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HUSTLER Honda Engine Z Parts Manual Download Page 6

1-2

108602 10/08

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.

Options Available From Your Dealer

Hardware Description Codes & Abbreviations

The following codes are used throughout this parts manual. Refer to this list when ordering parts.

PART NO.

DESCRIPTION

108556

"A" Baffles Kit XR7 (66" Side Discharge Deck)

108555

"A" Baffles Kit XR7 (60" Side Discharge Deck)

108554

"A" Baffles Kit XR7 (54" Side Discharge Deck)

108551

"B" Baffles Kit XR7 (66" Side Discharge Deck)

108550

"B" Baffles Kit XR7 (60" Side Discharge Deck)

108549

"B" Baffles Kit XR7 (54" Side Discharge Deck)

108561

Containment Baffles Kit (66" Side Discharge Deck)

108560

Containment Baffles Kit (60" Side Discharge Deck)

108559

Containment Baffles Kit (54" Side Discharge Deck)

108565

Mulch Kit (66" Side Discharge Deck)

108563

Mulch Kit (54/60" Side Discharge Deck)

106880

Stripe Kit (66" Side Discharge Deck)

107359

Stripe Kit (54/60" Side Discharge Deck)

798512

Gator Blade, 22.50"-GAT-F-CW (66" Side Discharge Deck)

794230

Gator Blade, 20.50"-GAT-F-CW (60" Side Discharge Deck)

797712

Gator Blade, 18.50"-GAT-F-CW (54" Side Discharge Deck)

798504

Mulch Blade, 22.50"-MUL-F-CW (66" Side Discharge Deck)

794214

Mulch Blade, 20.50"-MUL-F-CW (60" Side Discharge Deck)

797704

Mulch Blade, 18.50"-MUL-F-CW (54" Side Discharge Deck)

102186

Deck Lift Kit MMZ

353961

Steering Extension Kit

357897

Hitch Kit MMZ

799270

Flex Fork Kit

789537

Semi-Pneumatic Tire/Wheel Assy 13x6.50-6

927582

Snow Blade

928218

Bac-Vac Catcher Assy (Requires additional kits for installation, see dealer)

381475

Z Light Kit

ABBREVIATION

DESCRIPTION

ABBREVIATION

DESCRIPTION

CB

Carriage Bolt

MB

Machine Bushing

CE

Clevis Pin

MS

Machine Screw

CP

Cotter Pin

NT

Nut

CS

Cap Screw

SC

Self Tapping Cap Screw

CW

Cup Washer

SH

Socket Head

FDRW

Fender Washer

SB

Shoulder Bolt

FW

Flat Washer

SS

Set Screw

HX

Hex Head

OD

Outside Diameter

LW

Lock Washer

ID

Inside Diameter

Summary of Contents for Honda Engine Z

Page 1: ...Hustler Turf Equipment P O Box 7000 Hesston Kansas 67062 2097 Hustler Z Parts Manual...

Page 2: ...Owner s Manual provides information regarding the U S Environmental Protection Agency EPA and the California Emission Control Regulation of emission systems maintenance and warranty Keep Engine Owner...

Page 3: ...ngine Installation 5 16 Fuel System Installation Air Cooled Engines 5 18 Fuel System Installation Liquid Cooled Engines 5 20 Instrument Panel Assembly Air Cooled 5 22 Instrument Panel Assembly Liquid...

Page 4: ...Tensioning 8 4 60 Side Discharge Deck Belt Routing and Tensioning 8 5 54 Rear Discharge Deck Belt Routing and Tensioning 8 6 Seat Installation S N 08010000 Higher 8 8 Seat Installation S N Prior to 0...

Page 5: ...F CW 60 Side Discharge Deck 798496 Blade F22 50 H F CW 66 Side Discharge Deck 601012 Blade F18 50 L F CW 54 Rear Discharge Deck 601013 Blade F18 50 L F CCW 54 Rear Discharge Deck 797928 Belt B Sectio...

Page 6: ...les Kit 60 Side Discharge Deck 108559 Containment Baffles Kit 54 Side Discharge Deck 108565 Mulch Kit 66 Side Discharge Deck 108563 Mulch Kit 54 60 Side Discharge Deck 106880 Stripe Kit 66 Side Discha...

Page 7: ...ferent torque is shown in the Notes section next to the fastener NOTE Loctite 592 to be used on all pipe threads Lubricate all grease zerks SIZE FT LBS NM SIZE FT LBS NM 250 8 2 11 1 M3 1 1 3 312 17 2...

Page 8: ...1 4 108602 10 08...

Page 9: ...108602 10 08 2 1 Chapter 2 Contents Rivet Nut Installation 2 2 Footrest Assembly 2 3...

Page 10: ...FRAME 60 SIDE DISCHARGE 547752 106039 1 TRACTOR FRAME 66 SIDE DISCHARGE 548545 108093 1 TRACTOR FRAME 54 REAR DISCHARGE 2 808493 808493 13 3 8 16 THREAD RIVET NUT 3 600961 600961 8 1 2 13 THREAD RIVE...

Page 11: ...M NO SERVICE PART NO MFG PART NO QTY DESCRIPTION 1 359547 359547 2 STEP TREAD 2 395533 395533 1 FLOOR 3 305615 305615 2 PLATFORM STEP TREAD 4 086660 086660 2 NT 375 16 HX LK NY 5 767954 767954 4 FW 40...

Page 12: ...2 4 108602 10 08...

Page 13: ...108602 10 08 3 1 Chapter 3 Contents Hydraulic System Installation S N 07120009 and higher 3 2 Hydraulic System Installation S N prior to 07120009 3 6...

Page 14: ...3 2 108602 10 08 Hydraulic System Installation S N 07120009 and higher FRONT 18 1 32 2 3 4 19 20 5 6 7 22 21 19 10 11 24 12 25 26 27 9 30 11 10 20 22 14 31 15 19 11 13 28 25 12 29 8 17 16 16 17 23...

Page 15: ...X 812 X 060 ZN 12 600922 600922 2 MOTOR HGM 15E 3138 13 705186 705186 4 CS 437 14 X 1 375 HX G5 ZN 14 768341 768341 1 FILTER ELEMENT 15 768333 768333 1 FILTER HEAD 16 767962 767962 8 FW 531X 1 063X 0...

Page 16: ...do not turn in 15 seconds return handles to neutral and repeat step 3 and 4 one time 6 If motors do not turn after second attempt shut off the engine and check for oil at the pump 7 Increase throttle...

Page 17: ...108602 10 08 3 5 This page intentionally left blank...

Page 18: ...3 6 108602 10 08 Hydraulic System Installation S N prior to 07120009 8 22 FRONT 16 1 31 2 3 4 17 18 5 6 7 20 19 17 21 10 11 23 12 24 25 26 9 29 11 10 18 20 14 30 15 17 11 13 27 24 12 28...

Page 19: ...8 FW 453 X 812 X 060 ZN 12 781054 781054 2 ROSS PARKER WHEEL MOTOR MB 15 13 705186 705186 4 CS 437 14 X 1 375 HX G5 ZN 14 768341 768341 1 FILTER ELEMENT 15 768333 768333 1 FILTER HEAD 16 781575 N A 1...

Page 20: ...do not turn in 15 seconds return handles to neutral and repeat step 3 and 4 one time 6 If motors do not turn after second attempt shut off the engine and check for oil at the pump 7 Increase throttle...

Page 21: ...108602 10 08 4 1 Chapter 4 Contents Battery Installation 4 2 Deck Lift Assembly 4 4 Steering and Park Brake Assembly 4 6 Steering Sub Assembly 4 9 Pump Belt and Pulleys Installation 4 10...

Page 22: ...4 2 108602 10 08 Battery Installation 1 TRACTOR FRAME 11 12 9 9 10 8 4 1 3 1 6 5 8 5 7 2 11 9...

Page 23: ...TION 1 024927 024927 2 NT 250 20 HX GR 5 ZN 2 771428 771428 1 RED BATTERY CABLE BOOT 3 796219 796219 1 36 NEGATIVE BATTERY CABLE 4 744276 744276 1 POSITIVE BATTERY CABLE 5 768523 768523 3 FW 343 X 687...

Page 24: ...4 4 108602 10 08 Deck Lift Assembly 1 TRACTOR FRAME 1 1 1 4 1 3 2 5 5 5 5 5 4 4 5 6 8 8 4 4 4 4 14 13 9 7 10 10 4 10 11 12 8 10 6 9 9...

Page 25: ...3 704643 8 NT 437 14 HX FLG ZN 5 781294 781294 7 CLIP E 1 00 X 625 X 050 6 782995 782995 2 DECK LIFT SPRING SUBASSEMBLY 7 781229 781229 1 CE 750 X 2 25 X 1 75 HEADLESS 8 055749 055749 3 CS 437 14 X 1...

Page 26: ...ark Brake Assembly TRACTOR FRAME 1 2 20 6 19 4 5 23 5 25 25 26 29 7 28 6 6 21 28 24 5 23 32 30 31 34 5 27 5 35 6 7 16 17 18 6 8 6 11 5 10 22 9 4 5 2 3 1 6 10 6 12 13 14 14 15 6 7 22 6 5 22 SEE STEERIN...

Page 27: ...G5 ZN 17 063198 063198 4 CS 10 24 X 750 HXFLK ZN 18 781211 781211 2 PUSH BUTTON SWITCH 19 348797 348797 2 ADJUSTABLE PIVOT 20 036244 036244 6 CS 375 16 X 1 000 HX G5 ZN 21 059832 059832 4 NT 10 24 HX...

Page 28: ...with serial numbers prior to 07120009 Torque to 350 375 ft lbs Included with wheel motor 5 For units with serial numbers prior to 07120009 Torque brake assembly mounting bolts to 100 ft lbs 6 For unit...

Page 29: ...G5 ZN 5 705178 705178 6 CS 375 16 X 1 750 HX G5 ZN 6 023655 023655 2 NT 312 24 HXZY NL 7 768523 768523 4 FW 343X 687 X 051 080 HD ZN YL 8 348946 348946 2 STEERING ARM MOUNT 9 348888 348888 1 STEERLEV...

Page 30: ...4 10 108602 10 08 Pump Belt and Pulleys Installation 3 2 TRACTOR FRAME 1 2 2 1 6 7 11 6 4 14 16 17 15 18 19 20 12 10 21 22 2 5 13 8 7 3 10 10 8 9 23 24 25 26 13 5 6 27 7 7...

Page 31: ...750 SQ HD ZN 7 768127 768127 2 KEY 5MM X 30MM RADIUS ENDS 8 768705 768705 2 PULLEY 325308 325308 2 PULLEY FAN 9 008193 008193 2 NT 500 13 HX G5 ZNYC 10 767962 767962 4 FW 531 X 1 063 X 090 SAE HD ZN 1...

Page 32: ...4 12 108602 10 08...

Page 33: ...awasaki 29 HP Engine Installation With HD Air Cleaner 5 10 Honda Engine Installation 5 12 Kohler Engine Installation 5 16 Fuel System Installation Air Cooled Engines 5 18 Fuel System Installation Liqu...

Page 34: ...YELLOW 16 2 RED BLK 2 2 TRACTOR FRAME POSITIVE BATTERY CABLE 2 1 6 2 7 5 18 25 11 16 17 27 3 31 33 30 29 20 3 19 26 39 32 8 4 17 7 7 6 6 NEGATIVE BATTERY CABLE 9 STARTER SOLENOID GROUND 10 6 12 13 14...

Page 35: ...NALDSON AIR CLEANER CAP 17 057661 057661 3 HOSE CLAMP 18 788943 788943 1 AIR FILTER INDICATOR 19 785741 785741 1 MOUNTING BAND 20 034272 034272 6 NT 312 18 HX G5 ZN 21 601216 601216 1 FITTING 90 STREE...

Page 36: ...wner s manual 4 Engine RPM to be set at 3600 50 5 Includes one 1 of Item 17 057661 Hose Clamp 6 When installing lower hose clamp on air cleaner hose install as low as possible against carburetor inlet...

Page 37: ...108602 10 08 5 5 This page intentionally left blank...

Page 38: ...2 3 4 5 7 5 6 8 9 5 10 12 13 14 15 16 17 18 19 20 4 5 22 21 2 24 23 2 TO ENGINE SENSOR YELLOW PART OF ENGINE STARTER SOLENOID GROUND 26 TO BULLET TERMINALS 2 TO SPADE TERMINAL 2 25 28 23 24 29 31 24...

Page 39: ...X 090 SAE HD ZN 12 016527 016527 4 CS 500 13 X 1 00 HX G5 ZN 13 780841 780841 2 KAW 23 MUFFLER GASKET 14 781732 781732 1 MUFFLER MANIFOLD 15 360693 360693 1 HEAT SHIELD 16 017004 N A 4 LW 312 MED SPRI...

Page 40: ...PART OF WIRE HARNESS 7 30 1 2 3 4 5 6 1 6 7 8 9 8 10 KAWASAKI ENGINE SCREEN PART OF ENGINE PART OF ENGINE 11 11 12 12 12 13 14 17 12 15 16 20 21 22 23 29 24 25 26 9 8 19 18 30 27 28 POSITIVE BATTERY...

Page 41: ...27 10 CS 500 13 X 1 00 HX G5 ZN 10 008193 008193 4 NT 500 13 HX G5 ZNYC 11 064329 064329 2 CS 250 20 X 625 HX G5 12 073866 073866 4 FW 281 X 500 X 06 ZNYC 13 104133 104133 1 SCREEN SUPPORT 14 010470 0...

Page 42: ...1 6 9 8 7 10 11 11 12 13 14 15 16 17 18 19 9 8 21 20 15 22 24 25 3 26 28 YEL BLK 3 4 RED BLK 2 TO SPADE TERMINAL BULLET 3 CONNECTORS BLK 2 PUR 3 TO SPADE TERMINAL NEGATIVE BATTERY CABLE POSITIVE BATTE...

Page 43: ...664 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 HXFLK ZNYC 13 796524 796524 1 M20X2 5 OIL DRA...

Page 44: ...VE BATTERY CABLE GRA PUR 3 3 3 2 7 30 3 10 13 11 12 29 18 1 13 16 21 22 16 24 32 3 2 14 3 25 7 20 3 3 5 15 NEGATIVE BATTERY CABLE 8 4 2 BLK 2 YEL 2 6 9 11 11 3 16 3 17 28 3 9 35 19 26 PART OF ENGINE 3...

Page 45: ...AND 13 034272 034272 6 NT 312 18 HX G5 ZN 14 782763 782763 1 AIR CLEANER 15 366443 366443 1 REMOTE AIR CLEANER MOUNT BRACKET 16 036236 036236 9 CS 312 18 X 1 HX G5 ZNYC 17 785675 785675 1 REMOTE AIR F...

Page 46: ...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 MAI...

Page 47: ...108602 10 08 5 15 This page intentionally left blank...

Page 48: ...4 15 21 22 23 1 POSITIVE BATTERY CABLE RED BLK 2 PUR P O ENGINE 5 5 28 1 7 6 4 BLK 2 2 3 4 5 TRACTOR FRAME 8 8 8 9 11 12 13 4 14 4 4 15 13 16 3 4 4 17 18 6 19 20 4 15 24 25 25 26 27 29 NEGATIVE BATTER...

Page 49: ...216 601216 1 FITTING 90 STREET ELBOW 11 782763 782763 1 AIR CLEANER 12 785741 785741 1 MOUNTING BAND 13 034272 034272 6 NT 312 18 HX G5 ZN 14 366443 366443 1 REMOTE AIR CLEANER MOUNT BRACKET 15 036236...

Page 50: ...5 18 108602 10 08 Fuel System Installation Air Cooled Engines 1 1 1 2 3 4 4 4 4 5 6 7 1 6 7 1 6 7 8 8 9 10 9 9 1 6 11 11 12 13 14 14 13 15 17 16...

Page 51: ...11 FW 406 X 1 00 X 12 HRD ZN 8 036244 036244 2 CS 375 16 X 1 000 HX G5 ZN 9 767954 767954 3 FW 406 X 812 X 060 SAE HD ZN 10 797035 797035 1 HOSE CLAMP 1 75 11 797084 797084 1 3 WAY NYLON FUEL VALVE 1...

Page 52: ...5 20 108602 10 08 Fuel System Installation Liquid Cooled Engines 1 1 1 2 3 4 5 5 5 5 6 6 6 6 6 6 7 7 7 7 7 8 9 10 10 11 11 12 13 13 14 14 15 16 17 18 19 20 1 1 1...

Page 53: ...D Z 7 000323 000323 8 CLIP 8 068478 068478 1 IN LINE FUEL FILTER 9 797035 797035 1 1 75 DIA RUBBER COATED CLAMP 10 797084 797084 1 3 WAY NYLON FUEL VALVE 11 036244 036244 2 CS 375 16 X 1 00 HX G5 ZNYC...

Page 54: ...108602 10 08 Instrument Panel Assembly Air Cooled RIGHT SIDE FUEL TANK 1 10a FUSE SIZE AND LOCATION 15a 1 2 4 6 10 12 7 9 5 13 14 15 3 4 14 13 15a 3 11 18 8 7 9 7 16 17 WIRE HARNESS RELAYS RELAY ASSE...

Page 55: ...430 3 TIE STRAP 7 704932 704932 8 FW 219 X 500 X 048 ZN 8 714998 714998 3 MS 10 24 X 625 HX ZN 9 601098 601098 2 CB 10 24 X 500 ZYNC 10 059832 059832 5 NT 10 24 HX NL ZN 11 769166 769166 1 HOUR METER...

Page 56: ...602 10 08 Instrument Panel Assembly Liquid Cooled RIGHT SIDE FUEL TANK 1 10a FUSE SIZE AND LOCATION 15a 1 2 10 8 13 7 6 5 17 18 19 3 4 18 17 15a 3 9 11 14 7 8 7 15 16 WIRE HARNESS RELAYS RELAY ASSEMBL...

Page 57: ...X 500 ZYNC 7 704932 704932 8 FW 219 X 500 X 048 ZN 8 059832 059832 5 NT 10 24 HX NL ZN 9 769166 769166 1 HOUR METER 10 794347 794347 1 ULTRA LOUD WARBLE ALARM 11 601089 601089 2 RIVET 188 DIA BLK HD...

Page 58: ...5 26 108602 10 08 Electrical Schematic 799320...

Page 59: ...108602 10 08 5 27 Electrical Schematic Kawasaki LC 799338...

Page 60: ...5 28 108602 10 08...

Page 61: ...2 10 08 6 1 Chapter 6 Contents Front Wheel Assembly 6 2 Front Wheel Breakdown 747782 6 4 Optional Semi Pneumatic Tire Wheel 789537 6 5 Drive Wheel Assembly Installation 6 6 Anti Rollover Wheel Assembl...

Page 62: ...6 2 108602 10 08 Front Wheel Assembly TRACTOR FRAME 1 1 2 3 3 3 3 9 11 10 5 4 6 7 9 9 11 8 1 2 4 5 4 6 7 8 1 2 4 9 3 3...

Page 63: ...25 HX G5 ZN 2 344267 344267 2 FW 510 X 2 15 X 187 SPL ZN 3 712976 712976 2 FW 531X 1 375X 125 ZNY 4 784223 784223 4 BEARING W O COLLAR 5 387035 387035 2 SPACER 1 07 X 1 312 X 2 793 6 045765 045765 2 F...

Page 64: ...to 8 12 psi ITEM NO SERVICE PART NO MFG PART NO QTY DESCRIPTION 1 039677 N A 2 WHEEL BEARING 2 747741 N A 1 13 X 6 50 TIRE 3 747832 N A 1 6 X 4 5 WHEEL 4 782771 N A 1 BEARING SPACER 5 019521 N A 1 TI...

Page 65: ...Pneumatic Tire Wheel 789537 NOTES ITEM NO SERVICE PART NO MFG PART NO QTY DESCRIPTION 1 039677 N A 2 WHEEL BEARING 2 789537 N A 1 TIRE WHEEL ASSEMBLY 3 015511 N A 1 GREASE FITTING 45 DEG 1 4 4 782771...

Page 66: ...019521 N A TIRE VALVE 5 061077 061077 10 WHEEL NUT QTY PER TRACTOR 6 770859 N A 10 1 2 WHEEL LUG STUD 1 601238 601238 2 WHEEL TIRE ASSY FOR 60 54 QTY PER TRACTOR 2 781245 N A TIRE 12 X 12 X 24 FOR 60...

Page 67: ...el must turn freely ITEM NO SERVICE PART NO MFG PART NO QTY DESCRIPTION 1 068239 068239 2 CS 500 13 X 4 500 HX G5 ZN 2 031997 031997 2 ANTI SCALP WHEEL 3 767962 767962 4 FW 531 X 1 063 X 090 SAE HD ZN...

Page 68: ...6 8 108602 10 08...

Page 69: ...e Discharge XR7 Deck Pulley Assembly 7 12 Side Discharge Deck A Adaptors 7 14 Side Discharge Deck B Adaptors 7 16 54 Rear Discharge Deck Assy S N 08100000 Higher 7 18 54 Rear Discharge Deck Assy S N 0...

Page 70: ...7 2 108602 10 08 66 Side Discharge XR7 Deck Assembly 1 9 7 10 5 4 10 11 7 7 9 11 7 7 9 10 1 4 14 14 13 3 2 3 4 5 6 5 4 12 12 12 15 12 8 8 8 8 8 8 7 9 9 9 10 10 11 11 11 16 4...

Page 71: ...52860 8 CS 375 16 X 1 250 HX G5 ZN 4 767954 767954 18 FW 406 X 812 060 SAE HD ZN 5 086660 086660 10 NT 375 16 HXZY NL 6 103010 103010 1 DISCHARGE CHUTE MOUNT BRACKET 7 781708 N A 6 CS 500 13 X 4 25 HX...

Page 72: ...108602 10 08 66 Side Discharge XR7 Deck Pulley Assembly 1 3 2 16 18 21 22 20 23 25 24 26 29 1 2 6 7 10 11 12 16 8 9 4 13 17 28 30 5 BELT GUIDE INDEXING 14 14 3 6 66 DECK ASSY 15 19 15 15 15 27 28 16...

Page 73: ...UNT CHAIN 21 LINKS 9 781302 781302 1 IDLER SPRING 10 350884 350884 1 DECK IDLER 11 103721 103721 1 RS 66 XR7 PULLEY COVER 12 103739 103739 1 LS 66 XR7 PULLEY COVER 13 016972 016972 2 NT 625 11 HX G5 Z...

Page 74: ...108602 10 08 60 Side Discharge XR7 Deck Assembly 3 4 4 9 10 10 16 7 1 7 7 11 9 9 10 8 7 9 11 11 7 4 5 2 4 6 5 16 15 12 12 18 12 12 1 3 4 4 8 9 10 7 8 9 11 13 4 4 5 14 14 14 4 4 14 4 5 8 10 8 11 8 13 1...

Page 75: ...4 26 FW 406 X 812 X 060 SAE HD ZN 5 086660 086660 14 NT 375 16 HX LK NY 6 103010 103010 1 DISCHARGE CHUTE MOUNT BRACKET 7 781708 N A 6 CS 500 13 X 4 25 HX G5 ZN 8 767962 N A 12 FW 531 X 1 063 X 090 SA...

Page 76: ...8602 10 08 60 Side Discharge XR7 Deck Pulley Assembly 1 2 3 BELT GUIDE INDEXING 11 14 18 20 21 17 24 25 26 27 29 9 8 1 2 7 5 10 16 12 4 6 15 13 13 14 14 16 16 16 19 22 23 30 3 6 60 DECK ASSY 27 15 15...

Page 77: ...OUNT CHAIN 21 LINKS 9 781302 781302 1 IDLER SPRING 10 350884 350884 1 DECK IDLER 11 103192 103192 1 RS 60 XR7 PULLEY COVER 12 103200 103200 1 LS 60 XR7 PULLEY COVER 13 016972 016972 3 NT 625 11 HX G5...

Page 78: ...108602 10 08 54 Side Discharge XR7 Deck Assembly 1 9 10 13 13 4 5 11 12 11 11 10 10 9 9 12 13 5 7 11 10 9 1 14 15 2 3 4 8 8 8 17 6 12 4 12 4 5 14 4 3 4 5 17 12 4 4 4 16 16 11 10 13 9 9 10 8 11 6 13 4...

Page 79: ...ICE PART NO MFG PART NO QTY DESCRIPTION 1 548420 108607 1 54 DECK W A CRATED 2 798694 798694 1 54 DISCHARGE CHUTE 3 052860 052860 8 CS 375 16 X 1 25 HX G5 ZN 4 767954 767954 26 FW 406 X 812 X 060 SAE...

Page 80: ...12 108602 10 08 54 Side Discharge XR7 Deck Pulley Assembly BELT GUIDE POSITIONING 1 3 30 30 30 17 20 19 15 21 22 23 29 24 25 30 5 16 18 1 5 8 7 10 9 3 11 13 14 2 12 26 54 DECK ASSY 4 27 28 2 6 24 6 2...

Page 81: ...18 ZNYCG5 7 797910 797910 6 CS 312 18 X 1 50 FLT SH ZY 8 601434 601434 2 UHMW IDLER SLIDE 9 347443 347443 1 DECK BELT IDLER TOP GUIDE 10 781856 781856 1 5 00 IDLER PULLEY 11 350884 350884 1 DECK IDLE...

Page 82: ...7 14 108602 10 08 Side Discharge Deck A Adaptors 3 Deck Assembly 4 4 1 2 2 3...

Page 83: ...RT NO MFG PART NO QTY DESCRIPTION 1 108531 108531 2 AIR FLOW FLOOR 66 DECKS 108516 108516 2 AIR FLOW FLOOR 60 DECKS 108619 108619 2 AIR FLOW FLOOR 54 DECKS 2 025395 025395 4 CB 375 16X 1 00 STD CD 3 7...

Page 84: ...7 16 108602 10 08 Side Discharge Deck B Adaptors 1 4 3 Deck Assembly 4 6 5 7 5 6 4 5 Assembled Detail 2...

Page 85: ...E B RIGHT SIDE 54 DECKS 108532 108532 1 AIR FLOW BAFFLE B LEFT SIDE 66 DECKS 2 108517 108517 1 AIR FLOW BAFFLE B LEFT SIDE 60 DECKS 108620 108620 1 AIR FLOW BAFFLE B LEFT SIDE 54 DECKS 3 108221 108215...

Page 86: ...ck Assy S N 08100000 Higher 1 27 3 22 5 6 6 8 8 30 5 11 5 10 12 12 12 12 13 13 13 13 14 14 15 15 15 16 16 16 16 7 7 7 7 24 3 2 21 21 20 20 26 18 17 19 19 27 10 26 13 13 14 10 5 DEFLECTOR DETAIL 28 4 5...

Page 87: ...375 16 X 1 00 HX G5 ZN 11 107975 107975 1 54 REAR DISCHARGE FRONT ANGLE 12 781708 N A 4 CS 500 13 X 4 25 HX G5 ZN 13 767962 N A 8 FW 531 X 1 063 X 090 SAE HD ZN 14 053199 N A 4 NT 500 13 HX JAM ZN 15...

Page 88: ...k Assy S N 08010000 08100000 1 27 3 22 5 6 6 8 8 30 5 11 5 10 12 12 12 12 13 13 13 13 14 14 15 15 15 16 16 16 16 7 7 7 7 24 3 2 21 21 20 20 26 18 17 19 19 27 10 26 13 13 14 10 5 DEFLECTOR DETAIL 28 4...

Page 89: ...107975 107975 1 54 REAR DISCHARGE FRONT ANGLE 12 781708 N A 4 CS 500 13 X 4 25 HX G5 ZN 13 767962 N A 8 FW 531 X 1 063 X 090 SAE HD ZN 14 053199 N A 4 NT 500 13 HX JAM ZN 15 781567 781567 4 NT 50 13...

Page 90: ...e Deck Assy S N Prior to 08010000 1 2 26 3 22 5 6 6 8 8 9 5 11 5 10 12 12 12 12 13 13 13 13 14 14 15 15 15 16 16 16 16 7 7 7 7 23 23 26 3 24 25 21 21 20 20 25 18 17 19 19 24 26 3 10 25 13 13 14 10 5 D...

Page 91: ...44 036244 20 CS 375 16 X 1 00 HX G5 ZN 11 107975 107975 1 54 REAR DISCHARGE FRONT ANGLE 12 781708 N A 4 CS 500 13 X 4 25 HX G5 ZN 13 767962 N A 8 FW 531 X 1 063 X 090 SAE HD ZN 14 053199 N A 4 NT 500...

Page 92: ...54 Rear Discharge Deck Pulley Assy S N 08100000 Higher 1 1 10 13 12 9 18 15 11 20 4 2 8 14 22 22 22 19 20 21 19 26 10 27 29 28 32 23 33 24 24 2 3 30 23 23 22 19 10 25 3 1 23 5 6 21 5 17 5 19 27 16 2 3...

Page 93: ...63 X 090 SAE HD ZN 11 770867 770867 2 PLASTIC BUSHING 750X1 FS 12 109549 109549 1 IDLER PIVOT BUSHING 13 781302 781302 1 IDLER SPRING 14 259812 259812 1 CHAIN DECK LIFT SPRING 15 704759 704759 1 FW 50...

Page 94: ...10 08 54 Rear Discharge Deck Pulley Assy S N Prior to 08100000 1 1 5 2 5 6 4 4 7 15 8 9 10 12 13 13 13 13 14 15 16 14 18 17 20 21 22 23 23 24 27 27 2 3 28 23 26 25 14 17 19 3 1 23 5 7 16 5 7 5 14 20...

Page 95: ...11 X 1 500 HX G5 7 796714 796714 5 6 HB IDLER PULLEY RD 8 781302 781302 1 IDLER SPRING 9 373191 059931 1 SIDE MOUNT CHAIN 21 LINKS 10 797910 797910 6 CS 312 18 X 1 250 FLT SH ZNYC 11 601434 601434 2...

Page 96: ...extended inner race down 3 Apply grease to zerk ITEM NO SERVICE PART NO MFG PART NO QTY DESCRIPTION 1 077123 N A 2 BEARING W O COLLAR 2 766204 N A 1 BLADE SPINDLE BUSHING 3 034843 N A 1 CAST SPINDLE H...

Page 97: ...with extended inner race down 3 Apply grease to zerk ITEM NO SERVICE PART NO MFG PART NO QTY DESCRIPTION 1 077123 N A 2 BEARING W O COLLAR 2 766204 N A 1 BLADE SPINDLE BUSHING 3 034843 N A 1 CAST SPI...

Page 98: ...7 30 108602 10 08...

Page 99: ...Discharge Deck Belt Routing and Tensioning 8 4 60 Side Discharge Deck Belt Routing and Tensioning 8 5 54 Rear Discharge Deck Belt Routing and Tensioning 8 6 Seat Installation S N 08010000 Higher 8 8...

Page 100: ...8 2 108602 10 08 Deck Installation TRACTOR ASSEMBLY DECK ASSEMBLY 1 2 3 4 5 5...

Page 101: ...ks and 54 Rear Discharge Decks are similar ITEM NO SERVICE PART NO MFG PART NO QTY DESCRIPTION 1 055749 055749 4 CS 437 14 X 1 750 HX G5 ZN 2 061101 061101 2 NT 750 10 HX NL ZN 3 025296 025296 4 FW 76...

Page 102: ...108602 10 08 66 54 Side Discharge Deck Belt Routing and Tensioning NOTES 1 Spring length after tensioning belt Measure spring from outside of hook to outside of hook 2 Route belt as shown DECK ASSEMBL...

Page 103: ...8602 10 08 8 5 60 Side Discharge Deck Belt Routing and Tensioning NOTES 1 Spring length after tensioning belt Measure spring from outside of hook to outside of hook 2 Route belt as shown DECK ASSEMBLY...

Page 104: ...6 108602 10 08 54 Rear Discharge Deck Belt Routing and Tensioning NOTES 1 Spring length after tensioning belt Measure spring from outside of hook to outside of hook 2 Route belt as shown DECK ASSEMBLY...

Page 105: ...108602 10 08 8 7 This page intentionally left blank...

Page 106: ...8 8 108602 10 08 Seat Installation S N 08010000 Higher 1 10 12 19 14 5 6 16 4 3 17 5 5 7 8 9 13 4 11 5 4 23 15 4 20 19 21 22 2 21 18 1 20 LATCH W A DETAIL 14 2 1 10 10 25 24 21 21...

Page 107: ...080358 1 GM 50 X 1 00 X 75 X 12 GROMMET 14 109274 109274 1 LATCH W A 15 109283 109283 1 STOP ROD SEAT LATCH 16 781617 781617 3 RUBBER BUMPER 17 722199 722199 1 2 WIDE SCOTCH POLYURETHANE 5 55 LONG 18...

Page 108: ...8 10 108602 10 08 Seat Installation S N Prior to 08010000 1 1 10 12 15 1 2 5 5 6 14 16 4 3 17 3 8 5 5 7 8 9 13 4 11...

Page 109: ...8523 4 FW 343 X 687 X 051 080 HD ZN Y 11 034272 034272 4 NT 312 18 HX G5 ZN 12 781880 781880 2 BUMPER 13 080358 080358 1 GM 50 X 1 00 X 75 X 12 GROMMET 14 748756 748756 1 LATCH SPRING PLUNGER 15 35046...

Page 110: ...8 12 108602 10 08 ROPS Installation 5 6 7 8 9 11 1 2 3 3 9 10 7 5 6 2 1 4...

Page 111: ...O SERVICES PART NO MFG PART NO QTY DESCRIPTION 1 601440 N A 1 ROPS 2 601471 N A 2 LYNCH PIN W LANYARD 3 601470 N A 2 KNOB 4 601560 N A 1 ROPS WARNING DECAL 5 061812 N A 5 CS 500 13X3 500 HX G5 6 60147...

Page 112: ...8 14 108602 10 08...

Page 113: ...08602 10 08 9 1 Chapter 9 Contents Tractor Decals 9 2 66 Side Discharge XR7 Deck Decals 9 4 60 Side Discharge XR7 Deck Decals 9 5 54 Side Discharge XR7 Deck Decals 9 6 54 Rear Discharge Deck Decals 9...

Page 114: ...9 2 108602 10 08 Tractor Decals TOP OF SEAT PAN BOTTOM OF SEAT PAN 1 2 6 9 10 13 12 11 3 4 14 5 15 7 A A 8 17 18 7 B B VIEW B B 1 2...

Page 115: ...9503 789503 1 INSTRUMENT PANEL DECAL LIQUID COOLED ONLY 4 727008 727008 1 HYD PRESSURE DECAL 5 791830 791830 1 FUEL INDICATOR DECAL 6 782136 782136 1 Z OPERATION DECAL 7 788968 788968 1 ENGINE COMPART...

Page 116: ...60637 1 MOWER DECK QUICK REFERENCE DECAL 3 727420 727420 1 DEFLECTOR SHIELD DECAL 4 727172 727172 1 MADE IN U S A DECAL 5 727453 727453 2 BELT PULLEY DECAL 6 727438 727438 2 WHIRLING BLADES DECAL 7 78...

Page 117: ...60637 1 MOWER DECK QUICK REFERENCE DECAL 3 727420 727420 1 DEFLECTOR SHIELD DECAL 4 727172 727172 1 MADE IN U S A DECAL 5 727453 727453 2 BELT PULLEY DECAL 6 727438 727438 2 WHIRLING BLADES DECAL 7 79...

Page 118: ...60637 1 MOWER DECK QUICK REFERENCE DECAL 3 727420 727420 1 DEFLECTOR SHIELD DECAL 4 727172 727172 1 MADE IN U S A DECAL 5 727453 727453 2 BELT PULLEY DECAL 6 727438 727438 2 WHIRLING BLADES DECAL 7 78...

Page 119: ...SCHARGE DECK ID DECAL 2 760637 760637 1 DECAL MOWER DECK QUICK REFERENCE 3 727438 727438 4 DECAL WHIRLING BLADES 4 727453 727453 4 DECAL BELT PULLEY 5 727172 727172 1 DECAL MADE IN U S A 6 796953 7969...

Page 120: ...9 8 108602 10 08...

Page 121: ...r engines 10 10 Maintenance Adjustment Safety 10 13 Safe Maintenance Adjustment Practices 10 14 Using a ramp 10 15 Maintenance 10 18 Torque values 10 21 Hour meter 10 22 Lubrication 10 22 Electrical s...

Page 122: ...Mower blade removal 10 31 Adjustment 10 34 Introduction 10 34 Steering linkage 10 34 Control Lever Neutral Adjustment 10 34 Control lever stops 10 35 Steering dampener 10 36 Control lever adjustment...

Page 123: ...ssembly Pictures and Aids General information for all models PTO clutch wire routing FIG 1 PTO clutch switch installation Instrument Panel FIG 2 FIG 3 FIG 1 FIG 2 FIG 3 TIE STRAP CLUTCH PIGTAIL WIRE P...

Page 124: ...or 26 HP engines Throttle cable routing FIG 4 Choke cable routing front and rear tie straps FIG 5 FIG 6 FIG 4 FIG 5 FIG 6 THROTTLE HYDRAULIC RESERVOIR CABLE ROUTED THROUGH TUBE TIE STRAP CHOKE CABLE T...

Page 125: ...08 Fuel line routing FIG 7 FIG 8 FIG 7 FIG 8 WIRE HARNESS FUEL LINE TIE STRAP POS BATTERY CABLE TIE STRAP TIE STRAP FUEL LINE NEG BATTERY CABLE THROTTLE CABLE LEFT FUEL RIGHT FUEL TO ENGINE TANK TANK...

Page 126: ...uel lines to seat support as shown in FIG 11 right side shown left side similar Choke and throttle cable routed around engine see FIG 12 FIG 9 FIG 10 FIG 11 FIG 12 NEGATIVE CABLE BATTERY POSITIVE CABL...

Page 127: ...able clamp screw and remove throttle plate clamp 7 Cycle the throttle lever 2 times and then check the rpm If the rpm is out of tolerance then repeat steps 4 6 8 Attach choke cable to choke lever leav...

Page 128: ...Choke Throttle cable routing FIG 19 Tie throttle and choke cables to hydro hose as shown Fuel line routing FIG 20 FIG 21 FIG 17 FIG 18 FIG 19 THROTTLE CABLE CHOKE CABLE TIE STRAP CHOKE CABLE THROTTLE...

Page 129: ...ttle cable routing FIG 22 Tie choke and throttle cables together FIG 20 FIG 21 FIG 22 FUEL VALVE RIGHT FUEL LINE LEFT FUEL LINE TO ENGINE FUEL LINE TIE STRAP WIRE HARNESS WIRE HARNESS LEFT PUMP CHOKE...

Page 130: ...nda 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 FIG 23 FIG 24 TO CLUTCH VENT DRAIN HOSES NEGATIVE BATTERY CABLE PO...

Page 131: ...nd throttle cable routing FIG 27 FIG 25 FIG 26 FIG 27 TIE STRAP BATTERY CABLES FUEL LINES WIRE HARNESS WIRE HARNESS TIE STRAP WIRE HARNESS NEGATIVE BATTERY CABLE TIE STRAP ROUTE THROTTLE CABLE BELOW H...

Page 132: ...10 12 108602 10 08 Fuel line routing FIG 28 FIG 28 TIE STRAP FUEL LINE...

Page 133: ...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...

Page 134: ...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...

Page 135: ...oper 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 r...

Page 136: ...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...

Page 137: ...ing on hydraulic lines To find a leak under pressure use a piece of cardboard or wood never use your hands To relieve all pressure in system turn engine off and lower attachment Keep shields or covers...

Page 138: ...a Kawasaki 2b Fuel Filter Kohler 3 Engine Air Cleaner 4 Engine Oil Drain Plug 5 Battery 6 Fuel Tanks 7 Hydraulic Oil Reservoir 8 Hydraulic Oil Filter 9 Gauge Wheel Bearing Zerks 2 10 Engine Oil Filter...

Page 139: ...2 10 08 FIG 30 2 4 4 1 3 2 4 1 Deck Pusher Arm Zerks 2 2 Deck Belt 3 Spindle Housing Zerk 3 4 Blades Maintenance Locator Chart 60 XR7 deck 54 66 XR7 deck 1 3 3 4 3 3 3 1 1 1 1 2 3 3 3 4 4 54 Rear Disc...

Page 140: ...ours repeat cycle SERVICE AT INTERVALS INDICATED WEEKLY OR 50 HOURS MONTHLY OR 100 HOURS ANNUALLY OR 500 HOURS Verify safety start interlock system Daily Visually inspect unit for loose hardware and o...

Page 141: ...r 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 st...

Page 142: ...s 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 31 Lubrication 1...

Page 143: ...ly Acid will also damage clothing 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...

Page 144: ...release seat latch and tilt seat platform up and forward The seat platform catch FIG 33 will prevent the seat from going all the way over However if more access is desired under the seat platform the...

Page 145: ...event 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 base Tighten the oil...

Page 146: ...hicle 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 stati...

Page 147: ...fuel flow to the engine when servicing the fuel system or when transporting the unit on a trailer or truck Engine oil and filter Check engine oil daily and after every 4 hours of operation Crankcase...

Page 148: ...ary 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...

Page 149: ...ntering 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...

Page 150: ...nt FIG 41 FIG 42 FIG 43 FIG 44 show diagrams and descriptions of the unit s belt drive systems Inspect these belts frequently for wear and serviceability Replace a belt that shows signs of severe cuts...

Page 151: ...ore power from the engine Replace any blade which is bent cracked or broken WARNING INever attempt to straighten a bent blade by heating or weld a cracked or broken blade as the blade may break and ca...

Page 152: ...orque 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 t...

Page 153: ...10 33 108602 10 08 This page intentionally left blank...

Page 154: ...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...

Page 155: ...rods and rotate the rod to shorten the steering control linkage until the wheel s come to a stop FIG 49 Repeat for the opposite side if necessary NOTE The left linkage controls the left hydraulic pum...

Page 156: ...straight without the operator making minor steering adjustments with the control arms Steering dampener The steering dampener FIG 51 is spring loaded to return the control levers to the neutral posit...

Page 157: ...ive wheels are off of the floor 3 Open the hydraulic pump s bypass valve FIG 54 on the side that is being adjusted by turning bypass valves counter clockwise one half to one revolution The valve stems...

Page 158: ...e 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 57 There is no te...

Page 159: ...ompensate for a badly worn belt or pulley Engine RPM setting The Hustler Z is designed so that the engine will run at 3600 rpm static pump load only At this speed the hydraulic pumps are running at th...

Page 160: ...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 61 5 Clamp the height adjusting stop against the stop handle FIG...

Page 161: ...ng FIG 64 18 Tighten the hardware holding the chain and adjuster onto the deck lift arm 19 Go to the right rear of the tractor 20 Make sure that there is still slack in the chain If not loosen the two...

Page 162: ...10 42 108602 10 08 height indicator FIG 65 FIG 66 FOOT PEDAL NUTS 1 DECK LIFT ROD 1 LIFT BLOCK...

Page 163: ...11 037887 7 19 7 21 039677 6 4 6 5 041475 6 3 041707 3 3 3 7 044255 5 3 5 7 045088 5 21 045765 6 3 045898 5 23 5 25 050161 5 3 5 7 5 13 5 17 051169 8 3 052860 2 3 7 3 7 7 7 11 8 9 8 11 053199 4 7 7 3...

Page 164: ...961 1 2 357897 1 2 359547 2 3 9 4 9 5 9 6 360693 5 3 5 7 365742 5 13 5 17 366443 5 3 5 13 5 17 366765 4 11 367557 4 7 373191 7 5 7 9 7 13 7 27 377994 5 11 5 17 381475 1 2 382168 5 13 5 17 387035 6 3 3...

Page 165: ...7 5 7 9 7 13 770842 7 9 770859 6 6 770867 7 25 771428 4 3 5 3 5 7 771436 9 3 772079 1 1 776476 5 23 5 25 777656 5 3 778365 5 23 778399 7 19 7 21 7 23 778423 1 1 778985 3 7 779132 3 3 3 7 779280 9 3 7...

Page 166: ...793588 9 3 793661 8 9 8 11 794214 1 2 794230 1 2 794347 5 25 794446 7 25 7 27 794503 9 7 794610 8 9 794685 1 1 7 9 795310 5 17 795617 5 9 796219 4 3 5 7 796227 7 28 796235X 7 5 7 9 7 13 7 25 7 27 7962...

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