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Avaya 7960 IP Phone User Manual

1. PUR TOSPADE TERMINAL 2 ON s gt ED NEG BATTERI POS BATTERY CABLE D am CABLE Be We 29 EN RED BLK TO SPADE ON STARTER 5 2 108604 10 08 Kawasaki 31 HP Engine Installation ITEM SERVICE MFG NO PART NO PART NO an DESCRIPTION 1 601549 N A 1 KAWASAKI 31 HP ENGINE 2 109743 109743 1 CABLES HEAT SHIELD 3 720516 720516 3 CSM8X1 25X16G10 9HX 4 788018 788018 1 MUFFLER 5 785378 785378 1 1 50 MUFFLER CLAMP 6 601550 601550 1 MANIFOLD 29 31 KAW 7 780841 780841 2 KAW MUFFLER GASKET 8 017004 017004 5 LW 312 MED SPRING ZN 9 782664 782664 5 NT M8 1 25 HX STAINLESS STEEL 10 029751 029751 2 CS 375 16 X 1 00 HXFLK ZNYC 11 705137 705137 4 FW 391 X 1 250 X 060 ZNYC 12 016899 016899 2 NT 375 16 HX FLK ZNYC 13 055939 055939 6 CS 250 20 X 75 G5 ZNYC 14 768515 768515 6 FW 281 X 625 X 051 080 HD ZN YL 15 109748 109748 1 HOOD SCOOP 16 783837 783837 1 ELECTRIC COOLER FAN 17 109604 109604 1 REMOTE AIR BRACKET 18 778738 778738 1 312 WIRING CLAMP 19 768523 768523 12 FW 343 X 687 X 051 080 HD ZN YL 20 034272 034272 4 NT 312 18 HX G5 ZN 21 796524 796524 1 M20X2 5 OIL DRAIN VALVE 22 036236 036236 1 CS 312 18 X 1 00 HX G5 ZNYC 23 034280 034280 8 CS 312 18 X 750 HX G5 ZNYC 24 036244 036244 4 CS 375 16 X 1 00 HX G5 ZNYC 25 377994 377994 1 HEAT SHIELD MMZ ROLLER 26 601257 601257 1 FITTING 90 1 8 BRASS 27 788943 788943 1 AIR FILTER INDICATOR 28 029876 029876 1 LW 312 INT
2. 8 2 72 Side Discharge Deck Pulley Assembly XR7 8 4 60 Side Discharge Deck Assembly 8 6 60 Side Discharge Deck Pulley Assembly XR7 8 8 Side Discharge Deck A Adaptors 8 10 60 Rear Discharge Deck Assembly 8 12 60 Rear Discharge Deck Pulley Assembly 8 14 Spindle Assembly 796235 8 16 Spindle Assembly 796680 8 17 Chapter 9 Deck Installation 9 2 72 Side Discharge Belt Routing and Tensioning 9 4 60 Side Discharge Belt Routing and Tensioning 9 5 60 Rear Discharge Belt Routing and Tensioning 9 6 108602 10 08 c 1 Chapter 10 Tractor DEGAS teren poeti ek 10 2 72 amp 60 Side Discharge Deck 5 7 10 4 60 Rear Discharge Deck Decals 10 5 Chapter 11 SeabInstallallOH usu ER 11 2 Chapter 12 ee adel eae dies 12 22 ii be quo Porte ob UNT ope o OS i 1 c 2 108602 10 08 Chapter 1 General Information This Manual covers Hustler ATZ model 928143 Hustler ATZ model 928150 amp Hustler ATZ model 928168 Frequently Ordered Parts PART NO DESCRIPTION 783936 FILTER ELEMENT 781443 PUMP DRIVE BELT 784207 BELT 72 SIDE DISCHARGE DEC
3. NOTES 1 Spring length after tensioning belt Measure spring from outside of hook to outside of hook 2 Route belt as shown 108604 10 08 9 5 60 Rear Discharge Routing and Tensionin ka DECK NOTES 1 Spring length after tensioning belt Measure spring from outside of hook to outside of hook 2 Route belt as shown 9 6 108604 10 08 108604 10 08 Chapter 10 Contents Tractor DEGAS rs a aaa 72 amp 60 Side Discharge Deck Decals XR7 60 Rear Discharge Deck Decals 10 1 Tractor Decals TOP OF SEAT PAN 0 BOTTOM OF SEAT PAN 10 2 108604 10 08 Tractor Decals Oo e DESCRIPTION 1 781427 781427 1 DECK HEIGHT INDICATOR DECAL 2 779280 779280 1 H
4. Grease deck idler Grease deck pusher arms Grease pump idler Grease deck height pivots Grease gauge wheel bearings Change engine oil and filter 1 4 Clean cylinder and head fins a Check battery connections Check tire pressure with a gauge Check hydraulic oil level Clean engine exterior a P lt lt lt gt gt gt gt gt lt Clean amp regap spark plugs a Check pump and deck belt tension and condition 6 Check fuel and hydraulic lines 7 Check fuel valve and grommet 7 Tighten lug nuts on wheels 2 gt DS lt Sg Change fuel filter Clean or replace hydraulic fill cap Change hydraulic oil and filter 3 Grease deck spindle housings Replace spark plugs gt gt lt lt lt Sg NOTES Initial oil change is after 5 hours of operation Thereafter change oil after every 40 hours operation Change more often under dusty or dirty conditions and during hot weather periods Torque initially and after first 2 hours of operation Perform initial hydraulic filter change after 50 hours one week of operation Change engine oil filter per the engine manufacturer s recommendations Refer to Engine Owner s Manual for recommendations and other maintenance items Service more often under dusty or dirty conditions Use caution when servicing to prevent dust contamination in the
5. The owner should also ensure that the operator mechanic knows that they are responsible for their own safety as well as the safety of other persons within the vicinity Remember the operator mechanic is responsible for accidents or hazards occurring to other people or their property Safe Maintenance amp Adjustment Practices This product is capable of amputating hands and feet and throwing objects Always follow all safety instructions to avoid serious injury or death Unless specifically required DO NOT have engine running when servicing or making adjustments to tractor Place control levers in the park brake position disengage deck clutch remove ignition switch key and disconnect the negative battery cable Repairs or maintenance requiring engine power should be performed by trained personnel only To prevent carbon monoxide poisoning be sure proper ventilation is available when engine must be operated in an enclosed area Follow daily and weekly checklists making sure hoses are tightly secured and bolts are tightened Keep your machine clean and remove any deposits of trash and clippings which can cause engine fires and hydraulic overheating as well as excessive belt wear Clean up oil or fuel spillage Allow machine to cool before storing 108604 10 08 12 3 Clean flammable material from machine Prevent fires by keeping engine compartment battery hydraulic lines fuel line fuel tank and operator s station clean of accumulat
6. 7 N TRACTOR Sg Y FRAME N NE Eee 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 NOTES 1 Do not torque wheel must turn freely 6 6 108604 10 08 108604 10 08 Weight Installation ROPS Installation Chapter 7 Contents 7 1 Weight Installation TIRE WHEEL ASSEMBLY 7 2 108604 10 08 Weight Installation ITEM SERVICE MFG PART NO PART NO NO QTY DESCRIPTION 1 008193 008193 8 500 13 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 PLATE 5 792077 792077 8 CB 50 13 X 6 STD ZN 6 781567 781567 4 NT 50 13 HX LK NY 7 392035 392035 2 ATZ TOP WEIGHT PLATE 8 392191 392191 2 ATZ MIDDLE WEIGHT PLATE 9 392357 392357 4 ATZ BOTTOM WEIGHT PLATE 10 089938 089938 4 CS 500 13 X 4 00 HX G5 ZNYC NOTES 108604 10 08 7 3 ROPS Installation 108604 10 08 7 4 ROPS Installation ITEM SERVICE NO PART NO 1 008193 2 767962 3 391375 4 381657 5 381665 6 381673 7 008573 8 392985 9 789412 10 392613 11 392605 12 078386 13 077859 14 381723 15 381731 16 017616 17 016642 18 768002 19 016972 20 110855 21 381749 22 768523 23 036236 24 789404 25 789396 26 033035 27 033035 28 033035 29 033035 30 601979 PART
7. A restriction indicator takes the guesswork out of air cleaner servicing and allows you to safely benefit from the filter s optimum performance RESET BUTTON GENERAL ENGINE MAINTENANCE Detailed instructions and recommendations for break in and regular maintenance are specified in the Engine Owner s manual Please refer to this manual for engine servicing lubricating oil levels with quality and viscosity recommendations bolt torques etc The engine warranty is backed by the manufacturer Special attention should be paid to applicable data which will not be duplicated here BELT REPLACEMENT FIG 14 FIG 15 FIG 16 amp FIG 17 show diagrams and descriptions of the unit s belt drive systems 12 18 108604 10 08 Inspect these belts frequently for wear and serviceability Replace a belt that shows signs of severe cuts tears separation weather checking and cracking or burns caused by slipping Slight raveling of belt covering does not indicate failure trim ravelings with a sharp knife NOTE VIEWED FROM BOTTOM OF UNIT Pump belt Engine pulley Pump idler pulley Pump idler arm Pump pulley Electric deck clutch Pump idler spring Deck Belt Drive Layout 1 1 Spindle drive belt 2 Deck blade spindle pulley 3 Spi
8. s footrest per the Maintenance Schedule Use SAE multi purpose grease Grease the deck idler per the Maintenance Schedule Use SAE multi purpose grease Grease the pump idler per the Maintenance Schedule Use SAE multi purpose grease Grease the two deck pusher arm pivots per the Maintenance Schedule Use SAE multi purpose grease Grease the blade spindle assemblies per the Maintenance Schedule The spindle assemblies require lubrication annually Each spindle shaft is equipped with a grease zerk located under the deck Use no more than one or two ounces of SAE multi purpose grease 1 to 2 pumps on an average grease gun Do not force lubricant into grease zerks Bearings are sealed and do not require much lubricant nw ELECTRICAL SYSTEM The electrical system is a 12 volt negative ground Recommended battery size is a garden tractor BCI group U1R with 225 or better cranking AMP rating A maintenance free battery is recommended Other wise follow battery manufacturer s maintenance safety storing and charging specifications 12 10 108604 10 08 The battery is located under the seat platform FIG 4 FIG 4 WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling WARNING Avoid skin and clothing contact with battery acid Always wear eye protection when checking the battery acid c
9. Install lower bearing with extended inner race down 108604 10 08 8 17 8 18 108604 10 08 108604 10 08 Chapter 9 Contents Deck Installation 9 2 72 Side Discharge Belt Routing and Tensioning 9 4 60 Side Discharge Belt Routing and Tensioning 9 5 60 Rear Discharge Belt Routing and Tensioning 9 6 9 1 Deck Installation TRACTOR ASSEMBLY DECK ASSEMBLY 9 2 108604 10 08 Deck Installation Dr BUG MS uM DESCRIPTION 1 055749 055749 4 CS 437 14 X 1 750 HX G5 ZN 2 061101 061101 2 NT 750 10 HX NL ZN 3 025296 025296 4 FW 760 X 1 625 X 08 ZN 4 051169 051169 2 CS 750 10 X 3 000 HX G5 ZN 5 704643 704643 8 NT 437 14 HX FLG ZN NOTES 1 60 Side Discharge Deck installation is shown 72 Side Discharge Deck and 60 Rear Discharge Deck installation are similar 108604 10 08 9 3 ASSEMBLY 72 Side Discharge Belt Routing and Tensioning 93 103 NOTES 1 Spring length after tensioning belt Measure spring from outside of hook to outside of hook 2 Route belt as shown 9 4 108604 10 08 60 Side Discharge Routing and Tensioning 9310 3 m DECK ASSEMBLY
10. 21 Introductio rie yore tee a 12 21 Steering linkage 12 21 Control Lever Neutral Adjustment 12 21 108604 10 08 12 1 Control lever 5 12 22 Steering dampener 12 23 Control lever adjustment 12 23 Park brake adjustment 12 23 Hydraulic pump belt adjustment 12 25 Deck drive belt adjustment 12 25 Engine RPM setting 12 26 Deck leveling and height adjustment 12 26 Deck level adjustments 12 26 12 2 108604 10 08 Maintenance amp Adjustment Safety This safety alert symbol is used to call attention to a message intended to provide a reasonable degree of PERSONAL SAFETY for operators and other persons during the normal operation and servicing of this equipment DANGER denotes immediate hazards which WILL result in severe personal injury or death WARNING denotes a hazard or unsafe practice which COULD result in severe personal injury or death This manual uses two other words to highlight information IMPORTANT calls attention to special mechanical information and NOTE emphasizes general information worthy of special attention All operators should read this manual or be instructed about safe operating and maintenance procedures This i
11. 3 4 11 3 3 5 5 6 3 8 5 8 9 8 13 5 7 5 5 4 7 3 3 5 7 5 3 11 3 11 3 10 3 10 4 10 5 10 4 10 4 10 5 10 4 10 5 11 3 4 3 4 3 11 3 8 5 8 9 8 15 4 5 760637 765339 766204 767954 767962 768002 768515 768523 769166 769257 770842 770867 771428 772079 776476 778399 778738 779280 779306 779850 780841 781153 781211 781229 781260 781286 781294 781302 781385 781427 781443 781526 781534 781567 781583 781658 781708 781716 781831 781856 781872 781880 781922 782474 782573 10 4 10 5 4 7 8 16 8 17 2 3 4 7 4 9 4 11 5 5 8 3 8 7 8 11 8 13 11 3 3 3 4 13 5 5 6 6 7 3 7 5 8 3 8 5 8 7 8 9 8 13 8 15 11 3 7 5 3 3 4 9 5 3 5 7 3 3 4 3 4 7 4 9 4 11 4 13 5 3 7 5 8 5 8 9 8 13 8 15 11 3 5 7 8 5 8 9 8 9 8 15 8 15 11 3 4 3 1 1 5 7 8 13 5 3 10 3 5 5 4 3 5 3 4 11 4 7 4 5 4 11 4 9 4 5 8 5 8 9 8 15 8 5 8 9 10 3 1 1 3 3 3 3 6 6 7 3 8 3 8 7 8 13 8 15 11 3 4 11 3 3 8 3 8 7 8 13 4 9 4 11 4 5 4 13 8 5 8 9 4 13 2 3 11 3 4 9 8 5 8 9 8 15 10 3 108604 10 08 Part No 782615 782664 782771 782979 782995 783001 783118 783126 783563 783704 783712 783738 783829 783837 783928 783936 783993 784025 784066 784082 784108 784140 784207 784223 784918 784983 785188 785295 785378 785659 785808 786277 108604 10 08 Page No 10 3 5 3 6 4
12. 4 7 4 5 4 5 4 7 4 7 6 5 3 3 4 13 8 5 8 9 8 15 4 13 5 3 3 3 1 1 3 3 3 3 3 3 6 5 3 3 3 3 11 3 1 1 8 5 6 3 4 13 3 4 10 3 5 5 5 3 4 13 5 7 10 4 10 5 10 4 5 3 3 3 8 3 8 7 8 13 3 3 5 3 7 3 4 7 3 3 7 5 7 5 6 5 6 5 6 4 4 7 10 3 8 5 8 9 8 15 11 3 7 3 8 13 5 5 Part No 794107 794446 794685 795633 795781 796219 796227 796235X 796524 796680X 796698 796714 796722 796953 797076 797084 797449 797654 797720 797845 797910 798603 798694 798702 799353 799395 808485 808493 928143 928150 928168 Page No 5 5 8 15 1 1 8 9 1 1 8 15 1 1 8 15 4 3 8 16 8 5 8 9 8 15 5 3 8 15 8 17 8 15 8 15 10 5 11 3 5 5 8 5 8 9 4 13 1 1 8 9 10 4 10 5 8 5 8 9 8 15 6 3 8 3 8 7 1 1 8 5 10 4 10 4 8 3 8 7 2 2 8 3 8 7 1 1 1 1 1 1 108604 10 08
13. ATZ was adjusted before it left the factory and was checked during predelivery setup However after start up and continued use a certain amount of break in wear will cause some adjustments to change Remain alert for unusual noises they could be signaling a problem Visually inspect the machine for any abnormal wear or damage A good time to detect potential problems is while performing scheduled maintenance service Correcting the problem as quickly as possible is the best insurance Clear away heavy build up of grease oil and dirt especially in the area of reservoir and oil and engine combustion air minute dust particle are abrasive to close tolerance engine and hydraulic assemblies Some repairs require the assistance of a trained service mechanic and should not be attempted by unskilled personnel Consult your Hustler service center when assistance is needed STEERING LINKAGE The neutral adjustment for the control levers in the neutral position is discussed in this section The tractor steering has been factory adjusted to eliminate creeping when the control levers are in the neutral position FIG 21 However should the tractor begin to creep the control lever linkage can be adjusted as follows CONTROL LEVER IN HE NEUTRAL POSITION L PARK BRAKE SLOT FIG 21 CONTROL LEVER NEUTRAL ADJUSTMENT Before considering any adjustment check the tire air pressure and make certain hydraulic system oil is at operati
14. Assembly XR7 8 8 Side Discharge Deck A Adaptors 8 10 60 Rear Discharge Deck 8 12 60 Rear Discharge Deck Pulley 8 14 Spindle 796235 8 16 Spindle Assembly 796680 8 17 8 1 72 Side Discharge Deck Assembly XH7 8 2 108604 10 08 72 Side Discharge Deck Assembly ITEM SERVICE NO PART NO EP 548453 2 798694 3 052860 4 767954 5 086660 6 103010 7 781708 8 767962 9 031997 10 053199 11 781567 12 005116 13 808485 14 314104 15 015495 16 103184 17 025395 18 808493 ES 788166 2 Includes items 7 8 9 and 10 PART NO 108649 798694 052860 767954 086660 103010 N A N A N A N A 781567 005116 808485 314104 015495 103184 025395 808493 788166 QTY 1 E a N n O m N MM DESCRIPTION 72 DECK WACRATED RUBBER CHUTE ASSEMBLY CS 375 19 X 1 250 HX G5 ZN FW 406 X 812 060 SAE HD ZN 375 16 HXZY NL DISCHARGE CHUTE MOUNT BRACKET CS 500 13 X 4 25 HX G5 ZN FW 531 X 1 063 X 090 SAE HD ZN ANTI SCALP WHEEL NT 500 13 HX JAM ZN NT 50 13 HX LK NY CS 375 16X1 375 HX G5 5 16 18 THREAD RIVET NUT PUSHER STRAIGHT GREASE FITTING REAR ANTI SCALP BRACKET 375 16 X 1 00 STD CD 3 8 16 THREAD RIVET NUT ANTI SCALP WHEEL ASSY NOTES 1 Do not torque I
15. B SECTION BELT CS 312 18 X 1 50 FLT SH ZNYC UHMW IDLER SLIDE CS 625 11 X 1 75 G5 ZNYC DECK BELT IDLER GUIDE FW 62 X 1 00 X 134 ZN 5 00 IDLER PULLEY SIDE MOUNT CHAIN 21 LINKS IDLER SPRING DECK IDLER RS 60 XR7 PULLEY COVER LS 60 XR7 PULLEY COVER 625 11 HXG5 7 6 00 IDLER PULLEY FW 650 X1 125 X 18 ZNYCG5 5 16 18 X 3 4 MALE KNOB CS 500 13 X 1 00 HX G5 ZN CW 515 X 2 25 X 204 ZN DECK DRIVE PULLEY CS 500 13 X 1 25 HX G5 ZNYC FW 531 X 1 063 X 090 SAE HD ZN FW 343 X 687 X 051 080 HD ZN NT 312 18 HXZY NL KEY 1 4 SQ X 1 00 LONG SPINDLE HOUSING ASSEMBLY BLADE F20 50 H F CW CW 631 2 250 X 187 FW 656 X 1 250X 250 ZNYC CS 625 11 X 3 00 HX G5 ZNYC CS 625 11 X 3 00 FULL HX G5 ZN NOTES 3 See 60 Side Discharge Belt Routing and Tensioning on page 9 5 for belt tensioning 4 See Spindle Assembly 796235 on page 8 16 for breakdown 108604 10 08 8 9 Side Discharge Deck A Adaptors Dech Assembly 8 10 108604 10 08 Side Discharge Deck A Adaptors ITEM NO Ger PARTI 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 767954 767954 4 FW 406X 812 X 060 SAE 4 086660 086660 4 NT 375 16 HXZY NL NOTES 108604 10 08 8 11 60 Rear Discharge Deck Assembl DEFLECTOR DETAIL 108604 10 08 8 12 60 Rear Discharge Deck Asse
16. COVER 72 XR7 LS PULLEY COVER 72 XR7 NT 625 11 HX G5 ZNYC 6 00 IDLER PULLEY FW 650 X 1 125 X 18 ZNYCG5 5 16 18 X 3 4 MALE KNOB CS 500 13 X 1 00 HX G5 ZN CW 515 X 2 25 X 204 ZN DRIVE PULLEY DB 112 CS 500 13 X 1 25 HX G5 ZNYC FW 531 X 1 063 X 090 SAE HD ZN FW 343 X 687 X 051 080 HD ZN NT 312 18 HXZY NL KEY 1 4 SQ X 1 00 LONG SPINDLE HOUSING ASSEMBLY BLADE F24 50 H F CW CW 631 2 250 X 187 FW 656 X 1 250 X 250 ZNYC CS 625 11 X 3 00 HX G5 ZNYC CS 625 11 X 3 00 FULL HX G5 ZN NOTES 3 See 72 Side Discharge Belt Routing and Tensioning on page 9 4 for belt tensioning 4 See Spindle Assembly 796235 on page 8 16 for breakdown 108604 10 08 8 5 60 Side Discharge Deck Assembl 8 6 108604 10 08 60 Side Discharge Deck Assembly SERVICE ITEM bART NO ED 548438 2 798694 3 052860 4 767954 5 086660 6 103010 7 781708 8 767962 9 031997 10 053199 11 781567 12 808485 13 103184 14 005116 15 314104 16 015495 17 808493 18 025395 EP 788166 MFG PART NO 108501 798694 052860 767954 086660 103010 N A N A N A N A 781567 808485 103184 005116 314104 015495 808493 025395 788166 QTY DESCRIPTION 1 60 DECK W A CRATED 1 RUBBER CHUTE ASSEMBLY 8 CS 375 16 X 1 25 HX G5 26 FW 406 X 812 X 060 SAE HD ZN 14 NT 375 16 HX LK NY 1 DISCHARGE CHUTE MOUNT 6 CS 500 13 X 4 25 HX G5 ZN 12 FW 531 X 1 063 X 090 SAE HD ZN 6
17. EXT TOOTH ZN 29 601555 601555 1 XR7 COMMON WIRE HARNESS 30 601561 601561 1 WIRING HARNESS KAWASAKI 31 31 044818 044818 4 CN ZN TIN C7343 1420 32 047654 047654 1 CLIP NOTES 1 Includes mounting hardware 2 Wires from Item 29 ATZ 2008 Wire Harness 601555 3 Wires from Kawasaki 31HP Wiring Harness 601561 4 Supplied with engine 5 Engine oil capacity Refer to engine owner s manual 6 Air filter service parts 601652 MAIN AIR FILTER ELEMENT 601653 SAFETY AIR FILTER ELEMENT 108604 10 08 5 3 Fuel System Installation TRACTOR FRAME WITH ENGINE 5 4 108604 10 08 Fuel System Installation SERVICE MFG NO PART NO PART NO 1 779306 779306 2 793240 793240 3 793232 793232 4 106732 106732 5 712919 712919 6 767954 767954 7 055822 055822 8 000398 000398 9 036244 036244 10 045088 045088 11 347989 347989 12 015818 015818 13 015818 015818 14 015818 015818 15 000323 000323 16 705954 705954 17 767962 767962 18 797084 797084 000331 000331 Torque to 20 ft Ibs k 0 0 DD Aaaah DESCRIPTION 3 5 FUEL CAP LEFT SIDE Z FUEL TANK RIGHT SIDE Z FUEL TANK REAR SEAT SUPPORT FW 406 X 1 00 X 12 HRD ZN FW 406 X 812 X 060 SAE HD ZN CS 375 16 X 750 HX G5 ZN CLAMP CS 375 16 X 1 000 HX G5 ZN HOSE CLAMP 1 FUEL SHUT OFF BRACKET FUEL LINE 50 TOTAL FUEL LINE 39 TOTAL FUEL LINE 7 TOTAL CLIP CS 500 13 X 1 00 HX G
18. NO 008193 767962 391375 381657 381665 381673 008573 392985 789412 392613 392605 078386 077859 381723 381731 017616 016642 768002 016972 110855 381749 768523 036236 789404 N A 033035 033035 033035 033035 601979 QTY ND DD MO N OM A DESCRIPTION NT 500 13 HX G5 ZNYC FW 531 X 1 063 X 090 SAE HD ZN ATZ ROOF ATZ FRONT R S ROPS ATZ FRONT L S ROPS ATZ ROPS CROSS SECTION CS 500 13 X 2 50 HX G5 ZNYC ROPS CONNECTOR UB 50 13 X 3 25 X 3 0 R H ROPS L H ROPS FW 510 X 1 75 X 18 ZNYC CS 500 13 X 3 25 HX G5 ATZ REAR R S ROPS ATZ REAR L S ROPS CS 500 13 X 1 75 HX G5 ZNYC CS 625 11 X 2 00 HX G5 ZNYC FW 687 X 1 750 X 105 160 HD ZNYC NT 625 11 HX G5 ZNYG MUFFLER GUARD ATZ ENGINE GUARD FW 343 X 687 X 051 080 HD ZNYG CS 312 18 X 1 00 HX G5 ZNYC UB 50 13 X 2 0 X 3 0 TURF SERIAL NO PLATE WEATHERSTRIP 12X 75 X 29 WEATHERSTRIP 12X 75 X 6 25 WEATHERSTRIP 12X 75 X 18 5 WEATHERSTRIP 12X 75 X 15 5 ATZ ROPS DECAL 1 Torque to 73 ft Ibs 8 places 2 Torque to 145 ft Ibs 2 places 108604 10 08 NOTES 7 5 7 6 108604 10 08 108604 10 08 Chapter 8 Contents 72 Side Discharge Deck Assembly XR7 8 2 72 Side Discharge Deck Pulley Assembly XR7 8 4 60 Side Discharge Deck Assembly 8 6 60 Side Discharge Deck Pulley
19. SPARK IGNITION CONTROLLER NOTES 5 7 Electrical Schematic Kawasaki 601555 92 Le 4 RED 14 wi bl EERS 91 410 034 DE g 62 Mr 110 1 05 VJ 9 MJVdS 2 RED 14 Img REENEN 91 O34 NYL 2 yi N 91 18 114 1 syd 110 AV134 HH 1935 17111 E 7 4389 DHO 12 4 9 RED 419 034 21 NBA 12 812 9 A divas 1114 HI 493 DIL 108604 10 08 5 8 108604 10 08 Chapter 6 Contents Front Wheel lt 6 2 Semi Pneumatic Tire Wheel 789537 6 4 Drive Wheel Assembly Installation 6 5 Anti Rollover Wheel Assembly 6 6 6 1 Front Wheel Assembly TRACTOR le FRAME 6 2 108604 10 08 Front Wheel Assembly en DESCRIPTION 1 705954 705954 2 CS 500 13 X 1 25 HX G5 ZN 2 3442
20. a minimum weight rating of 2000 pounds to block the unit up Use in pairs only Follow the instructions supplied with the vehicle stands WARNING Never work under the machine or attachment unless it is safely supported with jack NOTE The front brake link is not adjustable FIG 26 2 Raise and block the tractor up so the drive wheels are off of the floor 3 Open the hydraulic pump s bypass valve FIG 27 on the side that is being adjusted by turning bypass valves counter clockwise one half to one revolution The valve stems on each hydraulic pump are located near the top and are identified as a hex stud sess z EXP YPASS VALVE FRONT BRAKE LINK EW RIGHT SIDE FIG 26 FIG 27 4 Rotate the tire The tire should rotate Remember hydraulic oil resistance will prevent the tire from rotating freely even with the bypass valves open There should be no resistance from the brakes at this point 5 Move the control lever to where it is just inside 1 8 the park brake slot FIG 28 NOTE When the control lever is against the outside edge of the the slot the brakes should not be engaged 6 Rotate the tire If the brake is adjusted properly the tire will still rotate but friction will start to become noticeable here However if no brake resistance is noticed the brake needs adjusted as follows 7 Loosen the brake linkage jam nuts FIG 29 MTURNBUCKLE URN PD FIG 28 FIG 29
21. block it should move with a slight drag Tighten the other nut on the opposite side of the block and jam them tightly together against the block Go to the left rear of the tractor Make sure that there is still slack in the chain If not loosen the two nuts on the block holding the threaded rod until there is slack in the deck lift chain FIG 35 Tighten the appropriate nut until the chain just becomes tight and carries most of the deck weight Check by moving the 3 25 block it should move with a slight drag Tighten the other nut on the opposite side of the block and jam them tightly together against the block Compress the deck lift assist springs so that there is 1 of space between the front nut and on the spring and the rear nut on the deck lift block FIG 39 Typical both sides When completed all chains will be tight and deck cutting height will be set to the deck 12 29 height indicator FIG 38 FIG 39 12 30 108604 10 08 Numerical Index Part No Index Page No Part Numbers 000323 000331 000398 000430 005116 008193 008573 012005 015495 015511 015818 016253 016527 016642 016899 016972 017004 017616 018846 019521 023655 024927 025007 025296 025395 028118 029751 029868 029876 029934 031997 032763 032771 033035 034272 034280 034843 036236 036244 037887 039677 041475 044818 045088 045765 045898 047654 108604 10 08
22. come to a stop FIG 22 Repeat for the opposite side if necessary NOTE The left linkage controls the left hydraulic pump and the right linkage controls the right hydraulic pump If wheel s are rotating in reverse then loosen the jam nuts on the pump linkage rods and rotate the rod to shorten the steering control linkage until the wheel s come to a stop FIG 22 Repeat for the opposite side if necessary NOTE The left linkage controls the left hydraulic pump and the right linkage controls the right hydraulic pump When both wheels remain in neutral tighten the jam nuts to lock the turnbuckle in place Test again by moving the control levers forward and backward before returning them to the neutral position If the tires are in neutral the unit is now ready for operation After adjusting for neutral it may be necessary to re adjust the control lever stop FIG 23 CONTROL LEVER STOPS The control lever stops FIG 23 are designed to do two things First and most important they must keep the pumps from bottoming out internally Secondly the stops may be adjusted to help drive straight when the control levers are pushed forward against the stops To keep the pumps from bottoming out internally use the following procedure 1 2 108604 10 08 make the first adjustment the tractor engine must be running Check to make sure the control levers are against the stops before the pumps are bottomed out internall
23. engine Do not clean filter element Replace with a new one Pump drive belt only Inspect every 100 hours and replace if worn or cracking is noticed Otherwise replace every 400 hours or 2 years whichever comes first Check fuel line hoses fuel valve and grommets for any cracks or leaks Clean more often under dirty or dusty conditions and during hot weather Do not clean filter element Replace with a new one 12 8 108604 10 08 REFERENCES a Refer to Engine Owner s Manual NOTE After completing maintenance cycle 300 hours repeat cycle INTRODUCTION Regular maintenance is the best prevention for costly downtime or expensive premature repair The following pages contain suggested maintenance information and schedules which the operator should follow on a routine basis Remain alert for unusual noises they could be signaling a problem Visually inspect the machine for any abnormal wear or damage A good time to detect potential problems is while performing scheduled maintenance service Correcting the problem as quickly as possible is the best insurance Clear away heavy build up of grease oil and dirt especially in the engine and hydraulic reservoir areas minute dust particles are abrasive to close tolerance engine and hydraulic assemblies Daily inspect mower for grass clippings and wire and string tangles The underside of the mower deck will collect a build up of grass clippings and dirt especially when grass is wet o
24. warnings for application of solvent type selected A hydraulic oil heat exchanger is installed on the Super Z This heat exchanger is designed to keep hydraulic system oil temperature lower in hot operating conditions or heavy continuous operating conditions This hydraulic heat exchanger is located above the engine Air is drawn across the cooling fins by an electric fan located above the heat exchanger FIG 7 Never force anything into the heat exhanger fins which may bend or distort them For cleaning use compressed air or pressurized water only 108604 10 08 12 13 FUEL SYSTEM DANGER Observe usual fuel handling precautions Do not smoke while refueling Do not fill tank with engine running or while engine is hot Clean up any gasoline spills Allow engine to cool before storing machine inside a building Keep fuel away from open flame or spark and store machine away from open flame or spark if there is fuel in the tank Use extra caution when handling gasoline and other fuels They are flammable and vapors are explosive A fire or explosion from gasoline can burn you and others and can damage property Refuel outdoors preferably or in well ventilated areas Never attempt to start engine when there is a strong odor of gasoline fumes present Locate and correct cause Store gasoline in an approved container and keep it out of the reach of children Never buy more than a 30 day supply of gasoline Always place ga
25. 01 1 NT 750 10 HX NL ZN 19 781856 781856 1 IDLER PULLEY 20 028118 028118 1 FW 62 1 00 X 134 ZN 21 781872 781872 1 CS 625 11 X 1 50 HX G5 ZN 22 601016 601016 1 IDLER SPRING 23 601463 601463 1 A SEC PUMP IDLER BELT 24 036236 036236 1 CS 312 18 X 1 00 HX G5 ZNYC 25 768523 768523 2 FW 343 X 687 X 051 080 HD ZNYC 26 034272 034272 1 NT 312 18 HX G5 ZNYC 27 797654 797654 1 FW 1 156X1 750X 250 ZY NOTES I Torque to 45 48 ft Ibs Torque to 12 15 ft Ibs Apply grease at zerk see owners manual Do not torque Item 18 NT 750 10 HX NL ZN Item 15 349761 Pump ldler Arm should pivot freely 5 Electric clutch burnishing procedure After installing a new clutch it is important to burnish the clutch to insure maximum deck clutch life In an open area with no bystanders set the engine speed to half throttle Cycle the deck clutch on for 15 seconds and then off for 15 seconds Repeat this operation 10 times it will require about 5 minutes to complete 108604 10 08 4 13 4 14 108604 10 08 108604 10 08 Chapter 5 Contents Kawasaki 31 HP Engine Installation 5 2 Fuel System lt 5 6 Instrument Panel Assembly Installation 2222 5 8 Electrical Schematic Kawasaki 601555 5 10 5 1 Kawasaki 31 HP Engine Installation
26. 1 No 3 3 5 3 5 3 5 3 8 15 5 7 5 7 8 13 8 15 8 15 4 11 11 3 4 9 4 11 4 11 11 3 7 5 4 13 8 5 8 9 8 15 8 5 8 15 6 3 2 3 8 3 8 7 6 3 8 5 8 9 4 9 5 5 4 5 4 5 4 3 4 5 4 11 4 11 4 9 4 11 4 11 4 11 6 3 4 13 8 13 4 7 4 7 4 7 11 3 8 5 8 9 8 13 8 13 4 7 11 3 3 3 2 3 10 4 10 5 4 13 8 9 377994 381657 381665 381673 381723 381731 381749 381848 387035 391375 392035 392191 392357 392597 392605 392613 392985 395533 538850 546572 548438 548453 549576 600221 600254 600296 600437 600893 600899 600901 600941 600961 601016 601053 601069 601089 601098 601130 601257 601260 601264 601265 601284 601285 601311 601344 601434 601461 601462 601463 601483 601549 601550 601554 8 13 8 13 8 15 8 17 10 3 1 1 8 15 10 3 2 2 4 13 11 3 8 13 5 7 11 3 11 3 11 3 601555 601561 601615 601616 601626 601627 601628 601629 601631 601647 601648 601652 601653 601656 601675 601687 601727 601768 601769 601779 601791 601815 601967 601968 601979 601980 700484 704163 704643 704759 704932 705137 705178 705608 705954 710194 712257 712919 712927 713198 714998 720516 722199 724716 727172 727420 727438 727453 728147 740696 744276 746131 752386 756270 11 3 11 3 1 1 5 3 1 1 5 3 1 1 5 7 3 3 4 11 4 11 4 11 8 15 10 3 10 3 10 3 10 3 7 5 10 3 3 3 4 9 4 5 9 3 8 15 5 7 11 3 5
27. 10 08 60 Rear Discharge Deck Decals m P z 7 7 108604 10 08 INDEX SERVICE NO PART NO 786277 760637 727438 727453 727172 796953 359547 797845 Jo Q WN 786277 760637 727438 727453 727172 796953 359547 797845 QTY A a A A A a DESCRIPTION 60 DECK ID DECAL MOWER DECK QUICK REFERENCE DECAL WHIRLING BLADES DECAL BELT amp PULLEY DECAL MADE IN U S A DECAL REAR DISCHARGE DECK ROUTING DECAL 5 00 X 9 00 STEP TREAD FUSION DECAL NOTES 10 5 108604 10 08 108604 10 08 Seat Installation Chapter 11 Contents 11 1 Seat Installation 108604 10 08 11 2 Seat Installation ITEM NO NDA WN Sea DESCRIPTION 792051 792051 1 SUSPENSION SEAT 784140 784140 1 SEAT BELT 797076 797076 4 CS 437 20 X 1 00 HX G8 ZNYC 728147 728147 2 FW 468 X 1 00 X 090 HT T ZNYC 746131 746131 2 SPACER 493 X 675 X 250 036236 036236 1 CS 312 18X1 000 HX G5 078386 078386 2 FW 510 X 1 750 X 18 ZNYC 110686 110686 1 TILTSEAT PIVOT TUBE 000331 000331 2 BLACK CABLE TIE 086660 086660 3 NT 375 16 HX LK NY 767954 767954 6 FW 406 X 812 X 060 SAE HD ZN 724716 7
28. 108604 10 08 12 25 8 Rotate the tire and at the same time rotate the turnbuckle to shorten the length the brake linkage to increase the brake pressure When you feel the brake begin to engage stop adjusting the turnbuckle Re tighten the jam nuts on the turnbuckle 9 Place the control lever in the park brake slot FIG 28 The tire should not rotate when the control lever is in the park brake position 10 Place the control lever in the neutral position The tire should rotate freely 11 Close the hydraulic pump s bypass valve 12 Repeat steps 3 thru 11 for the other side 13 Remove the jack stands and lower the unit It is now ready to operate HYDRAULIC PUMP BELT ADJUSTMENT The pump drive belt tension remains constant by means of a tension idler and spring FIG 30 There is no tension adjustment of this belt NOTE Replace the belt every 400 hours or every two 2 years whichever comes first WARNING If the pump belt fails loss of control will occur especially when operating on a slope If you lose steering control while operating the machine place the steering control levers in the park brake position immediately Inspect the machine and involve your Hustler dealer to resolve the problem before continuing to operate ll IA Kaa 77 71 d DECK DRIVE BELT ADJUSTMENT The spindle belt tension remains constant by means of a tension idler and spring FIG 31 The spring tension should be such tha
29. 2 2 NT 312 18 HX G5 ZN 12 779850 779850 2 CB 312 18 X 3 00 FUL ZN NOTES 1 When performing service on mower disconnect battery ground cable and black wire of harness and do not reconnect to battery until engine is ready to be started See Owners Manual 108604 10 08 4 3 Deck Lift Assembl TRACTOR FRAME 108604 10 08 4 4 Deck Lift Assembly EN P ae DESCRIPTION 1 348318 348318 1 STOP HANDLE 2 600437 600437 1 HEIGHT ADJUSTMENT STOP DIA PIN 3 783001 783001 1 DECK LIFT INDICATOR 4 704643 704643 8 NT 437 14 HX FLG ZN 5 781294 781294 7 CLIP E 1 00 X 625X 050 6 782995 782995 2 DECK LIFT SPRING ASSEMBLY 7 015495 015495 4 STRAIGHT GREASE FITTING 8 055749 055749 3 CS 437 14X1 750 HX G5 ZNYC 9 348391 018846 4 DECK LIFT CHAIN 10 756270 756270 1 CS 312 18 X 1 50 FLTHR GR5 ZNYC 11 034272 034272 1 NT 312 18 HX G5 ZNYC 12 348458 348458 1 DECK LEVELER YOKE W A 13 781229 781229 1 CE 750X2 25 X1 75 HEADLESS 14 781831 781831 1 CS 437 14 X 1 750 FULTH G5 ZNYC NOTES 1 Apply grease to zerks see owners manual 108604 10 08 4 5 Park Brake Assembly SEE Steering Sub Assembly on page 4 10 4 6 108604 10 08 Park Brake Assembly ITEM NO Q WN EE 14 15 17 18 19 20 21 22 SERVICE PART NO 767954 768523 023655 782979 063198 781211 059832 034272 054502
30. 2 SS 500 13 X 1 75 SH ZN 3 053199 053199 2 NT 500 13 HX JAM ZN 4 055822 055822 8 CS 375 16 X 750 HX G5 ZN 5 767954 767954 8 FW 406 X 812 X 060 SAE HD ZN 6 768523 768523 16 FW 34 3X 687 X 051 080 HD ZN YL 7 023655 023655 4 312 24 HXZY NL 8 781286 781286 2 PUMP ROD ADJUSTER ASSEMBLY 9 600221 600221 2 CENTERING DAMPENER 10 781922 781922 4 DAMPENER BALL STUD 11 029876 029876 2 LW 312 INT EXT TOOTH Z 12 347684 347684 2 SUPER Z PUMP ARM 13 704163 704163 2 CS 250 20 X 2 00 HX G5 ZN 14 768515 768515 4 FW 281 X 625 X 051 080 HD ZN YL 15 068551 068551 2 NT 250 20 HX NL ZN 16 348797 348797 2 ADJUSTABLE PIVOT 17 036244 036244 6 CS 375 16 X 1 000 HX G5 ZN 18 034272 034272 4 NT 312 18 HX G5 ZN NOTES 4 9 Steering Sub Assembl 108604 10 08 4 10 Steering Sub Assembly 108604 10 08 ITEM NO o O Q WN 11 12 13 14 15 16 17 18 19 20 21 SERVICE PART NO 781260 348755 767954 036244 705178 023655 768523 348946 348888 348714 781153 781716 781583 086660 348862 601769 601768 053660 110674 110681 601727 110680 MFG PART NO N A 348755 767954 036244 705178 023655 768523 348946 348888 348714 781153 781716 781583 086660 348862 N A N A 053660 110674 110681 601727 110680 QTY a au an N NO DESCRIPTION STEERING BAR GRIP STEERING BAR FW 406 X 812 X 060 SAE HD ZN CS 375 16 X 1 000 HX G5
31. 24716 1 FIBER WASHER 350421 350421 1 SEAT PAN STOP 036244 036244 1 CS 375 16 X 1 00 HX G5 ZNYC 108291 108291 1 SEAT PAN 357384 357384 1 ROPS LATCH 768523 768523 6 FW 343 X 687 X 051 080 HD ZN Y 034272 034272 5 NT 312 18 HX G5 ZN 783910 783910 1 ROPS LATCH TORSION SPRING 781880 781880 2 BUMPER 080358 080358 1 GM 50 X 1 00 X 75 X 12 GROMMET 052860 052860 2 CS 375 16 X 1 25 HX G5 ZNYC 781567 781567 2 NT 500 13 HX G8 ZY NL 722199 722199 1 2 WIDE SCOTCH POLYURETHANE 5 55 LONG 601130 601130 1 ELECTRIC LINEAR ACTUATOR 108290 108290 1 SEAT MOUNT 089938 089938 1 CS 500 13X4 00 HX G5 Z 770867 770867 2 PLASTIC BUSHING 750X1 FS 601053 601053 2 SEAL RELAY W BRACKET 601647 601647 1 15 AMP CIRCUIT BREAKER 601648 601648 1 RED CIRCUIT BREAKER BOOT 068239 068239 1 CS 500 13X4 500 HX G5 601098 601098 2 CB 10 24 X 500 ZYNC 110677 110677 1 RELAY MOUNT BRACKET 601089 601089 4 RIVET 188 DIA BLK HD 059832 059832 2 NT 10 24 HX NL ZN 704932 704932 2 FW 219 X 500 X 048 ZN 767962 767962 4 FW 531X 1 063X 090 SAE 1 Must pivot freely 2 Torque to 48 ft Ibs 3 Service parts available for Michigan suspension seat 108604 10 08 PART NO 793307 793323 793281 NOTES DESCRIPTION SLIDE KIT KNOB KIT BACK CUSHION KI 11 3 PART NO DESCRIPTION 793299 SEAT CUSHION KIT 793315 SEAT SWITCH 793265 MOLDED ARMREST KIT INCLUDES BOTH ARMRESTS 793273 ARMREST STOP ASSEMBLY 11 4 108604 10 08 Chapter 12 Contents Maintenance
32. 354035 005116 350397 350330 350264 765339 086660 783126 783118 789321 036236 789644 601344 712927 048876 MFG PART NO 767954 768523 023655 782979 063198 781211 059832 034272 054502 354035 005116 350397 350330 350264 765339 086660 783126 783118 789321 036236 N A N A 712927 048876 QTY N N N N N NA NA N N DESCRIPTION FW 406 X 812 X 060 SAE HD ZN FW 34 3X 687 X 051 080 HD ZN YL NT 312 24 HXZY NL CS 375 16 X 4 75 HX G5 ZN CS 10 24 X 750 HXFLK ZN PUSH BUTTON SWITCH NT 10 24 HX NL ZN NT 312 18 HX G5 ZN NT 375 16 HX GRD 5 ZN WHITE BRAKE LEVER EXTENSION CS 375 16 X 1 375 HX G5 ZN BRAKE LINK TURNBUCKLE L S BRAKE PIVOT ARM R S BRAKE PIVOT ARM BUSHING NT 375 16 HX LK NY LH WHITE BRAKE ASSY RH WHITE BRAKE ASSY WHITE HUB ASSEMBLY CS 312 18 X 1 000 HX G5 ZN NUT FOR WHITE MOTOR RC28 KEY FOR WHITE MOTOR FW 344 X 1 00 X 12 HRD ZNYC CS 312 18 X 750 HX G8 ZNYC de por Po sa 108604 10 08 NOTES Torque to 280 310 ft Ibs Included with wheel motor Torque to 24 ft Ibs 783126 used on left wheel 783118 used on right wheel 4 7 Assembl Steerin Sub Assembly on SEE Steering page 4 10 108604 10 08 4 8 Steering Assembly 108604 10 08 DESCRIPTION 1 110679 110679 1 STEERING CONTROL PANEL 2 781716 781716
33. 395533 1 FLOOR PLATE 3 305615 305615 2 STEP TREAD 4 086660 086660 2 NT 375 16 HX LK NY 5 767954 767954 4 FW 406 X 812 X 060 SAE HD ZN 6 052860 052860 2 CS 375 16 X 1 25 HX G5 ZNYC 7 781880 781880 2 RUBBER BUMPER NOTES 1 Do not tighten Floor must be able to pivot on these bolts 108604 10 08 2 3 2 4 108604 10 08 108604 10 08 Chapter 3 Contents Hydraulic System Installation Kawasaki 31 HP HT Engine 3 1 Ine Hydraulic System Installation Kawasaki 31 HP HT En 108604 10 08 3 2 Hydraulic System Installation Kawasaki 31HP HT Engine INDEX SERVICE NO PART NO 1 705608 2 768515 3 713198 4 033035 5 783704 6 068551 7 032763 8 032771 9 357616 10 034272 11 768523 12 055947 13 788042 14 008193 15 767962 16 783928 17 783936 18 109604 19 077859 20 789339 21 601260 22 700484 23 601629 24 601628 25 601627 26 601626 27 784082 28 781534 29 781658 30 784025 31 783993 32 788174 33 601687 34 601631 35 601265 36 601264 37 601284 38 601285 39 781526 40 784108 N A MFG PART NO 705608 768515 713198 033035 783704 068551 032763 032771 357616 034272 768523 055947 788042 008193 767962 783928 783936 109604 077859 789339 601260 700484 N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A 601616 QTY i NN N NN O e a N A RPO PH NN NN
34. 5 5 5 5 11 3 5 5 5 7 4 7 8 3 8 7 3 3 4 13 7 3 7 5 7 5 8 16 8 17 4 5 4 13 8 3 8 7 8 13 6 4 5 5 8 13 4 13 8 5 8 9 8 15 7 5 5 3 7 5 8 5 8 9 8 15 5 3 7 5 4 5 6 5 4 7 4 9 4 11 4 3 8 5 8 9 4 13 6 3 9 3 8 3 8 7 8 11 4 13 8 5 8 9 8 15 5 3 4 3 4 9 5 3 8 5 8 9 8 15 6 6 8 3 8 7 8 13 3 3 3 3 3 3 7 5 3 3 4 3 4 5 4 7 4 9 4 13 5 3 11 3 5 3 8 16 8 17 4 7 4 13 5 3 7 5 11 3 4 9 4 11 5 3 5 5 8 13 11 3 8 13 6 4 6 3 5 3 5 5 6 3 5 7 5 3 4 7 9 3 2 3 8 3 4 9 8 3 4 11 4 7 4 5 9 3 4 9 5 5 4 3 5 3 3 3 5 7 4 3 8 5 8 15 4 7 5 7 8 5 8 9 5 7 6 5 Part No 109604 109743 8 7 109748 8 7 8 13 109948 110151 110152 110402 110411 110412 110674 8 9 8 13 110677 110679 11 3 110680 8 15 110681 110686 110855 4 13 6 3 9 3 212076 4 7 6 6 11 3 1 1 3 3 4 9 8 16 212472 259812 263517 305615 314104 8 16 8 17 344267 3 3 7 5 7 5 11 3 11 3 4 13 10 3 2 3 4 7 347443 347684 347989 348318 348391 4 11 8 3 348417 8 7 8 11 8 13 11 3 348458 7 3 11 3 8 3 8 7 8 3 8 7 8 9 8 9 8 13 5 5 8 5 8 5 11 3 11 3 8 7 8 11 8 3 8 11 8 13 8 13 8 13 8 13 8 13 8 13 8 15 348714 348755 348797 348862 348888 348946 349266 349761 349803 350264 350330 350397 350421 350884 351676 352591 354035 357384 357616 359547 366765 37319
35. 5 ZN FW 531 X 1 063 X 090 SAE HD ZN 3 WAY FUEL VALVE BLACK CABLE TIE NOT SHOWN NOTES Supplied with Item 18 3 way fuel switch Included with new fuel tank Fuel tank service parts not shown PART NO 794107 794081 785295 792986 108604 10 08 DESCRIPTION 1 4 ID 3 8 OD 1 16 WALL TUBING 25 LONG FUEL FILTER SCREEN FLANGE GROMMET SITE LINE FUEL FITTING 5 5 Instrument Panel Assembly Installation 23 DSK RIGHT SIDE FUEL TANK FUSE SIZE AND LOCATION 5 6 108604 10 08 Instrument Panel Assembly Installation 1 Part of 601555 Wire Harness 108604 10 08 ITEM NO AN Oa WN a Pea te UO see O o bk WN SERVICE PART NO 776476 785808 045898 000430 785030 712257 714998 704932 769166 059832 601675 055947 768515 110151 601089 060731 110152 601554 MFG PART NO 776476 785808 045898 000430 785030 712257 714998 704932 769166 059832 601675 055947 768515 110151 601089 060731 110152 601554 QTY NN VW Co A KR ON eN BA ABs DESCRIPTION PTO SWITCH KEY SET KEY SWITCH SMALL LONG WIRE TIE CHOKE CABLE RED INDICATOR LIGHT MS 10 24 X 625 HX ZN FW 219 X 500 X 048 ZN HOUR METER NT 10 24 HX NL ZN THROTTLE CABLE CS 250 20 X 500 HX G5 ZN FW 281 X 625 X 051 080 HD ZN YL INSTRUMENT PANEL RIVET 188 DIA BLK HD CS 10 24X 500 HXFLK ZN RELAY MODULE BRACKET Z
36. 67 344267 2 FW 510 X 2 15 X 187 SPL ZN 3 798603 798603 2 FW 515X1 65X 125 HD ZY 4 263517 263517 2 BEARING DISC 5 784223 784223 4 BEARING W O COLLAR 6 387035 387035 2 SPACER 1 07 X 1 312 X 2 793 7 045765 045765 2 FW 1 030 X 1 500 X 134 ZN 8 349266 349266 2 FORK 9 041475 041475 2 CS 750 10 X 9 50 HX ZN 10 025296 025296 4 FW 760 X 1 625 X 08 ZN 11 061101 061101 2 NT 750 10 HXNL ZN 12 789537 789537 2 WHEEL amp TIRE ASSY NOTES Apply grease to zerks see owners manual Torque to 100 ft Ibs 3 Assemble with extended inner race toward item 6 387035 Spacer 1 07 1 312 x 2 793 108604 10 08 6 3 Semi Pneumatic Tire Wheel 789537 ITEM NO 1 2 3 4 SERVICE PART NO 039677 789537 015511 782771 MFG PART NO N A N A N A N A 2 QTY DESCRIPTION ND WHEEL BEARING TIRE WHEEL ASSEMBLY GREASE FITTING 45 DEG 1 4 BEARING SPACER NOTES 6 4 108604 10 08 Drive Wheel Assembly Installation ITEM NO 4 0c Go SERVICE PART NO 789529 789420 783563 784066 019521 061077 601085 MFG PART NO 789529 789420 N A N A N A 061077 N A QTY 1 1 DESCRIPTION LH TIRE WHEEL ASSEMBLY RH TIRE WHEEL ASSEMBLY TIRE 24 X 12 12 AT101 WHEEL ASSY 12 X 8 50 ATZ TIRE VALVE WHEEL NUT QTY PER WHEEL V WHEEL LUG STUD 1 Torque to 65 75 ft Ibs 2 Inflate tire to 8 12 psi 108604 10 08 NOTES 6 5 Anti Rollover Wheel Assembl
37. ANTI SCALP WHEEL 6 NT 500 13 HX JAM ZN 6 NT 50 13 HX LK NY 4 5 16 18 THREAD RIVET NUT 2 REAR ANTI SCALP BRACKET 4 CS 375 16 X 1 375 G5 ZNYC 1 PUSHER 2 STRAIGHT GREASE FITTING 2 3 8 16 THREAD RIVET NUT 2 CB 375 16 X 1 00 STD CD 4 ANTI SCALP WHEEL ASSY NOTES 1 Do not torque Item 2 798694 Discharge Chute must pivot freely 2 Includes items 7 8 9 and 10 3 Service part deck includes decals see 72 amp 60 Side Discharge Deck Decals XR7 on page 10 4 for listing of decals 108604 10 08 8 7 60 Side Discharge Deck Pulley Assembly XR7 BELT GUIDE INDEXING 8 8 108604 10 08 60 Side Discharge Deck Pulley Assembly XR7 ITEM SERVICE NO PART NO 1 797720 2 797910 3 601434 4 025007 5 347443 6 028118 7 781856 8 373191 9 781302 10 350884 11 103192 12 103200 13 016972 14 781385 15 797449 16 792002 17 016527 18 752386 19 770842 20 705954 21 767962 22 768523 23 058776 24 212472 ER 25 796235 26 794685 27 782474 28 769257 29 029934 30 783738 Torque to 118 ft lbs Torque to 65 75 ft lbs MFG PART NO 797720 797910 601434 025007 347443 028118 781856 059931 781302 350884 103192 103200 016972 781385 797449 792002 016527 752386 770842 705954 767962 768523 058776 212472 796235 794685 782474 769257 029934 783738 QTY Aa WN A a ot N 00 O O DESCRIPTION
38. EP 25 796680X 796680 1 REAR DISCHARGE DECK SPINDLE ASSEMBLY EP 26 796235X 796235 2 DECK SPINDLE ASSY 27 212472 212472 3 KEY 1 4 SQ X 1 00 LONG 28 600901 600901 2 BLADE F20 50 L F CW 29 795633 795633 1 BLADE F20 50 L F CCW 30 796722 796722 1 CS 625 11 X 3 00 LH HX G 31 029934 029934 2 CS 625 11 X 3 00 HX G5 ZNYC 32 768523 768523 1 FW 343X 687X 051 080H 33 058776 058776 1 NT 312 18 HXZY NL NOTES Torque to 118 ft lbs Torque to 65 75 ft lbs 3 See 60 Rear Discharge Belt Routing and Tensioning on page 9 6 for belt tensioning 4 See Spindle Assembly 796235 on page 8 16 for breakdown 5 See Spindle Assembly 796680 on page 8 17 for breakdown 108604 10 08 8 15 T__ E n NL nus dm 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 GREASE FITTING 5 072272 N A 1 FW 1 06 X 2 00 X 134 SAE ZN 6 796227 N A 1 SADDLELESS SPINDLE SHAFT NOTES 1 Install upper bearing with extended inner race up 2 Install lower bearing with extended inner race down 8 16 108604 10 08 Spindle Assembly 796680 E uc d 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 GREASE FITTING 5 600893 N A 1 BEARING DUST COVER 6 796698 N A 1 SPINDLE SHAFT NOTES 1 Install upper bearing with extended inner race up 2
39. Hustler ATZ Parts Manual HUSTLER P O Box 7000 Hesston Kansas 67062 2097 108604 10 08 Table of Contents Chapter 1 General Information 1 1 Chapter 2 Rivet Nut 5 2 2 FOONGSECASSEMDbN terre ol ideal 2 3 Chapter 3 Hydraulic System Installation Kawasaki 31 HP HT Engine 3 2 Chapter 4 Battery Installation s o 4 959 d 4 2 Deck Lift Assembly 4 4 Park Brake 4 6 Steering Assembly 4 8 Steering 4 10 Pump Belt and Pulleys Installation 4 12 Chapter 5 Kawasaki 31 HP Engine Installation 5 2 Fuel System Installation 5 4 Instrument Panel Assembly Installation 5 6 Electrical Schematic Kawasaki 601555 5 8 Chapter 6 Front Wheel Assembly 6 2 Semi Pneumatic Tire Wheel 789537 6 4 Drive Wheel Assembly Installation 6 5 Anti Rollover Wheel Assembly 6 6 Chapter 7 Weight Installations omer Y a aa 7 2 MOPS E e WEE or eme ei 7 4 Chapter 8 72 Side Discharge Deck Assembly XR7
40. K FIG 5 WARNING Always wear adequate eye protection when servicing the hydraulic system and battery HYDRAULIC SYSTEM IMPORTANT Never use hydraulic or automatic transmission fluid in this system use only motor oil as specified Remember dirt is the primary enemy of any hydraulic system WARNING Hydraulic oil escaping under pressure can penetrate skin Hydraulic oil may cause infec A tion in a minor cut or opening in the skin If exposed to hydraulic fluid see a doctor at once Before applying pressure to hydraulic system make sure all connections are tight and all hoses and lines are in good condition To find a leak under pressure use a piece of cardboard or wood never use your hands Relieve all pressure in the system before disconnecting or working on hydraulic lines To relieve pressure lower all attachments and shut off engine The 1 0 U S gallon 3 79 liter hydraulic reservoir is located in front of the engine and under the operator s platform FIG 6 Check oil level in hydraulic system after every 50 hours of operation or weekly whichever occurs first Check more often if system appears to be leaking or otherwise malfunctioning Fluid level should be 1 from top of reservoir Use only SAE 10W40 SG SF CC CD service motor oil Change hydraulic system filter element FIG 6 after first 50 hours of tractor operation then replace filter and oil in reservoir every 500 hours thereafter When
41. K 797720 B SECTION BELT 60 SIDE DISCHARGE DECK 795781 B SECTION BELT 60 REAR DISCHARGE DECK 068478 FUEL FILTER 601652 MAIN AIR FILTER ELEMENT 601653 SAFETY AIR FILTER ELEMENT 772079 KAWASAKI ENGINE OIL FILTER 798702 BLADE F24 50 H F CW 72 SIDE DISCHARGE DECK 794685 BLADE F20 50 H F CW 60 SIDE DISCHARGE DECK 600901 BLADE F20 50 L F CW 60 REAR DISCHARGE DECK 795633 BLADE F20 50 L F CCW 60 REAR DISCHARGE DECK Service Literature PART NO DESCRIPTION 601656 ATZ OWNER S MANUAL 601615 KAWASAKI ENGINE MANUAL Note When ordering parts you must use the part number as shown for each part not the item number Always give the model and serial number to your parts and service representative Note Items sold in bulk such as seals and hoses are sold by the foot Using this manual Illustrations used were current at the time of printing but subsequent production changes may cause your machine to vary slightly in detail Excel Industries Inc reserves the right to redesign and change the machine as deemed neces sary without notification If a change has been made to your machine which is not reflected in this parts manual see your Hustler dealer for current information and parts 108604 10 08 1 1 Hardware Description Codes amp Abbreviations The following codes are used throughout this parts manual Refer to this list when ordering parts ABBREVIATION DESCRIPTION CB Carriage Bolt CE Clevis Pin CP Cotter Pin CS Cap S
42. OT amp HYDRAULIC OIL DECAL 3 601980 601980 1 INSTRUMENT PANEL DECAL 4 601968 601968 1 HYD PRESSURE DECAL 5 791830 791830 1 FUEL INDICATOR DECAL 6 601967 601967 1 ENGINE COMPARTMENT DECAL 7 600899 600899 1 BELT WARNING DECAL 8 785188 785188 1 2 ARMREST WARNING DECAL 9 601815 601815 1 BATTERY DECAL 10 600941 600941 1 PATENTS DECAL 11 083279 1 PRODUCT SERIAL NO PLATE 12 727172 727172 1 MADE IN USA DECAL 13 782573 782573 1 FIRST ZERO TURN DECAL 14 793588 793588 1 HUSTLER NAME PLATE 15 782615 782615 1 SUPER Z ID DECAL 16 601791 601791 1 ATZ SAFETY DECAL NOTES 108604 10 08 10 3 72 amp 60 Side Discharge Deck Decals XR7 En N m INDEX NO 1 NO Q G nm SERVICE PART NO 786285 786277 760637 727420 727172 727453 727438 799395 781419 799353 359547 797845 MFG PART NO 786285 786277 760637 727420 727172 727453 727438 799395 781419 799353 359547 797845 QTY NS ID IND skr xl DESCRIPTION 72 SIDE DISCHARGE DECK ID DECAL 60 SIDE DISCHARGE DECK ID DECAL MOWER DECK QUICK REFERENCE DECAL DEFLECTOR SHIELD DECAL MADE IN U S A DECAL BELT amp PULLEY DECAL WHIRLING BLADES DECAL BELT ROUTING DECAL 60 DECK ONLY BELT ROUTING DECAL 72 DECKS DECK XR7 ID DECAL 5 00 X 9 00 STEP TREAD FUSION DECAL 10 4 108604
43. ZN CS 375 16 X 1 750 HX G5 ZN 312 24 HXZY NL FW 343X 687 X 051 080 HD ZN YL STEERING ARM MOUNT STEERLEVER SUPPORT LH SHOWN STEERLEVER SUPPORT RH BUSHING SS 500 13 X 1 75 SH ZN BRAKE ROD ASSEMBLY NT 375 16 HX LK NY STEERLEVER BUSHING GRIP RH HANDLE LOWER GRIP RH HANDLE END RP 125DX1 000 LG ZN TILT SWITCH HOUSING KEY TILT SWITCH HANDLE TILT SWITCH WIRE HARNESS STEERING HANDLE W A NOTES 1 Includes Item 1 781260 Steering Bar Grip 2 Includes Item 15 601769 Lower Handle Grip and Item 16 601768 End Handle Grip Pump Belt and Pulleys Installation TRACTOR FRAME 4 12 108604 10 08 Pump Belt and Pulleys Installation en DESCRIPTION 1 601462 601462 1 ENGINE PULLEY 2 212076 212076 1 KEY 1 4 SQ X 1 50 LONG 3 601311 601311 1 WARNER CLUTCH 4 783829 783829 1 FW 460 X 1 750 X 250 ZNYC 5 785659 785659 1 CS 437 20 X 2 50 HX G5 ZNYC 6 083196 083196 4 SS 312 18X 750 SQ HD ZN 7 601461 601461 2 PULLEY BDP 21 8 783712 783712 2 KEY FOR BDP21L 9 791251 791251 1 CLUTCH PIGTAIL HARNESS WITH DIODE 10 008193 008193 2 NT 500 13 HX G5 ZNYC 11 767962 767962 4 FW 531 X 1 063 X 090 SAE HD ZN 12 016527 016527 2 CS 500 13 X 1 00 HX G5 ZNYC 13 366765 366765 1 CLUTCH ANCHOR ANGLE 14 784918 784918 2 RUBBER BUMPER 15 349761 349761 1 PUMP IDLER ARM 16 015495 015495 1 STRAIGHT GREASE FITTING 17 025296 025296 1 FW 760 X 1 625 X 08 ZN 18 061101 0611
44. age the fibers of the belt covering Keep oil and grease away from belts and never use belt dressings Any of these will destroy the belt composition in a very short time MOWER BLADE MAINTENANCE Check the mower blades daily they are the key to power efficiency and well groomed turf Keep them sharp a dull blade will tear rather than cut the grass leaving a brown ragged top on the grass within a few hours A dull blade also requires more power from the engine Replace any blade which is bent cracked or broken WARNING Never attempt to straighten a bent blade by heating or weld a cracked or broken blade as the blade may break and cause serious injury Always place deck clutch switch in the disengaged position place control levers in the park brake position and turn engine off and disconnect negative battery cable Block up mower when you must work under it Wear gloves when handling blades Always check for blade damage if mower strikes rock branch or other foreign object during mowing DANGER Never work with blades while engine is running or deck clutch switch is engaged on WARNING Always wear adequate eye protection when grinding mower blades MOWER BLADE REMOVAL Use a 15 16 wrench to remove the 5 8 cap screw holding the blade to the spindle shaft from underneath Sharpen the blades on a grinder following pattern as shown FIG 18 Touch up sharpening can be done with a file Check the blades for balance foll
45. amp Adjustment 12 2 Safe Maintenance amp Adjustment Practices 12 2 Using re DEE 12 4 Safety and Instruction 12 4 Ma linlenance ti Ce 4b cam EEn ln Eek ae ee bw eee ER 12 5 litro s le dein EE 12 8 Torque 12 8 TIPS ita amu ROSEO 12 8 Hour MEIS reden 12 9 IGANG ne ee A ele i 12 9 Electrical 5 lt 12 9 Access to engine and hydraulic pumps 12 11 Aydra lie system ene ces ese eaten 12 11 FUSLSYSIBITI Sis tenten tetek 12 13 Engine oil and 12 14 Enginar filte zt orte 12 15 Recommended service 12 15 OVErRservicingi iesus on et UE eee RSS 12 16 Improper installation of an air filter element 12 16 Damaged filter seals or canister 12 16 Incorrect air cleaner element 12 16 Recommended service procedure 12 17 Air restriction Rn Te EE 12 17 General engine maintenance 12 17 Belt 12 17 Mower blade maintenance 12 19 Mower blade 12 19 Adjustment eert Ie ee re LR cuti 12
46. an cause serious injury to skin and eyes If contact occurs flush area with clean water and call physician immediately Acid will also damage clothing gt gt Do not drink the battery electrolyte Do not allow open flame near the battery when charging Hydrogen gas forms inside the battery This gas is both toxic and flammable and may cause an explosion if exposed to flame Always remove the negative ground first and replace it last Do not overfill battery Electrolyte may overflow and damage paint wiring or structure When cleaning the battery use soap and water Be careful not to get soap and water into the battery Clean the battery terminals with a solution of four parts water and one part baking soda when they become corroded WARNING Shorts caused by battery terminals or metal tools touching metal tractor components can cause sparks Sparks can cause battery gas explosion which will result in personal injury Prevent the battery terminals from touching any metal tractor parts when removing or installing the battery Do not allow metal tools to short between the battery terminals and metal tractor parts WARNING Incorrect battery cable routing could cause damage to the tractor and battery cables This AA can cause sparks which can cause a battery gas explosion which will result in personal injury Always disconnect the negative black battery cable before disconnecting the positive red cable Always connect the p
47. c Oil Filter Gauge Wheel Bearing Zerks 2 Engine Oil Filter Deck Height Pivot Zerks 4 Park Brake Switch 2 Drive Tire Pump Idler Zerk 1 Pump Belt Hydraulic Oil Heat Exchanger 108604 10 08 MAINTENANCE LOCATOR CHART 72 XR 7 deck 1 Deck Pusher Arm Zerks 2 60 XR 7 deck 2 Deck Belt 3 Spindle Housing Zerk 3 4 Blades 60 Rear Discharge deck FIG 2 108604 10 08 12 7 SERVICE INTERVALS INDICATED WEEKLY OR 50 MONTHLY OR 100 ANNUALLY OR 500 HOURS HOURS HOURS Verify safety start interlock system Daily Visually inspect unit for loose hardware and or damaged parts Daily Visually inspect tires Daily Check oil level engine 1 Daily or every 4 hours Clean air intake screen 5 Daily or every 4 hours Clean oil heat exchanger 5 Daily or every 4 hours Check amp clean engine compartment Daily or every 4 hours Check air cleaner service indicator Every 8 hrs Check fuel level Daily Blades sharpen amp securely fastened Daily Discharge chute securely in place amp in lowest position Daily Clean engine and pump compartment Daily Replace air cleaner paper element 5 As needed
48. changing hydraulic oil use 1 2 unit approximately 3 5 oz of Lubrizol additive Hustler P N 027912 This additive available from your Hustler dealer will increase the performance life of the hydraulic system components 12 12 108604 10 08 The system filter is located directly in front of the hydraulic reservoir A standard oil filter wrench is used to change filter threads are right handed Use a Hustler approved filter element only COOLING FAN di HYDRAULIC FILTER Lm FIG 6 FIG 7 IMPORTANT Prefill the filter element with clean oil before installing to prevent drawing air into the system pump 1 Fill the filter element with clean system oil Smear a light coating of oil on upper surface of rubber seal 2 Install the filter element on Tighten the oil filter by hand until the filter seal makes contact with the filter head then tighten an additional 3 4 1 turn with an oil filter wrench DO NOT OVERTIGHTEN 3 Start tractor engine and let run at approximately 2 3 throttle for a few minutes to work any trapped air out of the system before engaging the steering control lever 4 Stop the engine and check the filter and connections for leaks 5 Check the hydraulic reservoir for specified oil level Add clean oil as necessary Clean or replace hydraulic reservoir cap annually Cap may be cleaned by dipping in or flushing with cleaning solvent Follow manufacturer s instructions and
49. crew CW Cup Washer FDRW Fender Washer FW Flat Washer HX Hex Head LW Lock Washer MB Machine Bushing MS Machine Screw NT Nut SC Self Tapping Cap Screw SH Socket Head SB Shoulder Bolt SS Set Screw OD Outside Diameter ID Inside Diameter Standard Torques The following chart lists the standard torque values for the threaded fasteners found in this manual Torque all cap screws nuts and set screws to these values unless a different torque is shown in the Notes section next to the fastener SIZE FT LBS NM SIZE 250 8 2 11 1 M3 312 17 23 4 373 30 40 M5 438 48 65 M6 500 73 99 8 562 105 143 M10 625 145 200 M12 750 260 350 M16 875 420 565 20 1 00 625 850 24 Loctite 592 to be used on all pipe threads Lubricate all grease zerks 1 2 FT LBS 2 2 4 5 7 7 18 5 37 64 160 320 555 NM 1 3 3 6 1 10 4 25 50 87 215 435 750 108604 10 08 108604 10 08 Chapter 2 Contents Rivet Nut Installation Footrest Assembly 2 1 Rivet Nut Installation ITEM SERVICE MFG PART NO PART NO NO QTY DESCRIPTION 546572 381848 1 ATZ FRAME N A 808493 13 RIVET NUT 3 8 16 THREAD 3 N A 600961 8 RIVET NUT 1 2 13 THREAD NOTES 2 2 108604 10 08 Footrest Assembly ITEM SERVICE MFG PART NO PART NO NO QTY DESCRIPTION 1 359547 359547 2 STEP TREAD 2 395533
50. e is running never refuel near an open flame or near devices which can create a spark Refuel outdoors preferably or in well ventilated areas Never attempt to start engine when there is a strong odor of gasoline fumes present Locate and correct cause Never run the engine in an enclosed area unless exhaust is vented to the outside Exhaust gases contain carbon monoxide which is odorless and deadly poison Never attempt to make any adjustments or repairs to the tractor drive system mower deck or any attachment while the tractor engine is running or deck clutch is engaged Repairs or maintenance requiring engine power should be performed by trained personnel only Never work under the machine or attachment unless it is safely supported with jack stands Make certain machine is secure when it is raised and placed on the jack stands The jack stands should not allow the machine to move when the engine is running and the drive wheels are rotating Use only certified jack stands Use only appropriate jack stands with a minimum weight rating of 2000 pounds to block the unit up Use in pairs only Follow the instructions supplied with the vehicle stands Before working on or under the deck make certain engine cannot be accidentally started Shut engine off and remove ignition switch key for maximum safety Repairs or maintenance requiring engine power should be performed by trained personnel only Use a stick or similar instrument to clean under th
51. e mower making sure that no part of the body especially arms and hands are under mower Exercise caution when working under the deck as the mower blades are extremely sharp Wearing gloves or wrapping the blade s is advisable when working around or with the blades Do not touch hot parts of machine Keep nuts and bolts tight especially the blade attachment bolts Keep equipment in good condition Never tamper with safety devices Check their proper operation regularly Grass collection system components are subject to wear damage and deterioration which could expose moving parts or allow objects to be thrown Frequently check components and replace with manufacturer s recommended parts when necessary Use only genuine Hustler replacement parts to ensure that original standards are maintained 12 4 108604 10 08 Using a ramp Use extreme caution when loading and unloading a unit with a ramp Use only a single full width ramp do not use individual ramps for each side of the unit Having a full width ramp provides a surface for the tractor frame to contact if the unit starts to tip backwards It also reduces the risk of a wheel going off and the machine tipping over Do not exceed a 15 degree angle between the ramp and the ground or between the ramp and the trailer or truck When on a ramp avoid sudden acceleration Safety and Instruction Decals Specific safety warning decals are located on the equipment near the immediate area
52. eated for an effective seal so that no dirt can enter the engine DAMAGED FILTER SEALS OR CANISTER Never bang or bump the filter element against the tire or any solid object as dust and dirt particles will be forced through the media causing continual passing of dirt into the engine Visually inspect the outside of the air cleaner canister periodically for external damage and replace if necessary INCORRECT AIR CLEANER ELEMENT Use only the correct Donaldson air filter element Hustler part number 785261 which is designed to fit the canister properly Hustler air filter elements have the correct media composition filter area micron size and dimensions Always use genuine Hustler filters Many aftermarket filters have been found to be incompatible with Hustler s canisters and engines The air filter must remain intact to block passage of dirt and foreign particles from entering the engine Being inclined to disbelieve the need for more expensive air filter elements used on gasoline engines may cause some individuals to opt for a less expensive part The filter element must be sufficient size and construction to withstand stresses caused by rapid cycling of the air volume demanded by the engine without cracking or tearing under fatigue and pressure especially diesel engines Therefore Hustler Turf Equipment and the engine manufacturers have carefully selected a reliable filter designed to fit the needs of the engines The filter specifi
53. ed is a Donaldson filter Hustler part number 785261 108604 10 08 12 17 Owners should be reminded that failure to use original equipment replacement parts is an alteration and will not be considered for warranty in the event of engine damage RECOMMENDED SERVICE PROCEDURE 1 2 oar Ww Release clamps and remove element Clean the canister with a damp cloth Before installing a new element inspect it by placing a bright light inside and rotate the element slowly looking for any holes or tears in the paper Also check gaskets for cuts or tears Do not attempt to use a damaged element which will allow abrasive particles to enter the engine Reinstall the dust cup Make sure it seals all the way around the air cleaner body then tighten the clamps Check all fittings and clamps periodically for tightness and inspect hoses for holes or cracks Periodically check the intake hose for signs of ingested dust Locate and repair the source of ingested dirt Never operate a machine without an air filter installed AIR RESTRICTION INDICATOR Any unit with a Kohler or Kawasaki engine will have an air restriction indicator installed in the air cleaner FIG 13 Replace the element whenever the restriction indicator shows reaches the change filter red line Check the indicator daily and replace element as needed or annually whichever occurs first Reset the indicator by pushing in on the yellow button after each element change FIG 13
54. ed trash grass clippings and other debris Always clean up spilled fuel and oil Always wear adequate ear protection such as earplugs when operating this equipment as prolonged exposure to uncomfortable or loud noises can cause impairment or loss of hearing Do not wear radios or music headphones while operating the machinery Safe operation requires your full attention Never put hands or feet under any part of the machine while it is running Except when changing or checking belt always keep belt covers on mower for safety as well as cleanliness Stop the engine before removing the grass catcher or unclogging the discharge chute Never clear the discharge chute with the engine running Turn off the engine and be sure the blades have stopped before cleaning Use a stick to clear a plugged discharge area Never use your hand Exercise caution when loading or unloading the machine onto a trailer or truck Always wear safety goggles or safety glasses with side shields when operating the mower Never leave machine unattended with ignition key in switch especially with children present Be alert and turn the machine off if children enter the area Always wear adequate eye protection when servicing the battery hydraulic system cooling system or when grinding mower blades and removing accumulated debris Use extra caution when handling gasoline and other fuels They are flammable and vapors are explosive Never refuel tractor while engin
55. eo DESCRIPTION CS 250 20 X 2 25 G5 ZNYC FW 281 X 625 X 051 080 HD ZNYC SEAL 3 8 X 3 4 X 7 25 LONG WEATHERSTRIP 12 X 75 X 11 75 LONG OIL COOLER NT 250 20 HX NL ZNYC BREATHER CAP STRAINER SUPER Z RESERVOIR NT 312 18 HX G5 ZNYC FW 343 X 687 X 051 080 HD ZNYC CS 250 20 X 50 HX G5 ZNYC PUMP HYDRO GEAR BDP 21L 408 NT 500 13 HX G5 ZNYC FW 531 X 1 063 X 090 SAE HD ZN ZAF SERIES FILTER HEAD FILTER ELEMENT REMOTE AIR MOUNT BRACKET W A CS 500 13X3 250 HX G5 MOTOR WHITE RC26 CCW MOTOR WHITE RC26 CW HOSE CLAMP HOSE COOLER LT RES HOSE LEFT PUMP COOLER HOSE COOLER RT RES HOSE RIGHT PUMP COOLER FITTING 8 BEADED TUBE ORB 90 FITTING STR 8MORB 8MSL HEX PLUG FITTING STR 8MORB SUCTION HOSE ASSY FILTER PUMP SUCTION HOSE ASSY FILTER PUMP FITTING T 8MJIC 8MJIC FITTING 10 FX05 S SUCTION HOSE 12 16 LONG TUBE LP BM LT LOOP TUBE RP TM LT LOOP TUBE RP TM RT LOOP TUBE LP BM RT LOOP FITTING 90 10MORB 8MSL FITTING 6 BEADED TUBE ORB 45 HYDRO KIT INCLUDES ITEMS 23 40 NOTES 1 Hydraulic system capacity is 5 US quarts of 20W50 motor oil Fill reservoir to within 1 of top of Item 8 032771 Strainer 108604 10 08 3 3 Note SIDE x HYDRAULIC SYSTEM CHARGING PROCEDURE Set handles in the neutral position Start engine at idle Let run for a minimum of 30 seconds Stroke handles to forward position If motors do not turn in 15 seconds return handle
56. have the same amount of air pressure The recommended pressures are Drive wheels 8 12 psi 55 69 KPa Gauge wheels semi pneumatic The bar tread tires are reversed from what is considered the normal operating position this allows for bet ter traction when backing up a slope 108604 10 08 12 9 Solid fill tires are not recommended for Hustler turf equipment any machine with solid filled tires the warranty claim will be denied WARNING Explosive separation of a tire and rim can cause serious injury or death Do not attempt to mount a tire without the proper equipment and experience to perform the task Always maintain the correct tire pressure and never over inflate Never weld or heat a wheel and tire assembly as an explosion may occur Welding can weaken or deform a wheel When inflating tires stand to one side and not in front of or over the tire assembly Check tires for low pressure blemishes damaged rims or missing lug bolts and nuts HOUR METER To recognize when your machine needs servicing check the hour meter and the maintenance schedule The hour meter shows the number of hours the engine has run and the maintenance schedule lists the service intervals FIG 3 LUBRICATION 1 Grease the front gauge wheel bearings per the Maintenance Schedule Use SAE multi purpose grease 2 Grease the four deck lift pivots located to the side of the operator
57. is cleaned by any method the person or company performing the cleaning assumes responsibility for the integrity of the filter from then on The Donaldson warranty for air filters expires upon cleaning or servicing in any manner because the condition of the filter after servicing is completely out of their control Therefore on a dust ingested engine failure there will be no warranty consideration if the air filter element has been cleaned or serviced in any manner A partially dirty air filter element works better than a new element Therefore a dirty filter element is not bad for the engine unless it is excessively restricting the air flow and engine performance is affected The reason is simple The media in the filter must be porous to allow air to pass through it When dirty air passes through the filter the dirt plugs some of the holes in the media and actually acts as part of the filter media When the next round of dirt enters the first dirt helps filter out even smaller particles making the filter more efficient at stopping dirt from entering the engine This is referred to as barrier filtration Of course at some point the filter media becomes too clogged to allow air to pass The mowing conditions will determine the frequency of air filter element changing IMPROPER INSTALLATION OF AN AIR FILTER ELEMENT Dust must not leak past the seals on each end of the air filter element The filter must be aligned within the canister and properly s
58. led in top hole for shipping purposes 2 Includes Items 12 through 14 and 16 3 Service part deck includes decals see 72 amp 60 Side Discharge Deck Decals XR7 page 10 4 108604 10 08 8 13 60 Rear Discharge Deck Pulley Assembl a A 7 X 2 W Z 108604 10 08 8 14 60 Rear Discharge Deck Pulley Assembly EN DESCRIPTION 1 795781 795781 1 60 REAR DISCHARGE DECK BELT 2 110411 110411 1 PULLEY COVER RH 60 3 110412 110412 1 PULLEY COVER LH 60 4 794446 794446 1 CS 625 11X1 500 HX G5 Z 5 028118 028118 T FW 62 X 1 00 X 134 ZN 6 796714 796714 5 6 HB IDLER PULLEY RD 7 781567 781567 1 NT 500 13 HX G8 ZY NL 8 767962 767962 13 FW 531 X 1 063 X 090 SAE HD ZN 9 770867 770867 2 BUSHING PLAS 750X1 FS 10 109549 109549 1 BUSHING IDLER PIVOT 11 600296 600296 1 DECK IDLER SPACER 12 109948 109948 1 IDLER ARM W A 13 601779 601779 1 IDLER SLIDE UHMW 14 797910 797910 2 CS 312 18X1 50FLT SH ZY 15 704759 704759 1 FW 500 1 250X 075 16 781302 781302 1 IDLER SPRING 17 259812 059931 1 DECK LIFT CHAIN 13 LINKS 18 016972 016972 4 625 11 HX G5 ZNYC 19 016527 016527 15 CS 500 13 X 1 00 HX G5 ZN 20 752386 752386 3 FW 510 X 1 75 X 18 ZN 21 770842 770842 3 B SECTION PULLEY 22 792002 792002 4 5 16 18 X 3 4 MALE KNOB 23 782474 782474 5 CW 631 X 2 250 X 187 PNT 24 783738 783738 2 CS 625 11X3 00 FULL HX G5 ZN
59. m both nuts against the block Push or pull on the deck lift foot pedal until the chain on the left front just becomes tight making sure that the deck stays tight against the 4 block While keeping the chain tight tighten the nuts against the deck lift block on the height indicator rod just enough to carry most of the deck weight on that side the 4 block should be able to move with only a slight drag FIG 38 Jam nuts tightly together against the deck lift block Go to the right front of the tractor Loosen the 5 16 jam nut on the adjuster lift chain FIG 37 and back the adjuster bolt out to allow the adjuster to move up and down freely Be sure that adjuster is free to move up and down Tighten the adjuster bolt until the chain just becomes tight Then tighten just enough more to carry the weight of the front of the deck on that side to check move the 4 blocks back and forth they should move with a slight drag Tighten the adjuster bolt jam nut to prevent the adjuster bolt from moving FIG 37 Tighten the hardware holding the chain and adjuster onto the deck lift arm Go to the right rear of the tractor Make sure that there is still slack in the chain If not loosen the two nuts on the block holding the threaded rod until there is slack in the deck lift chain FIG 36 Tighten the appropriate nut until the chain just becomes tight and carries most of the deck weight Check by moving the 3 25
60. mbly ITEM SERVICE NO PART NO 549576 2 109484 3 768523 4 086660 5 767954 6 710194 7 601069 8 015495 9 349803 10 036244 11 352591 12 781708 13 767962 14 053199 15 781567 16 031997 17 109486 18 109487 19 601483 20 106716 21 600254 22 351676 23 109482 24 109483 25 778399 26 016253 27 058776 28 037887 29 109485 30 792887 ED EP 788166 MFG PART NO 110402 109484 768523 086660 767954 710194 601069 015495 349803 036244 352591 N A N A N A 781567 N A 109486 109487 601483 106716 600254 351676 109482 109483 778399 016253 058776 037887 109485 792887 788166 QTY 1 1 10 6 22 mo o SN MM A a A 0 AGH E R DESCRIPTION 60 REAR DISCHARGE DECK DISCHARGE SHIELD FW 343 X 687 X 051 080 HD ZN NT 375 16 HX LK NY FW 406 X 812 X 060 SAE HD ZN CB 375 16 X 1 50 STD G5 CN 312 18X 200 STRAIGHT GREASE FITTING PUSHER CS 375 16 X 1 00 HX G5 ZN 60 REAR DISCHARGE FRONT ANGLE CS 500 13 X 4 25 HX G5 ZN FW 531 X 1 063 X 090 SAE HD ZN NT 500 13 HX JAM ZN NT 50 13 HXZY NL ANTI SCALP WHEEL CLAMP ANGLE LS CLAMP ANGLE RS SIDE FLAP RUBBER ANGLE DISCHARGE CHUTE RD REAR FLAP DECK STIFFENER ANGLE CHUTE BRACKET RS CHUTE BRACKET LS FW 781 X 1 375 X 250 ZNYC CB 312 18 X 750 FUL ZN 312 18 HXZY NL CB 312 18 X 1 000 FUL Z GUARD MTG ANGLE 5 16 18 HX TH RIVET NUT ANTI SCALP WHEEL ASSEMBLY NOTES 1 Factory assemb
61. ndle belt tension idler 4 Spindle belt tension idler spring 9 0 at operation 5 Deck belt idler Idler arm FIG 16 60 XR 7 DECK 1 Replace the belt every 400 hours or every two 2 years whichever comes first Deck Belt Drive Layout Spindle drive belt Deck blade spindle pulley 2 3 4 Spindle belt tension idler spring Spindle belt tension idler 72 XR 7 DECK 9 0 at operation Deck belt idler Idler arm Deck Belt Drive Layout 1 Spindle drive belt 2 Deck blade spindle pulley 3 Spindle belt tension idler 4 Spindle belt tension idler spring 9 0 at operation Deck belt idler Idler arm FIG 17 WARNING If the pump belt fails loss of control will occur especially when operating on a slope If you lose steering control while operating the machine place the steering control levers in the park brake position immediately Inspect the machine and involve your Hustler dealer to resolve the problem before continuing to operate Inspect the belt pulley grooves and flanges for wear A new belt or one in good condition should never 108604 10 08 12 19 run against the bottom of the groove Replace the pulley when this is the case otherwise belt will lose power and slip excessively Never pry a belt to get it on a pulley as this will cut or dam
62. ng temperature Unequal tire pressure will cause the tractor to drift to one side Refer to tire pressure information in the Maintenance section of this manual Fine adjustment to the unit s steering is made with the adjustable pump linkage rods located between the control lever and pump arms FIG 22 Neutral is properly adjusted when the control levers are in the neutral position and the drive wheels are not turning 12 22 108604 10 08 FIG 22 FIG 23 If the tractor creeps in the neutral position the control linkage may be adjusted as follows 1 Raise and block the tractor up so the drive wheels are off of the floor WARNING Never work under the machine or attachment unless it is safely supported with jack stands Make certain machine is secure when it is raised and placed on the jack stands The jack stands should not allow the machine to move when the engine is running and the drive wheels are rotating Use only certified jack stands Use only appropriate jack stands with a minimum weight rating of 2000 pounds to block the unit up Use in pairs only Follow the instructions supplied with the vehicle stands Position the control lever in the neutral position Disengage the deck clutch Start the engine and observe which way the wheels are rotating If wheel s are rotating forward loosen the jam nuts on the pump linkage rods and rotate the rod to lengthen the steering control linkage until the wheel s
63. ny cracks or leaks Replace as needed Hustler ATZ tractors are equipped with a fuel shutoff valve located on the right fuel tank mount FIG 10 Rotate the valve to the middle position shown to prevent fuel flow to the fuel pump The forward position allows fuel to flow from the right fuel tank to the fuel pump The rear position allows fuel to flow from the left fuel tank to the fuel pump Close this valve to prevent fuel flow to the engine when servicing the fuel system or when transporting the unit on a trailer or truck RIGHT TANK POSITION VALVE CLOSED POSITION SHOWN 4 LEFT TANK POSITION A ENGINE OIL AND FILTER Check engine oil daily and after every 4 hours of operation Crankcase dipstick and oil filler tube are located at the rear of the machine FIG 11 Tractor must be sitting level when checking oil Refer to engine manual and maintenance schedule for oil recommendation and capacities Change the engine oil and filter after the first 5 hours of operation per the engine manufacturer s recommendations after that If tractor is being operated in extremely dirty conditions then it is recommended oil be changed more frequently 108604 10 08 12 15 The oil drain and oil filter are located at the rear of the engine FIG 11 ENGINE OIL dn FILTER E IN S UJ ENGINE OIL lt gt Will DRAIN PLUG 2 EET FIG 11 ENGINE AIR FILTER Perform engine air filter maintenance
64. ositive red battery cable before connecting the negative black cable Common circuit failures are usually caused by shorting corroded or dirty terminals loose connections defective wire insulation or broken wires Switches solenoids and ignition components may also fail causing a shorted or open circuit 108604 10 08 12 11 Before attempting any failure diagnosis of the electrical system use a test light or voltmeter to check the battery voltage If the battery voltage is satisfactory check the cleanliness and tightness of the terminals and ground connections A general understanding of electrical servicing and use of basic test equipment is necessary for troubleshooting and repair Major overhaul or repair of the starting motor or charging system should be performed by trained technicians only ACCESS TO ENGINE AND HYDRAULIC PUMPS The hydraulic pumps are accessed by lifting the seat platform The seat platform is hinged at the front To raise it release seat latch and tilt seat platform up and forward The seat platform catch FIG 5 will prevent the seat from going all the way over However if more access is desired under the seat platform the seat platform catch can be raised allowing the seat to pivot more Make certain to place the control arms in the park brake position and pivot the arm rests upward before placing the seat platform in the full forward position to prevent arm rest damage Ed b SEAT PLATFORM CHEC
65. owing grinding A commercial balancing tool is available through most hardware supply stores or balancing can be done by placing the blade on an inverted line punch or 1 2 bolt Blade should not lean or tilt Spin the blade slowly blade should not wobble If blade is out of balance true it up before reinstalling Lay the blade on a flat surface and check for distortion FIG 19 and FIG 20 Replace any distorted blade Do not re use spindle bolts which have stripped worn or undercut threads Torque bolts to 118 foot pounds when reinstalling blades WARNING When mounting blades rotate them after installation to ensure blade tips do not touch each other or sides of the mower WARNING Failure to correctly torque the bolt may result in the loss of the blade which can cause seri ous injury WARNING Mower blades are sharp and can cut Wrap the blade s or wear gloves and use extra caution when servicing them 12 20 108604 10 08 Straight Blade Replace Comparison of Warped and Straight Blades Resharpening pattern Do not sharpen to original pattern below It is easier to get a straight cutting edge following the resharpening pattern shown above Twisted Blade Edge Cutting Plane replace Cutting edge Straight Blade Edge End view of blades comparing twisted and straightened blades FIG 20 Original edge FIG 18 108604 10 08 12 21 Adjustment INTRODUCTION Your Hustler
66. per the scheduled maintenance chart See SERVICE AT INTERVALS INDICATED on page 12 8 A specially designed dry filter is standard equipment on the Hustler ATZ tractors and supplies clean combustion air to the engine FIG 12 RECOMMENDED SERVICE PROCEDURE AIRONE Many engine failures can be attributed to improper air cleaner servicing Ingested dust and dirt will cause cylinder piston and bearing damage in a few hours Dusted engines will result from Overservicing the air filler element Improper installation Damaged filter seals or canister Incorrect air filter element size Use of poorly designed aftermarket air filter elements 12 16 108604 10 08 Air cleaner servicing is an inexpensive maintenance check that can prevent costly non warrantable premature engine damage OVERSERVICING Overservicing occurs when an air filter element is removed for cleaning or replacement before it is necessary Each time the filter is removed a small amount of dirt and dust could fall in the intake system This accumulated dirt can cause a dusted engine It only takes a few grams of ingested dirt over the normal service life of an engine to cause a dusted engine Do not clean element replace with a new element only Cleaning used air filter elements through improper cleaning procedures can get dust on the inside of the filter causing dirt ingestion and engine failure It is important to note that whenever an air filter element
67. r a sense of neutral during operation To set the steering dampeners in the correct operating position follow these steps Place the control lever in the neutral position Loosen the steering dampener s front ball stud Pull the dampener spring housing pass the point that the internal spring is engaged Release the dampener spring housing and allow the interna spring to bring the housing back to the neutral position Tighten the nut on the steering dampener s front ball stud LEVER pe s P Boy oem 4 RON SPRING HOUSING CAP SCREWS 5 a LOWER CONTRO LEVER FIG 25 CONTROL LEVER ADJUSTMENT The control levers can be adjusted for operator comfort By loosening the cap screws that attaches the upper control lever to the lower lever FIG 25 the upper control lever can be pivoted to fit the operator s personal preference The control levers should be adjusted so that they align with each other when in the neutral position PARK BRAKE ADJUSTMENT Occasionally check the park brakes and adjustment using the following method 1 Position the control levers in the neutral position Disengage the deck clutch 12 24 108604 10 08 stands Make certain machine is secure when it is raised and placed on the jack stands The jack stands should not allow the machine to move when the engine is running and the drive wheels are rotating Use only certified jack stands Use only appropriate jack stands with
68. r has high moisture content This build up will harden restricting blade and air movement and will probably show a poorer quality of cutting Therefore it should be removed routinely To do this it will be necessary to raise and block the deck in the full up position using jack stands or blocks and scrape the build up from underneath Some repairs require the assistance of a trained service mechanic and should not be attempted by unskilled personnel Consult your Hustler service center when assistance is needed TORQUE VALUES WARNING Particular attention must be given to tightening the drive wheel lug nuts wheel motor nuts and blade spindle bolts Failure to correctly torque these items may result in the loss of a wheel or blade which can cause serious damage or personal injury Torque values are given below Ft Ibs Nm Wheel lug nuts een 65 75 88 14 101 7 Wheel motor nut 290 310 393 2 420 4 Blade spindle bolt top 65 70 renee 88 14 101 7 Blade spindle bolt bottom 118 5 es 160 01 It is recommended that these be checked after the first 2 hours of operation initially every 50 hours and following removal for repair or replacement For all other torques refer to the various tractor parts manuals for standard torque charts NOTE Forengine torque values see engine owner s manual TIRES It is important for level mowing that the tires
69. s of potential hazards These decals should not be removed or obliterated Replace them if they become non readable The following illustrations show the various safety decals that are located on the machine A brief expla nation for those requiring one is shown to help the operator understand the meanings of these decals 108604 10 08 12 5 MAINTENANCE LOCATOR CHART Maintenance Viewed from bottom of tractor FIG 1 12 6 1 2 3 4 5 6 7 8 be eRe eRe eH Ch UV OQ P2 C o Engine Oil Fill amp Dipstick Fuel Filter Engine Air Cleaner Engine Oil Drain Plug Battery Fuel Tanks Hydraulic Oil Reservoir Hydrauli
70. s the owner s responsibility Improper use or maintenance by the operator mechanic or owner can result in injury To reduce the potential for injury comply with these safety instructions and always pay attention to the safety alert symbol which means DANGER or WARNING personal safety instructions Failure to comply with the instructions may result in personal injury or death Incorrect usage of this machine may result in severe injury Personnel operating and maintaining it should be trained in the proper use and should read the manuals completely and thoroughly before attempting to set up operate adjust or service this machine The Quick Reference Decals located in front of and to the right of the seat are designed to give the operator mechanic brief information needed in the daily operation and service of the machine These decals are not intended to be used in place of this manual but instead is to be used as an extension of this manual These decals should not be removed or obliterated Replace these decals if they become unreadable It is the owner s responsibility to make certain that the operator mechanic reads and understands this manual and all decals before operating this machine It is also the owner s responsibility to make certain that the operator mechanic is a qualified and physically able individual properly trained in the operation of this equipment Local regulations may restrict the age of the operator mechanic
71. s to neutral and repeat step 3 and 4 one time If motors do not turn after second attempt shut off the engine and check for oil at the pump Increase throttle to half speed and work handles through forward and reverse position until the motor operates smoothly throughout the entire speed range Seal Kit for hydraulic pump 784983 BDP21L Overhaul Seal Kit 3 4 108604 10 08 108604 10 08 Chapter 4 Contents Battery Installation edt een 4 2 Deck Lift Assembly 4 4 Park Brake Assembly 4 6 Steering Assembly 4 8 Steering Sub Assembly 4 10 Pump Belt and Pulleys Installation 4 12 4 1 Battery Installation ED BLACK WIRE PART OF WIRE HARNESS RED WIRE PART OF WIRE HARNESS zg o TRACTOR FRAME 4 2 108604 10 08 Battery Installation ne DESCRIPTION 1 024927 024927 2 NT 250 20 HX GR 5 ZN 2 771428 771428 1 RED BATTERY CABLE BOOT 3 796219 796219 1 BATTERY GROUND CABLE 4 744276 744276 1 POSITIVE BATTERY CABLE 5 768523 768523 2 FW 343 X 687 X 051 080 HD ZNYC 6 058776 058776 2 NT 312 18 HX NL ZN 7 348417 348417 1 BATTERY CLAMP STRAP 8 055939 055939 2 CS 250 20 X 750 HX G5 ZN 9 029868 029868 4 LW 250 INT EXT TOOTH ZN 10 740696 740696 1 BATTERY 11 034272 03427
72. soline containers on the ground away from your vehicle before filling Do not fill gasoline containers inside a vehicle or on a truck or trailer as interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge When practical remove equipment from the truck or trailer and refuel the equipment with its wheels on the ground If this is not possible then refuel the equipment on the truck or trailer using a portable container and not a gasoline dispenser nozzle If a gasoline dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete WARNING Gasoline is harmful or fatal if swallowed Long term exposure to vapors can cause serious injury and illness Avoid prolonged breathing of vapors Keep face away from nozzle and gas tank or conditioner opening Keep gas away from eyes and skin g FUEL FILTER FIG 9 12 14 108604 10 08 The fuel tanks are located in the tractor s fenders FIG 8 Total capacity for the fuel tanks is 15 U S gallon 56 8 liter Use regular unleaded gasoline with an octane rating of 87 or higher The fuel filter FIG 9 is installed in the fuel line between fuel tanks and engine fuel pump Replace filter annually or after every 500 hours of operation whichever occurs first When replacing the fuel filter check the fuel line hoses and fuel shut off valve grommet for a
73. t the belt does not slip under normal operating load conditions assuming the belt is not excessively worn or damaged As belt stretches and wears in adjustment may become necessary To increase belt tension move the spring chain one or more link s at the anchor bracket FIG 31 Installed spring length should be 9 0 3 22 8 cm 76 cm originally with adjustments of GO 15 2mm per chain link FIG 32 IMPORTANT Do not over tension the spring to compensate for a badly worn belt or pulley 12 26 108604 10 08 Spring Extension gt FIG 33 FIG 31 ENGINE RPM SETTING The Hustler ATZ is designed so that the engine will run at 3600 rpm static pump load only At this speed the hydraulic pumps are running at their maximum rated speed DECK LEVELING AND HEIGHT ADJUSTMENT The mower deck has three areas that may need to be checked and adjusted periodically Before considering any mower deck leveling adjustments check that the tire air pressure is within the specified range DECK LEVEL ADJUSTMENTS Leveling the deck must be done in the following manner and order Check tire pressures to make certain they are properly inflated before starting to level 1 deck The recommended pressures are as follows Drive wheels tire pressure i Gauge wheels tire pressure 8 12 psi WARNING Stop engine Make sure deck clutch switch is in the down OFF position Place control le
74. tem 2 798694 Discharge Chute must pivot freely 3 Service part deck includes decals see 72 amp 60 Side Discharge Deck Decals XR7 on page 10 4 for listing of decals 108604 10 08 8 3 72 Side Discharge Deck Pulley Assembly XR7 26 N N 4274 Y BELT GUIDE INDEXING 108604 10 08 8 4 72 Side Discharge Deck Pulley Assembly 7 ITEM NO O Q WN ND NN N N BA un a BONA O o bk 26 27 28 29 30 Torque to 118 ft lbs Torque to 67 75 ft lbs SERVICE PART NO 784207 797910 601434 025007 347443 028118 781856 259812 781302 350884 107620 107621 016972 781385 797449 792002 016527 752386 538850 705954 767962 768523 058776 212472 796235X 798702 782474 769257 029934 783738 MFG PART NO 784207 797910 601434 025007 347443 028118 781856 059931 781302 350884 107620 107621 016972 781385 797449 792002 016527 752386 538850 705954 767962 768523 058776 212472 796235 798702 782474 769257 029934 783738 QTY bk ANN We A a ot N N O DESCRIPTION B SECTION BELT CS 312 18 X 1 50 FLT SH ZNYC UHMW IDLER SLIDE CS 625 11 X 1 75 HX G5 ZNYC DECK BELT IDLER GUIDE FW 62 X 1 00 X 134 ZN 5 00 IDLER PULLEY CHAIN DECK LIFT SPRING 13 LINKS IDLER SPRING DECK IDLER RS PULLEY
75. vers in the brake position before leaving machine 2 Park the unit on a flat surface 108604 10 08 12 27 3 Raise deck and place 3 25 block under the back of the deck and 4 block under the front of the deck FIG 33 This will set the cutting height at 3 1 2 NOTE Back of deck will automatically be set approximately 14 higher 4 Set cutting height at 3 1 2 in the height indicator by placing the height adjusting stop in the 3 1 2 hole and turning the height stop so that the pin side is against the stop handle FIG 34 5 Clamp the height adjusting stop against the stop handle FIG 34 This will assure that the height will not move during the setting process Otherwise spring pressure from the deck lift springs will tend to pull the stop away from the handle STOP HANDLE ca lt FIG 34 6 Loosen all nuts on the deck lift threaded rods and the hardware on the adjuster the right front until all the deck lift chains are loose and the deck is sitting tightly on all four blocks FIG 35 FIG 36 FIG 37 lt 3 HREADED ROD 12 28 108604 10 08 8 9 10 11 12 108604 10 08 HARDWARE FIG 37 Loosen the two nuts on the front of height indicator so that the foot pedal is free FIG 38 Start the leveling process on the left front of the tractor Set the amount of threads protruding on the deck lift rod from the lift block at approximately 1 FIG 39 Ja
76. y To do this gently and slowly move the control levers forward and feel if there is some resistance on the pump lever before the control levers hit the stops Check one side at a time If you sense that the pump arms are stopping the forward motion of the control arms loosen the jam nut on the adjustable stop of the 12 23 corresponding side and turn the stop set screw inward to stop the control levers slightly before the pump bottoms out Lock in place when the adjustment is correct by re tightening the jam nut 3 Do this for each side To adjust the stops for driving straight when control levers are against the stops during operation 1 Determine which drive tire is rotating too fast when both control levers are against the stops Then stop the tractor and loosen the lock nut on the side which is rotating too fast and turn the stop set screw inward to stop the control lever sooner Tighten the loek nut on the stop and test again Repeat this procedure until unit drives straight NOTE Since this is a hydrostatic drive variables such as temperature of oil efficiency of pumps and motors tire pressure etc may effect the con sistency of the ability to rely on the stops to drive straight without the operator making minor steering adjustments with the control arms STEERING DAMPENER The steering dampener FIG 24 is spring loaded to return the control levers to the neutral position from the reverse position This gives the operato

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