HUSTLER Honda Engine Z Parts Manual
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HUSTLER Honda Engine Z Parts Manual

HUSTLER Honda Engine Z Parts Manual

Hustler honda engine parts manual
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Hustler Z
Parts Manual
•••••••
Hustler Turf Equipment
•••••
P.O. Box 7000
•••
Hesston, Kansas
•
67062-2097

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  • Page 1 Hustler Z Parts Manual ••••••• Hustler Turf Equipment ••••• P.O. Box 7000 ••• Hesston, Kansas • 67062-2097...
  • Page 2 WARNING: The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. IMPORTANT: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate this engine on any forest-covered, brush-covered, or grass-covered unimproved land.

  • Page 3: Table Of Contents

    Chapter 1 General Information ........1-1 Chapter 2 Rivet Nut Installation .
  • Page 4 54" Rear Discharge Deck Assy—S/N 08010000—08100000 ..7-20 54" Rear Discharge Deck Assy–S/N Prior to 08010000..7-22 54" Rear Discharge Deck Pulley Assy—S/N 08100000 & Higher . 7-24 54" Rear Discharge Deck Pulley Assy—S/N Prior to 08100000 . . 7-26 Spindle Assembly–796235 .

  • Page 5: General Information

    General Information This Manual covers Hustler Z models 927723A/B, 927749A/B, 927756A/B, 927772A/B, 927798A/ B, 927806A/B, 927814A/B, 928432, 928853A/B, and 928861A/B, with serial numbers higher than 07020000. Frequently Ordered Parts PART NO. 027912 Lubrizol 7 oz. Bottle 027920 Lubrizol 10 oz. Bottle 768341 Hydraulic Oil Filter 781443...

  • Page 6: Options Available From Your Dealer

    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.

  • Page 7: Standard Torques

    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 .250...
  • Page 8 108602 10/08...

  • Page 9: Chapter 2 Contents

    Chapter 2 Contents Rivet Nut Installation ........2-2 Footrest Assembly .

  • Page 10: Rivet Nut Installation

    Rivet Nut Installation FOR KAWASAKI 26 HP LIQUID COOLED ONLY FOR ALL MOWERS EXCEPT 26 HP LIQUID COOLED SERVICE ITEM NO. PART NO. 548032 547760 547752 548545 808493 600961 808477 808477 547950 549303 1. Seat supports 547950 and 549303 include rivet nuts. 2.

  • Page 11: Footrest Assembly

    Footrest Assembly ITEM SERVICE PART NO. 359547 395533 305615 086660 767954 781880 052860 1. Do not tighten, Item 2 (348276 Floor) must be able to pivot on these bolts. 108602 10/08 MFG. DESCRIPTION PART NO. 359547 STEP TREAD 395533 FLOOR 305615 PLATFORM STEP TREAD 086660...
  • Page 12 108602 10/08...
  • Page 13 Chapter 3 Contents Hydraulic System Installation—S/N 07120009 and higher ..3-2 Hydraulic System Installation—S/N prior to 07120009 ... 3-6 108602 10/08...

  • Page 14: Hydraulic System Installation-S/N 07120009 And Higher

    Hydraulic System Installation—S/N 07120009 and higher FRONT 108602 10/08...
  • Page 15 Hydraulic System Installation—S/N 07120009 and higher ITEM SERVICE PART NO. 768515 055947 032771 032763 548636 034272 768523 601133 601134 041707 704742 600922 705186 768341 768333 767962 008573 781575 763946 601252 781591 779132 781542 781658 781526 781500 600915 781484 781476 781534 781518 763953 1.
  • Page 16 HYDRAULIC SYSTEM CHARGING PROCEDURE 1. Set handles in the neutral position. 2. Start engine at idle. 3. Let run for a minimum of 30 seconds. 4. Stroke handles to forward position. 5. If motors do not turn in 15 seconds return handles to neutral and repeat step 3 and 4 (one time).
  • Page 17 This page intentionally left blank. 108602 10/08...

  • Page 18: Hydraulic System Installation-S/N Prior To 07120009

    Hydraulic System Installation—S/N prior to 07120009 FRONT 108602 10/08...
  • Page 19 Hydraulic System Installation—S/N prior to 07120009 ITEM SERVICE PART NO. 768515 055947 032771 032763 548636 034272 768523 781062 781047 041707 704742 781054 705186 768341 768333 781575 763946 778985 781591 779132 781559 781542 781658 781526 781500 781492 781484 781476 781534 781518 763953 1.
  • Page 20 HYDRAULIC SYSTEM CHARGING PROCEDURE 1. Set handles in the neutral position. 2. Start engine at idle. 3. Let run for a minimum of 30 seconds. 4. Stroke handles to forward position. 5. If motors do not turn in 15 seconds return handles to neutral and repeat step 3 and 4 (one time).
  • Page 21 Chapter 4 Contents Battery Installation ........4-2 Deck Lift Assembly .

  • Page 22: Battery Installation

    Battery Installation TRACTOR FRAME 108602 10/08...
  • Page 23 Battery Installation ITEM SERVICE PART NO. 024927 771428 796219 744276 768523 058776 348417 055939 029868 740696 034272 779850 1. When performing service on mower, disconnect battery ground cable and do not reconnect to battery until engine is ready to be started. See Owners Manual.

  • Page 24: Deck Lift Assembly

    Deck Lift Assembly TRACTOR FRAME 108602 10/08...

  • Page 25: Deck Lift Assembly

    Deck Lift Assembly ITEM SERVICE PART NO. 348318 600437 783001 704643 781294 782995 781229 055749 348391 015495 034272 756270 348458 781831 1. Apply grease to zerks (see owner’s manual). 108602 10/08 MFG. DESCRIPTION PART NO. 348318 STOP HANDLE 600437 DECK HEIGHT 1/2" PIN W/A 783001 DECK LIFT INDICATOR SUBASSEMBLY 704643...

  • Page 26: Steering And Park Brake Assembly

    Steering and Park Brake Assembly SEE STEERING SUB-ASSEMBLY page 4-9 TRACTOR FRAME 108602 10/08...
  • Page 27 Steering and Park Brake Assembly ITEM SERVICE PART NO. 348987 781716 053199 055822 767954 768523 023655 781286 600221 781922 029876 367557 704163 768515 068551 782979 063198 781211 348797 036244 059832 034272 054502 101766 350272 005116 350397 350330 350264 765339 086660 600925 600924 781112...
  • Page 28 2. For units with serial number 07120009 and higher: Torque to 17 ft.-lbs. 3. For units with serial number 07120009 and higher: 600925 used on left wheel. 600924 used on right wheel. 4. For units with serial numbers prior to 07120009: Torque to 350-375 ft.- lbs.

  • Page 29: Steering Sub-Assembly

    Steering Sub-Assembly SERVICE ITEM NO. PART NO. 781260 348755 767954 036244 705178 023655 768523 348946 348888 348714 781153 781716 781583 086660 348862 1. Includes Item 1 (781260 Steering Bar Grip). 108602 10/08 MFG. PART QTY. STEERING BAR GRIP 348755 STEERING BAR 767954 FW .406 X .812 X .060 SAE HD ZN 036244...

  • Page 30: Pump Belt And Pulleys Installation

    Pump Belt and Pulleys Installation TRACTOR FRAME 4-10 108602 10/08...
  • Page 31 Pump Belt and Pulleys Installation ITEM SERVICE NO.ITE PART NO. M NO. 779876 212076 601311 783829 785659 083196 768127 768705 325308 008193 767962 016527 366765 784918 349761 015495 025296 061101 781856 028118 781872 601016 781443 791251 036236 768523 034272 797654 1.
  • Page 32 4-12 108602 10/08...
  • Page 33 Chapter 5 Contents Kawasaki Engine Installation (Remote Air Cleaner) ... . . 5-2 Kawasaki 25 HP Engine Installation (With HD Air Cleaner) ..5-6 Kawasaki 26 HP Engine Installation .

  • Page 34: Kawasaki Engine Installation (Remote Air Cleaner)

    Kawasaki Engine Installation (Remote Air Cleaner) TO ENGINE PART OF SENSOR ENGINE YELLOW TO SPADE TERMINAL TO BULLET TERMINALS RED/BLK 13 14 POSITIVE BATTERY CABLE TRACTOR FRAME STARTER SOLENOID GROUND NEGATIVE BATTERY CABLE PART OF COMMON WIRE HARNESS 108602 10/08...
  • Page 35 Kawasaki Engine Installation (Remote Air Cleaner) ITEM SERVICE PART NO. 777656 782318 058776 768523 029876 792762 768515 024927 799312 799320 044255 030817 055947 792192 771428 050161 786673 057661 788943 785741 034272 601216 782763 366443 036236 786038 796524 350371 349704 767962 016527 064006 781732...
  • Page 36 1. Includes mounting hardware. 2. Part of Item 8 (799312 Wire Harness Adapter). 3. Engine oil capacity: Refer to engine owner’s manual. 4. Engine RPM to be set at 3600± 50. 5. Includes one (1) of Item 17 (057661 Hose Clamp). 6.
  • Page 37 This page intentionally left blank. 108602 10/08...

  • Page 38: Kawasaki 25 Hp Engine Installation (With Hd Air Cleaner)

    Kawasaki 25 HP Engine Installation (With HD Air Cleaner) TO ENGINE SENSOR YELLOW PART OF ENGINE STARTER SOLENOID GROUND RED/BLK PURPLE 30 24 TO SPADE TERMINAL TO BULLET TERMINALS PART OF COMMON WIRE HARNESS 108602 10/08...
  • Page 39 Kawasaki Engine Installation (With HD Air Cleaner) ITEM SERVICE PART NO. 601119 601257 788943 058776 768523 050161 796524 350371 349704‘ 064006 767962 016527 780841 781732 360693 017004 782664 782649 781724 720177 029876 796219 024927 768515 792762 799320 799312 044255 030817 055947 792192 744276...

  • Page 40: Kawasaki 26 Hp Engine Installation

    Kawasaki 26 HP Engine Installation POSITIVE BATTERY CABLE NEGATIVE BATTERY CABLE 27 28 PART OF ENGINE PART OF WIRE HARNESS KAWASAKI ENGINE SCREEN PART OF ENGINE 108602 10/08...
  • Page 41 Kawasaki 26 HP Engine Installation ITEM SERVICE PART NO. 795617 796748 780841 017004 782664 796755 785378 767962 016527 008193 064329 073866 104133 010470 035626 030437 024927 033035 033035 796524 109566 055939 768515 768523 028035 109717 029876 720516 017004 077545 799338 1.

  • Page 42: Kawasaki 29 Hp Engine Installation (With Hd Air Cleaner)

    Kawasaki 29 HP Engine Installation (With HD Air Cleaner) YEL/BLK TO SPADE TERMINAL ON RECT. NEGATIVE BATTERY CABLE 5-10 PART OF COMMON WIRE HARNESS BULLET CONNECTORS RED/BLK TO SPADE TERMINAL ON STARTER POSITIVE BATTERY CABLE (2 WIRES) 108602 10/08...
  • Page 43 Kawasaki 29 HP Engine Installation (With HD Air Cleaner) ITEM SERVICE PART NO. 601548 109743 720516 788018 785378 601550 780841 017004 782664 029751 705137 016899 796524 034272 768523 109749 338475 337394 016253 767962 016527 036244 377994 601257 788943 029876 799320 601561 789131 1.

  • Page 44: Honda Engine Installation

    Honda Engine Installation PART OF ENGINE NEGATIVE BATTERY CABLE RED/BLK PART OF COMMON WIRE HARNESS TRACTOR FRAME GRA/PUR POSITIVE BATTERY CABLE 5-12 108602 10/08...
  • Page 45 Honda Engine Installation ITEM SERVICE PART NO. 785014 058776 768523 799320 029876 077545 017004 799304 050161 786673 057661 785741 034272 782763 366443 036236 785675 787689 787713 382168 377994 365742 767962 016527 017038 024927 785477 768515 056077 784843 720177 785378 785543 782664 784959 789131...
  • Page 46 7. Supplied with engine. 8. When installing lower hose clamp on air cleaner hose, install as low as possible (against carburetor inlet). 9. This connector used for optional electrical equipment. 10. Air filter service parts: 785261 763318 MAIN AIR FILTER ELEMENT VACUATOR VALVE 5-14 108602 10/08...
  • Page 47 This page intentionally left blank. 108602 10/08 5-15...

  • Page 48: Kohler Engine Installation

    Kohler Engine Installation POSITIVE BATTERY CABLE PUR (P/O ENGINE) RED/BLK TRACTOR FRAME NEGATIVE BATTERY CABLE PART OF COMMON WIRE HARNESS 5-16 108602 10/08...
  • Page 49 Kohler Engine Installation ITEM SERVICE PART NO. PART NO. 788216 788216 799320 799320 058776 058776 768523 768523 029876 029876 050161 050161 786673 786673 057661 057661 788943 788943 601216 601216 782763 782763 785741 785741 034272 034272 366443 366443 036236 036236 795310 795310 796672 796672...

  • Page 50: Fuel System Installation (Air Cooled Engines)

    Fuel System Installation (Air Cooled Engines) 5-18 108602 10/08...
  • Page 51 Fuel System Installation (Air Cooled Engines) ITEM SERVICE PART NO. 779306 793240 793232 000323 106732 055822 712919 036244 767954 797035 797084 347989 705954 767962 015818 015818 015818 015818 015818 000331 1. Torque to 20 ft.-lbs. 2. Fuel tank service part not shown: 108602 10/08 MFG.

  • Page 52: Fuel System Installation (Liquid Cooled Engines)

    Fuel System Installation (Liquid Cooled Engines) 5-20 108602 10/08...
  • Page 53 Fuel System Installation (Liquid Cooled Engines) ITEM SERVICE PART NO. 779306 793240 793232 109678 055822 712919 000323 068478 797035 797084 036244 347989 705954 767962 015818 015818 015818 015818 045088 000331 1. Torque to 20 ft.-lbs. 2. Fuel tank service part not shown: 108602 10/08 MFG.

  • Page 54: Instrument Panel Assembly (Air Cooled)

    Instrument Panel Assembly (Air Cooled) RELAYS FUSE SIZE AND LOCATION RIGHT SIDE FUEL TANK 5-22 RELAY ASSEMBLY WIRE HARNESS 108602 10/08...
  • Page 55 Instrument Panel Assembly (Air Cooled) ITEM SERVICE PART NO. 776476 785808 045898 785030 786657 712257 000430 704932 714998 601098 059832 769166 778365 601675 055947 768515 106633 601053 107920 601089 762195 1. Part of 799320 (Common Wire Harness) 108602 10/08 MFG. DESCRIPTION PART NO.

  • Page 56: Instrument Panel Assembly (Liquid Cooled)

    Instrument Panel Assembly (Liquid Cooled) RELAYS FUSE SIZE AND LOCATION RIGHT SIDE FUEL TANK 5-24 RELAY ASSEMBLY WIRE HARNESS 108602 10/08...
  • Page 57 Instrument Panel Assembly (Liquid Cooled) ITEM SERVICE PART NO. 776476 785808 045898 785030 712257 601098 704932 059832 769166 794347 601089 000430 787788 714998 601053 107920 055947 768515 106633 762195 1. Fuses are part of the wiring harness 108602 10/08 MFG. DESCRIPTION PART NO.

  • Page 58: Electrical Schematic (799320)

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

  • Page 59: Electrical Schematic-Kawasaki Lc (799338)

    Electrical Schematic—Kawasaki LC (799338) 108602 10/08 5-27...
  • Page 60 5-28 108602 10/08...
  • Page 61 Chapter 6 Contents Front Wheel Assembly........6-2 Front Wheel Breakdown—747782.

  • Page 62: Front Wheel Assembly

    Front Wheel Assembly TRACTOR FRAME 108602 10/08...
  • Page 63 Front Wheel Assembly ITEM SERVICE PART NO. 705954 344267 712976 784223 387035 045765 349266 041475 025296 061101 747782 789537 1. Apply grease to zerks. 2. Torque to 100 ft.-lbs. 3. Assemble with extended inner race toward item 5 (387035 Spacer, 1.07 x 1.312 x 2.793).

  • Page 64: Front Wheel Breakdown-747782

    Front Wheel Breakdown—747782 ITEM SERVICE PART NO. 039677 747741 747832 782771 019521 015511 1. Inflate tire to 8-12 psi. MFG. DESCRIPTION PART NO. WHEEL BEARING 13 X 6.50 TIRE 6 X 4.5 WHEEL BEARING SPACER TIRE VALVE GREASE FITTING 45 DEG 1/4 NOTES: 108602 10/08...

  • Page 65: Optional Semi-Pneumatic Tire/Wheel-789537

    Optional Semi-Pneumatic Tire/Wheel—789537 ITEM SERVICE PART NO. 039677 789537 015511 782771 108602 10/08 MFG. DESCRIPTION PART NO. WHEEL BEARING TIRE/WHEEL ASSEMBLY GREASE FITTING 45 DEG 1/4 BEARING SPACER NOTES:...

  • Page 66: Drive Wheel Assembly Installation

    Drive Wheel Assembly Installation ITEM SERVICE PART NO. 784058 781245 784066 019521 061077 770859 601238 781245 796250 019521 061077 770859 782078 782284 782086 019521 061077 770859 1. Torque to 65-75 ft. lbs. 2. Inflate tire to 8-12 psi. 3. For mowers with serial numbers prior to 07120009, use 781237 for the wheel and tire assembly, and 781252 for the wheel assembly.

  • Page 67: Anti-Rollover Wheel Assembly

    Anti-Rollover Wheel Assembly TRACTOR FRAME ITEM SERVICE PART NO. 068239 031997 767962 781567 1. Do not torque, wheel must turn freely. 108602 10/08 MFG. DESCRIPTION PART NO. 068239 CS .500-13 X 4.500 HX G5 ZN 031997 ANTI-SCALP WHEEL 767962 FW .531 X 1.063 X .090 SAE HD ZN 781567 NT .50-13 HX LK NY NOTES:...
  • Page 68 108602 10/08...
  • Page 69 Chapter 7 Contents 66" Side Discharge XR7 Deck Assembly ..... 7-2 66" Side Discharge XR7 Deck Pulley Assembly ....7-4 60"...

  • Page 70: 66" Side Discharge Xr7 Deck Assembly

    66" Side Discharge XR7 Deck Assembly 108602 10/08...
  • Page 71 66" Side Discharge XR7 Deck Assembly ITEM SERVICE PART NO. 548446 798694 052860 767954 086660 103010 781708 767962 031997 053199 781567 808485 314104 015495 025395 808493 788166 1. Do not torque, Item 2 (798694 Discharge Chute) must pivot freely. 2. Includes items 7, 8, 9, and 10. 3.

  • Page 72: 66" Side Discharge Xr7 Deck Pulley Assembly

    66" Side Discharge XR7 Deck Pulley Assembly 66" DECK ASSY BELT GUIDE INDEXING 108602 10/08...
  • Page 73 66" Side Discharge XR7 Deck Pulley Assembly ITEM SERVICE PART NO. 797936 797910 601434 025007 347443 028118 781856 373191 781302 350884 103721 103739 016972 781385 797449 792002 016527 752386 798975 705954 767962 768523 058776 212472 796235X 798496 769257 782474 029934 783738 1.

  • Page 74: 60" Side Discharge Xr7 Deck Assembly

    60" Side Discharge XR7 Deck Assembly 108602 10/08...
  • Page 75 60" Side Discharge XR7 Deck Assembly SERVICE ITEM NO. PART NO. 548438 798694 052860 767954 086660 103010 781708 767962 031997 053199 781567 808485 103184 005116 314104 015495 808493 025395 788166 1. Do not torque, Item 2 (798694 Discharge Chute) must pivot freely. 2.

  • Page 76: 60" Side Discharge Xr7 Deck Pulley Assembly

    60" Side Discharge XR7 Deck Pulley Assembly 60" DECK ASSY BELT GUIDE INDEXING 108602 10/08...
  • Page 77 60" Side Discharge XR7 Deck Pulley Assembly ITEM SERVICE PART NO. 797720 797910 601434 025007 347443 028118 781856 373191 781302 350884 103192 103200 016972 781385 797449 792002 016527 752386 770842 705954 767962 768523 058776 212472 796235X 794685 782474 769257 029934 783738 1.

  • Page 78: 54" Side Discharge Xr7 Deck Assembly

    54" Side Discharge XR7 Deck Assembly 7-10 108602 10/08...
  • Page 79 54" Side Discharge XR7 Deck Assembly SERVICE ITEM NO. PART NO. 548420 798694 052860 767954 086660 025395 103010 808485 781708 767962 053199 781567 031997 015495 314104 005116 103184 808493 788166 1. Do not torque, Item 2 (798694 Discharge Chute) must pivot freely. 2.

  • Page 80: 54" Side Discharge Xr7 Deck Pulley Assembly

    54" Side Discharge XR7 Deck Pulley Assembly 54" DECK ASSY BELT GUIDE POSITIONING 7-12 108602 10/08...
  • Page 81 54" Side Discharge XR7 Deck Pulley Assembly ITEM SERVICE PART NO. 797928 016972 025007 028118 781385 797449 797910 601434 347443 781856 350884 373191 781302 103986 103994 016527 752386 798967 705954 767962 212472 796235X 797696 782474 768523 058776 783738 769257 029934 792002 1.

  • Page 82: Side Discharge Deck-"A" Adaptors

    Side Discharge Deck—"A" Adaptors Deck Assembly 7-14 108602 10/08...
  • Page 83 Side Discharge Deck—"A" Adaptors SERVICE ITEM NO. PART NO. 108531 108516 108619 025395 767954 086660 108602 10/08 MFG. QTY. DESCRIPTION PART NO. 108531 AIR FLOW FLOOR (66" DECKS) 108516 AIR FLOW FLOOR (60" DECKS) 108619 AIR FLOW FLOOR (54" DECKS) 025395 CB .375-16X 1.00 STD CD 767954...

  • Page 84: Side Discharge Deck-"B" Adaptors

    Side Discharge Deck—"B" Adaptors Deck Assembly Assembled Detail 7-16 108602 10/08...
  • Page 85 Side Discharge Deck—"B" Adaptors SERVICE ITEM NO. PART NO. 108533 108518 108621 108532 108517 108620 108221 108212 108254 025395 767954 086660 029751 1. Service part includes rivet nuts. 108602 10/08 MFG. QTY. DESCRIPTION PART NO. 108533 AIR FLOW BAFFLE, "B" RIGHT SIDE (66" DECKS) 108518 AIR FLOW BAFFLE, "B"...

  • Page 86: 54" Rear Discharge Deck Assy-S/N 08100000 & Higher

    54" Rear Discharge Deck Assy—S/N 08100000 & Higher DEFLECTOR DETAIL 7-18 27 3 108602 10/08...
  • Page 87 54" Rear Discharge Deck Assy—S/N 08100000 & Higher ITEM SERVICE PART NO. 549733 109490 768523 086660 767954 710194 601069 015495 349803 036244 107975 781708 767962 053199 781567 031997 109486 109487 601483 107972 601017 107973 109482 109483 778399 016253 058776 107978 037887 109491 600994...

  • Page 88: 54" Rear Discharge Deck Assy-S/N 08010000-08100000

    54" Rear Discharge Deck Assy—S/N 08010000—08100000 DEFLECTOR DETAIL 7-20 108602 10/08...
  • Page 89 54" Rear Discharge Deck Assy—S/N 08010000—08100000 ITEM SERVICE PART NO. 548644 109490 768523 086660 767954 710194 601069 015495 349803 036244 107975 781708 767962 053199 781567 031997 109486 109487 601483 107972 601017 107973 109482 109483 778399 016253 058776 107978 037887 109491 600994 788166 1.

  • Page 90: 54" Rear Discharge Deck Assy-S/N Prior To 08010000

    54" Rear Discharge Deck Assy–S/N Prior to 08010000 7-22 DEFLECTOR DETAIL 108602 10/08...
  • Page 91 54" Rear Discharge Deck Assy–S/N Prior to 08010000 ITEM SERVICE PART NO. 548644 108066 768523 086660 767954 025395 601069 015495 349803 036244 107975 781708 767962 053199 781567 031997 106724 106666 601113 107972 601017 107973 106591 778399 016253 058776 107978 600994 788166 1.

  • Page 92: 54" Rear Discharge Deck Pulley Assy-S/N 08100000 & Higher

    54" Rear Discharge Deck Pulley Assy—S/N 08100000 & Higher 7-24 108602 10/08...
  • Page 93 54" Rear Discharge Deck Pulley Assy—S/N 08100000 & Higher ITEM SERVICE PART NO. 601015 110449 110448 794446 028118 796714 600296 109948 781567 767962 770867 109549 781302 259812 704759 601779 797910 016972 016527 752386 798967 792002 782474 783738 796680X 796235X 212472 601013 601012 796722...

  • Page 94: 54" Rear Discharge Deck Pulley Assy-S/N Prior To 08100000

    54" Rear Discharge Deck Pulley Assy—S/N Prior to 08100000 7-26 108602 10/08...
  • Page 95 54" Rear Discharge Deck Pulley Assy—S/N Prior to 08100000 ITEM SERVICE PART NO. 601015 107945 107946 016972 028118 794446 796714 781302 373191 797910 601434 350884 792002 016527 752386 798967 767962 796235X 796680X 212472 601012 601013 782474 029934 768523 058776 783738 796722 1.

  • Page 96: Spindle Assembly-796235

    Spindle Assembly–796235 ITEM SERVICE PART NO. 077123 766204 034843 012005 600893 796227 1. Install upper bearing with extended inner race up. 2. Install lower bearing with extended inner race down. 3. Apply grease to zerk. MFG. QTY. DESCRIPTION PART NO. BEARING W/O COLLAR BLADE SPINDLE BUSHING CAST SPINDLE HOUSING...

  • Page 97: Spindle Assembly-796680

    Spindle Assembly–796680 ITEM SERVICE PART NO. 077123 766204 034843 012005 600893 796698 1. Install upper bearing with extended inner race up. 2. Install lower bearing with extended inner race down. 3. Apply grease to zerk. 108602 10/08 MFG. QTY. DESCRIPTION PART NO.
  • Page 98 7-30 108602 10/08...
  • Page 99 Chapter 8 Contents Deck Installation ........8-2 66"...

  • Page 100: Deck Installation

    Deck Installation TRACTOR ASSEMBLY DECK ASSEMBLY 108602 10/08...
  • Page 101 Deck Installation ITEM SERVICE PART NO. 055749 061101 025296 051169 704643 1. 66" Deck installation is shown, 60" and 54" Side Discharge Decks, and 54" Rear Discharge Decks are similar. 108602 10/08 MFG. DESCRIPTION PART NO. 055749 CS .437-14 X 1.750 HX G5 ZN 061101 NT .750-10 HX NL ZN 025296...

  • Page 102: 66" & 54" Side Discharge Deck Belt Routing And Tensioning

    66" & 54" Side Discharge Deck Belt Routing and Tensioning 1. Spring length after tensioning belt. Measure spring from outside of hook to outside of hook. 2. Route belt as shown. DECK ASSEMBLY NOTES: 108602 10/08...

  • Page 103: 60" Side Discharge Deck Belt Routing And Tensioning

    60" Side Discharge Deck Belt Routing and Tensioning 1. Spring length after tensioning belt. Measure spring from outside of hook to outside of hook. 2. Route belt as shown. 108602 10/08 DECK ASSEMBLY NOTES:...

  • Page 104: 54" Rear Discharge Deck Belt Routing And Tensioning

    54" Rear Discharge Deck Belt Routing and Tensioning 1. Spring length after tensioning belt. Measure spring from outside of hook to outside of hook. 2. Route belt as shown. DECK ASSEMBLY NOTES: 108602 10/08...
  • Page 105 This page intentionally left blank. 108602 10/08...

  • Page 106: Seat Installation-S/N 08010000 & Higher

    Seat Installation—S/N 08010000 & Higher LATCH W/A DETAIL 108602 10/08...
  • Page 107 Seat Installation—S/N 08010000 & Higher ITEM SERVICES PART NO. 793661 109307 000331 086660 767954 724716 350421 036244 052860 768523 034272 781880 080358 109274 109283 781617 722199 794610 601444 754101 017129 704635 783910 108851 034280 1. Must pivot freely. 2. Part of seat. 3.

  • Page 108: Seat Installation-S/N Prior To 08010000

    Seat Installation—S/N Prior to 08010000 8-10 108602 10/08...
  • Page 109 Seat Installation—S/N Prior to 08010000 ITEM SERVICES PART NO. 793661 350041 000331 086660 767954 724716 350421 036244 052860 768523 034272 781880 080358 748756 350462 781617 722199 1. Must pivot freely. 2. Service parts available for Michigan Standard seat; PART NO. 793307 793315 793331...

  • Page 110: Rops Installation

    ROPS Installation 8-12 108602 10/08...
  • Page 111 ROPS Installation ITEM SERVICES PART NO. 601440 601471 601470 601560 061812 601472 023317 077859 767962 601473 349704 3. ROPS come standard on all Hustler Z units with serial numbers 08010000 and higher. Prior to this serial number, ROPS were optional for Hustler Z mowers.
  • Page 112 8-14 108602 10/08...
  • Page 113 Chapter 9 Contents Tractor Decals ......... . 9-2 66"...

  • Page 114: Tractor Decals

    Tractor Decals VIEW B-B TOP OF SEAT PAN BOTTOM OF SEAT PAN 108602 10/08...
  • Page 115 Tractor Decals ITEM SERVICE PART NO. 781427 779280 784702 789503 727008 791830 782136 788968 785188 782128 727016 771436 727172 782573 793588 786426 600899 600941 1. Location for item 7 (788968-Engine Compartment Decal) for mowers with HD air cleaners only. 2. Location for item 7 (788968-Engine Compartment Decal) for all mowers except those with HD air cleaners.

  • Page 116: 66" Side Discharge Xr7 Deck Decals

    66" Side Discharge XR7 Deck Decals ITEM SERVICE PART NO. 799189 760637 727420 727172 727453 727438 781419 799353 359547 797845 MFG. QTY. DESCRIPTION PART NO. 799189 66" SIDE DISCHARGE DECK ID DECAL 760637 MOWER DECK QUICK REFERENCE DECAL 727420 DEFLECTOR SHIELD DECAL 727172 "MADE IN U.S.A."...

  • Page 117: 60" Side Discharge Xr7 Deck Decals

    60" Side Discharge XR7 Deck Decals ITEM SERVICE PART NO. 786277 760637 727420 727172 727453 727438 799395 799353 359547 797845 108602 10/08 MFG. QTY. DESCRIPTION PART NO. 786277 60" SIDE DISCHARGE DECK ID DECAL 760637 MOWER DECK QUICK REFERENCE DECAL 727420 DEFLECTOR SHIELD DECAL 727172...

  • Page 118: 54" Side Discharge Xr7 Deck Decals

    54" Side Discharge XR7 Deck Decals ITEM SERVICE PART NO. 799171 760637 727420 727172 727453 727438 781419 799353 359547 797845 MFG. QTY. DESCRIPTION PART NO. 799171 54" SIDE DISCHARGE DECK ID DECAL 760637 MOWER DECK QUICK REFERENCE DECAL 727420 DEFLECTOR SHIELD DECAL 727172 "MADE IN U.S.A."...

  • Page 119: 54" Rear Discharge Deck Decals

    54" Rear Discharge Deck Decals ITEM SERVICE PART NO. 799171 760637 727438 727453 727172 796953 794503 797845 108602 10/08 MFG. QTY. PART NO. 799171 54" REAR DISCHARGE DECK ID DECAL 760637 DECAL MOWER DECK QUICK REFERENCE 727438 DECAL WHIRLING BLADES 727453 DECAL BELT &...
  • Page 120 108602 10/08...
  • Page 121 Chapter 10 Contents Assembly Pictures and Aids ......10-3 General information for all models: ....10-3 Hustler Z’s with Kawasaki engines: .
  • Page 122 Recommended service procedure ....10-29 Air restriction indicator ......10-29 General engine maintenance .

  • Page 123: Assembly Pictures And Aids

    Assembly Pictures and Aids General information for all models: PTO clutch wire routing "FIG. 1". PTO clutch switch installation (Instrument Panel) "FIG. 2" & "FIG. 3". PTO SWITCH FIG. 2 TIE STRAP CLUTCH PIGTAIL WIRE FIG. 1 TIE STRAP 10-3 FIG.

  • Page 124: Hustler Z's With Kawasaki Engines

    Hustler Z’s with Kawasaki engines: Does not include machines with 29 HP or 26 HP engines. Throttle cable routing "FIG. 4". HYDRAULIC RESERVOIR Choke cable routing, front and rear tie straps "FIG. 5" & "FIG. 6". POS. & NEG. BATTERY CABLES TIE STRAP CHOKE...
  • Page 125 Fuel line routing "FIG. 7" & "FIG. 8". NEG. BATTERY CABLE TIE STRAP FUEL LINE LEFT FUEL TANK RIGHT FUEL TANK TO ENGINE THROTTLE CABLE TIE STRAP WIRE HARNESS POS. BATTERY TIE STRAP CABLE FIG. 7 WIRE HARNESS FIG. 8 10-5 FUEL LINE...

  • Page 126: Hustler Zs With Kawasaki 29 Hp Engines

    Hustler Zs with Kawasaki 29 HP engines: Routings "FIG. 9". WIRE HARNESS TIE STRAP NEGATIVE BATTERY CABLE Route fuel lines, battery cables, and choke and throttle cables and tie as shown, "FIG. 10". Tie fuel lines to seat support as shown in "FIG. 11" (right side shown, left side similar). TIE STRAP POS.

  • Page 127: Hustler Z's With Kawasaki 26 Hp Engines

    Choke and throttle cable connections to engine, see "FIG. 13". CHOKE CABLE CABLE CLAMP THROTTLE CABLE FIG. 13 THROTTLE AND CHOKE CABLE INSTALLATION TO ENGINE (SEE "FIG. 13" & "FIG. 14"). 1. Clamp Instrument Panel to side of seat support in installed orientation 2.

  • Page 128: Hustler Z's With Honda Engines

    Throttle and choke cable connections to engine: "FIG. 17" and "FIG. 18". THROTTLE CABLE FIG. 17 Hustler Z’s with Honda engines: Choke/Throttle cable routing "FIG. 19". Tie throttle and choke cables to hydro hose as shown.Fuel line routing "FIG. 20" & "FIG. 21". TIE STRAP WIRE HARNESS...
  • Page 129 FUEL VALVE LEFT FUEL LINE RIGHT TO ENGINE FUEL LINE FIG. 20 Choke/Throttle cable routing "FIG. 22". Tie choke and throttle cables together. WIRE HARNESS CHOKE AND THROTTLE CABLE STRAP LEFT PUMP FIG. 22 10-9 WIRE TIE STRAP HARNESS FUEL LINE FIG.

  • Page 130: Hustler Z's With Kohler Engines

    Honda carburetor drain/vent hose routing "FIG. 23". Hustler Z’s with Kohler engines: Wire harness and cable routing "FIG. 24", "FIG. 25", and "FIG. 26". TO CLUTCH VENT/DRAIN HOSES FIG. 23 POSITIVE BATTERY CABLE NEGATIVE BATTERY CABLE FIG. 24 10-10 108602 10/08...
  • Page 131 TIE STRAP WIRE HARNESS BATTERY CABLES FUEL LINES & WIRE HARNESS FIG. 25 Choke and throttle cable routing "FIG. 27". CHOKE CABLE WIRE HARNESS NEGATIVE BATTERY CABLE FIG. 26 TIE STRAP ROUTE THROTTLE CABLE BELOW HYDRAULIC HOSE FIG. 27 10-11 TIE STRAP 108602 10/08...
  • Page 132 Fuel line routing "FIG. 28". FUEL LINE TIE STRAP FIG. 28 10-12 108602 10/08...

  • Page 133: Maintenance & Adjustment Safety

    Maintenance & Adjustment Safety This safety alert symbol is used to call attention to a message intended to provide a reasonable degree of PERSONAL SAFETY for operators and other persons during the normal operation and servicing of this equipment. DANGER – denotes immediate hazards which WILL result in severe personal injury or death. WARNING –...

  • Page 134: Safe Maintenance & Adjustment Practices

    Safe Maintenance & 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.

  • Page 135: Using A Ramp

    off and remove ignition switch key for maximum safety. Repairs or maintenance requiring engine power should be performed by trained personnel only. ▲ Use a stick or similar instrument to clean under the mower making sure that no part of the body, especially arms and hands are under mower.

  • Page 136: Safety And Instruction Decals

    Safety and Instruction Decals ▲ Specific safety warning decals are located on the equipment near the immediate areas of potential hazards. These decals should not be removed or obliterated. Replace them if they become 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.
  • Page 137 Do not remove or modify stabilizer wheels or rear engine guard or injury can result. Part Number 771436 Keep engine and pump compart-ment(s) clean (especially in exhaust area) to prevent fire and provide Part Number 788968 maximum engine and hydraulic cooling.

  • Page 138: Maintenance

    Maintenance Locator Chart 1a. Engine Oil Fill & Dipstick (Kawasaki & Honda) 1b. Engine Oil Fill & Dipstick (Kohler) 2a. Fuel Filter (Honda & Kawasaki) 2b. Fuel Filter (Kohler) 3. Engine Air Cleaner 4. Engine Oil Drain Plug 5. Battery 6.
  • Page 139 Maintenance Locator Chart 54" & 66" XR7 deck 60" XR7 deck 1. Deck Pusher Arm Zerks (2) 2. Deck Belt 3. Spindle Housing Zerk (3) 4. Blades 54" Rear Discharge deck FIG. 30 10-19 108602 10/08...
  • Page 140 SERVICE AT INTERVALS INDICATED Verify safety start interlock system Visually inspect unit for loose hardware and/or damaged parts Visually inspect tires Check oil level, engine (1) Clean air intake screen (5) Check fuel level Blades - sharpen & securely fastened Discharge chute - securely in place &...

  • Page 141: Torque Values

    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.

  • Page 142: Hour Meter

    Drive wheels ...8-12 psi (55-69 KPa) Gauge wheels...8-12 psi (55-69 KPa) Solid fill tires are not recommended for Hustler turf equipment. On any machine, with solid filled tires, the warranty claim will be denied. WARNING: Explosive separation of a tire and rim can cause serious injury or death.

  • Page 143: Electrical System

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

  • Page 144: Access To Engine And Hydraulic Pumps

    WARNING: Incorrect battery cable routing could cause damage to the tractor and battery cables. This can cause sparks which can cause a battery gas explosion which will result in personal injury. Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. Always connect the positive (red) battery cable before connecting the negative (black) cable.
  • Page 145 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 20W50 SG, SF/CC, CD service motor oil. Change hydraulic system filter element ("FIG.

  • Page 146: Fuel System

    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.

  • Page 147: Engine Oil And Filter

    The fuel filter ("FIG. 36") 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 any cracks or leaks.

  • Page 148: Engine Air Filter

    Engine air filter Perform engine air filter maintenance per the scheduled maintenance chart. See “SERVICE AT INTERVALS INDICATED” on page 10-20. A specially designed dry filter is standard equipment on the Hustler Z and Super Z tractors and supplies clean combustion air to the engine "FIG. 39". ENGINE AIR FILTER RECOMMENDED SERVICE PROCEDURE...

  • Page 149: Improper Installation Of An Air Filter Element

    (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 specified is a Donaldson filter, Hustler part number 785261.

  • Page 150: General Engine Maintenance

    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.

  • Page 151: Mower Blade Maintenance

    Deck Belt Drive Layout 1. Spindle drive belt 2. Deck blade spindle pulley 3. Spindle belt tension idler 4. Spindle belt tension idler spring (9.0" at operation) 5. Deck belt idler 6. Idler arm FIG. 43 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.
  • Page 152 Sharpen the blades on a grinder following pattern as shown "FIG. 45". Touch-up sharpening can be done with a file. Check the blades for balance following grinding. A commercial balancing tool is available through most hardware supply stores, or balancing can be done by placing the blade on an inverted line punch or 1/2" bolt.
  • Page 153 This page intentionally left blank. 10-33 108602 10/08...

  • Page 154: Adjustment

    Introduction Your Hustler Z 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.

  • Page 155: Control Lever Stops

    JAM NUT PUMP LINKAGE FIG. 49 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.

  • Page 156: Steering Dampener

    pump arms are stopping the forward motion of the control arms, loosen the jam nut on the adjustable stop of the 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.
  • Page 157 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. WARNING: Never work under the machine or attachment unless it is safely supported with jack stands.

  • Page 158: Hydraulic Pump Belt Adjustment

    CONTROL LEVER PARK BRAKE SLOT 1/8" OUTSIDE EDGE FIG. 55 8. Rotate the tire and at the same time rotate the turnbuckle to shorten the length of the brake linkage to increase the brake pressure. When you feel the brake begin to engage, stop adjusting the turnbuckle.

  • Page 159: Deck Drive Belt Adjustment

    Deck drive belt adjustment The spindle belt tension remains constant by means of a tension idler and spring "FIG. 58". The spring tension should be such that the belt does not slip under normal operating load conditions, assuming the belt is not excessively worn or damaged. As belt stretches and wears in, adjustment may become necessary.
  • Page 160 Drive wheels tire pressure ...8 - 12 psi Gauge wheels tire pressure...8 - 12 psi WARNING: Stop engine. Make sure deck clutch switch is in the down (OFF) position. Place control levers in the brake position before leaving machine. 2. Park the unit on a flat surface. 3.
  • Page 161 ADJUSTER HARDWARE 7. Loosen the two nuts on the front of height indicator so that the foot pedal is free "FIG. 65". 8. Start the leveling process on the left front of the tractor. 9. Set the amount of threads protruding on the deck lift rod from the lift block at approximately 1"...
  • Page 162 height indicator. FOOT PEDAL LIFT BLOCK 1" 1" DECK LIFT ROD NUTS FIG. 65 FIG. 66 10-42 108602 10/08...

  • Page 163: Numerical Index

    Numerical Index Part Page Index Part Numbers 000323 5-19 5-21 000331 5-19 5-21 8-11 000430 5-23 5-25 005116 7-11 008193 4-11 008573 010470 012005 7-28 7-29 015495 4-11 7-11 7-19 7-21 7-23 015511 015818 5-19 5-21 016253 5-11 7-19 7-21 7-23 016527 4-11...
  • Page 164 Part Page 108533 7-17 108536 108549 108550 108551 108554 108555 108556 108559 108560 108561 108563 108565 108607 7-11 108619 7-15 108620 7-17 108621 7-17 108851 109274 109283 109307 109482 7-19 7-21 109483 7-19 7-21 109486 7-19 7-21 109487 7-19 7-21 109490 7-19 7-21...
  • Page 165 Part Page 705178 705186 705954 5-19 5-21 7-13 710194 7-19 7-21 712257 5-23 5-25 712919 5-19 5-21 712976 714998 5-23 5-25 720177 5-13 720516 5-11 722199 8-11 724716 8-11 727008 727016 727172 727420 727438 727453 727756 740696 742684 744276 747303 747741 747782 747832...
  • Page 166 Part Page 785030 5-23 5-25 785188 785261 5-14 5-17 785279 785378 5-11 5-13 5-17 785477 5-13 785543 5-13 785634 785642 785659 4-11 785675 5-13 785741 5-13 5-17 785808 5-23 5-25 786038 786277 786335 7-13 7-27 786426 786657 5-23 786673 5-13 5-17 787366 4-11...

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