 FIG . 19[...]

10-9 108602 10/08 Choke/Throttle cable routing "FIG . 22". Tie ch oke and throttle cables together . FIG . 20 FIG . 21 FIG . 22 FUEL VA LV E RIGHT FUEL LINE LEFT FUEL LINE TO EN GI NE FUEL LINE TIE STRAP WIRE HARNESS WIRE HARNESS LEFT PUMP CHOKE AND THROTTLE CABLE TIE STRAP[...]

10-10 108602 10/08 Honda carburetor drain/vent hose routing "FIG . 23". Hustler Z’ s with Kohler engines: Wire harness and cable r outing "FIG . 24", "FIG . 25", and "FIG . 26". FIG . 23 FIG . 24 TO CLUTCH VENT/DRAIN HOSES NEGA TIVE BA TTER Y CABLE POSITIVE BA TTERY CABLE[...]

10-11 108602 10/08 Choke and thro ttle cab le ro ut ing "FIG . 27 ". FIG . 25 FIG . 26 FIG . 27 TIE STRAP BA T TER Y CABLES FUEL LINES & WIRE HARNESS WIRE HARNESS TIE STRAP WIRE HARNESS NEGA TIVE BA TTER Y CABLE TIE STRAP ROUTE THROTTLE CABLE BELOW HYDRAULIC HOSE CHOKE CABLE[...]

10-12 108602 10/08 Fuel line routing "FIG . 28". FIG . 28 TIE STRAP FUEL LINE[...]

10-13 108602 10/08 Maintenance & Adjustment Safety This safety alert symbol is used to call attentio n to a message intended to provide a reason able degree of PERSONAL SAFETY for op era tors and other persons durin g the normal operation and servicing of this equipment. DANGER – denotes immediate hazar ds which WILL result in severe personal[...]

10-14 108602 10/08 Safe Maintenance & Adjustment Practices ▲ This product is capable of amputating hands and f eet and throwing object s. Always follow all safety instructions to avoid serious injury or death. ▲ Unless specifically required, DO NOT have engine running wh en servicing or making adjustment s to tractor . Place control levers [...]

10-15 108602 10/08 off and remove ignit ion switch key for maximum safety . Repairs or maintenance requiring eng ine power should be perfo rm e d by trained personnel on ly . ▲ Use a stick or similar instrument to clean under th e mowe r ma kin g sur e that no part of the body , especially arms and hands are under mower . ▲ Exercise caution whe[...]

10-16 108602 10/08 Safety and Instruction Decals ▲ S pecific s afety warning decals ar e located on the equipment near the immediate ar eas of potential hazards. These decals should not be removed or obliter ated. Replace them if they become non- readable. The following illustration s show the various safety decals tha t are located on the machin[...]

10-17 108602 10/08 Do not remove or modify stabilizer wheels or rear engine guard or injur y can result. Keep engine and pump compart-ment(s) clean (especially in exhaust area) to prevent fire and pr ovide maximum engine and hydraulic cooling. Hydraulic fluid escaping under pressure can penetrate skin . Hydraulic fluid may also cause infection in a[...]

10-18 108602 10/08 Maintenance FIG . 29 1a 3 2b 8 1b 11 11 10 6 6 12 7 2a 12 9 4 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 T anks 7. Hydraulic Oil Reservoir 8. [...]

10-19 108602 10/08 FIG . 30 2 4 4 1 3 2 4 1. Deck Pusher Arm Zerks (2) 2. Deck Belt 3. Spindle Housing Zerk (3) 4. Blades Maintenance Locator Chart 60" XR7 deck 54" & 66" XR7 deck 1 3 3 4 3 3 3 1 1 1 1 2 3 3 3 4 4 54" Rear Discharge deck[...]

10-20 108602 10/08 NOTES: 1. Initial oil change is after 5 hours of operation. Thereafter , chang e oil af ter every 40 hours opera tion. Change more of ten under dusty or dirty conditions and during hot weathe r periods. 2. T orque initially and after first 2 hours of operation. 3. Perform initial hydraulic filte r change after 50 hours (one wee k[...]

10-21 108602 10/08 INTRODUCTION Regular maintenance is the best pr even tion for costly downtime or expensive, premature rep air . The following p age s contain suggested mainten ance info rmation and schedu les which the operator should follow on a routine basis. Remain alert for unusual noises, they could be signalin g a problem. Visually insp ec[...]

10-22 108602 10/08 Ti re s It is important for level mowing that th e 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 an y machine,[...]

10-23 108602 10/08 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 batter y is recommended. Other- wise, follow battery manufactur er ’s mainte nanc e, safety , storing an d char gin g spec ifica tio ns . Th[...]

10-24 108602 10/08 W ARNING: Incorrect battery cable routing could cause da mage to the tractor and b attery cables. This can cause sparks which can cause a battery gas explosion which will result in personal injury . Always disconnect the ne gative (black) battery cable before disconnecting the positive (red) cable. Always connect the positive (re[...]

10-25 108602 10/08 Check oil level in hy draulic system after every 50 hours of operation or weekly , whichever occurs first. Check more often if system appe ars to be leaking or otherwise malfunctioning. Fluid level should be 1” from top of reservoir . Use only SAE 20W50 SG , SF/C C, CD service motor oil. Change hydr aulic system filter e lement[...]

10-26 108602 10/08 Fuel system DANGER: Observe usu al fu el ha ndlin g pr eca 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[...]

10-27 108602 10/08 The fuel filter ("FIG . 36") is installe d in the fuel line betwee n fuel t anks and engin e fuel pump. Replace filter annually or af ter every 500 hours of operation, wh ichev er occurs first. When replacing the fuel filter , check the fuel line hose s and fuel shut-of f valve grommet for any cracks or leaks. Replace a[...]

10-28 108602 10/08 Engine air filter Perform engine air filte r maintenance per the scheduled maintenance chart. See “SERVICE A T INTERV ALS INDICA TE D” on page 10-20. A specially designed dry filte r is standard equipmen t on the Hustler Z and Super Z tractors and su pplies clean combustion air to the engine "FIG . 39". RECOMMENDED [...]

10-29 108602 10/08 bad for the engine u nless it is excessively restricting the air flow and engine perfor mance is affected. The reason is simple. The media in th e filter must be poro us to allow air to p ass through it. W hen dirty air passes through th e filter , the d irt p lug s some of the holes in th e m edia an d ac tually acts as p art of[...]

10-30 108602 10/08 A restriction indicator takes the guessw ork out of air clea ner servicing and allows you to safely bene fit from the filter ’ s optimum performance. General engine maintenance Detailed in structions and recommendations for bre ak- in an d re gu la r ma int en a nce are specified in the Engine Owner’s manual. Please refer to [...]

10-31 108602 10/08 W ARNING: If the pump belt fails, loss of control will occur espec ially when operating on a slope. If you lose steering control while operating the machine , place the steering co ntrol levers in the p ark brake position imme diately . Inspect t he machine and involve your Hustler dealer to res olve the problem before contin uin[...]

10-32 108602 10/08 Sharpen the blades on a grin der following p a ttern as shown "FIG . 45". T ouch-up sharpening can be done with a file. Check the bl ades for balance following grinding. A co mmercial balancing tool is available through most hardware supply stores, or balan cing can be done by placing the blade on an inverted line punch[...]

10-33 108602 10/08 This p age intentionally lef t blank.[...]

10-34 108602 10/08 Adjustment Introduction Y our Hustler Z was adjusted before it left the factory and was checke d during predeliver y setup. However , after st art-up and c ontinued use, a certain 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 [...]

10-35 108602 10/08 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 off 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 plac[...]

10-36 108602 10/08 pump arms are stopping th e forward motion of the c ontrol arms, loosen the jam nut on the adjust able stop of the corresponding side and tu rn the stop (set screw) inward to stop the control levers slightly before the pump bottom s ou t. Lock in place when the adjustment is correct by re-tightening the jam nut. 3. Do this for ea[...]

10-37 108602 10/08 Park brake adjustment Occasionally check the park bra ke s and adjustment using the following method: 1. Position the control le vers in the ne utra l position. Disen gage the deck clutch. 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[...]

10-38 108602 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 the brak e be gin to engage, stop adjusting th e turnbuckle. Re-tighten the jam nuts on the turnbuckle. 9. Place the control lever in the park brake slot "FIG . 5[...]

10-39 108602 10/08 Deck drive belt adjustment The spindle belt tension re mains constant by means of a tension idler and spring "FIG . 58". The spring tension should be such that the belt does not slip under normal operating load conditions, assuming the belt is not excessively worn or damaged . As be lt stretches and wears in , adjustmen[...]

10-40 108602 10/08 Drive wheels tire pressure ..... ...... 8 - 12 psi Gauge wheels tire pressure ...... ... 8 - 12 psi WA R N I N G : S top engine. Make sure deck clutch switch is in the down ( OFF) position . Place control levers in the brake position before lea ving machine. 2. Park the unit on a flat surface. 3. Raise deck and place 3” block u[...]

10-41 108602 10/08 7. Loosen the two nut s on the front of heig ht indicator so that the foot ped al is free "FIG . 65". 8. S tart the leve lin g pr oc ess on th e left front of the tractor . 9. Set the amount of threads protr udin g on the deck lift rod from the lift blo ck at approximately 1" "FIG . 6 6". 10. Jam both nut[...]

10-42 108602 10/08 height indicato r . FIG . 65 FIG . 66 FOOT PEDAL NUTS 1" DECK LIFT ROD 1" LIFT BLOCK[...]

108602 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 , 5-21 000331 5 - 1 9 , 5-21 , 8-9 , 8-11 000430 5 - 2 3 , 5-25 005116 4 - 7 , 7-7 , 7-11 008193 4 - 1 1 , 5-9 008573 3 - 3 010470 5 - 9 012005 7 - 2 8 , 7-29 015495 4 - 5 , 4-11 , 7-3 , 7-7 , 7-11 , 7-19 , 7-21 , 7-23 015511 6 -[...]

Part Page No. No. Part Page No. No. Part Page No. No. i-2 108602 10/08 108533 7 - 1 7 108536 7 - 3 108549 1 - 2 108550 1 - 2 108551 1 - 2 108554 1 - 2 108555 1 - 2 108556 1 - 2 108559 1 - 2 108560 1 - 2 108561 1 - 2 108563 1 - 2 108565 1 - 2 108607 7 - 1 1 108619 7 - 1 5 108620 7 - 1 7 108621 7 - 1 7 108851 8 - 9 109274 8 - 9 109283 8 - 9 109307 8 [...]

108602 10/08 i-3 Part Page No. No. Part Page No. No. Part Page No. No. 705178 4 - 9 705186 3 - 3 , 3-7 705954 5 - 1 9 , 5-21 , 6-3 , 7-5 , 7-9 , 7-13 710194 7 - 1 9 , 7-21 712257 5 - 2 3 , 5-25 712919 5 - 1 9 , 5-21 712976 6 - 3 714998 5 - 2 3 , 5-25 720177 5 - 3 , 5-7 , 5-13 720516 5 - 9 , 5-11 722199 8 - 9 , 8-11 724716 8 - 9 , 8-11 727008 9 - 3 [...]

Part Page No. No. Part Page No. No. Part Page No. No. i-4 108602 10/08 785030 5 - 2 3 , 5-25 785188 9 - 3 785261 1 - 1 , 5-4 , 5-7 , 5-9 , 5-14 , 5-17 785279 1 - 1 , 5-7 , 5-9 785378 5 - 9 , 5-11 , 5-13 , 5-17 785477 5 - 1 3 785543 5 - 1 3 785634 1 - 1 785642 1 - 1 785659 4 - 1 1 785675 5 - 1 3 785741 5 - 3 , 5-13 , 5-17 785808 5 - 2 3 , 5-25 78603[...]