HUSTLER Diesel Z Parts Manual
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HUSTLER Diesel Z Parts Manual

Hustler lawn mower parts manual
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See also: Owner's Manual , Operator's Manual
Enlarged version
Hustler Diesel Z
Parts Manual
•••••••
Hustler Turf Equipment
•••••
P.O. Box 7000
•••
Hesston, Kansas
•
67062-2097

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Summary of Contents for HUSTLER Diesel Z

  • Page 1 Hustler Diesel 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 Footrest Assembly .
  • Page 4 72" Rear Discharge Deck Pulley Assembly ....7-24 60" Rear Discharge Deck Assembly ..... . . 7-26 60"...

  • Page 5: General Information

    General Information This Manual covers Hustler Diesel Z models 928606A/B, 928614A/B, 928622A/B, 928630A/B, 928648, 928655 & 928663. Frequently Ordered Parts PART NO. 601413X 601424 601531 601528 601466 601525 601692 601673 601691 798702 798496 794685 797696 796839 796508 600901 795633 601012...

  • Page 6: Standard Torques

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

  • Page 8: Footrest Assembly

    Footrest Assembly 109706 10/08...
  • Page 9 Footrest Assembly SERVICE INDEX NO. PART NO. 785485 785493 056069 767954 549410 601571 781880 109399 086660 054502 052860 1. Do not tighten, Item 5 (109104 Floor Plate) must be able to pivot on these bolts. 2. Service part includes Items 1 and 2 (step treads). 109706 10/08 MFG.

  • Page 10: Rivet Nut Installation

    Rivet Nut Installation SERVICE INDEX NO. PART NO. 549139 549121 549113 549105 549758 549618 549766 808493 600961 1. Service part includes Items 2 and 3 and decals. See “Tractor Decals” on page 9-2. MFG. PART QTY. 109624 TRACTOR FRAME (72" SIDE DISCHARGE) 109621 TRACTOR FRAME (66"...
  • Page 11 Chapter 3 Contents Hydraulic Component Fittings ......3-2 Hydraulic Component Mounting ......3-4 Hydraulic Line Connections .

  • Page 12: Hydraulic Component Fittings

    Hydraulic Component Fittings 109706 10/08...
  • Page 13 Hydraulic Component Fittings SERVICE INDEX NO. PART NO. 601556 601557 032763 032771 549345 601413X 781658 781542 779132 795922 601568 601592 601523 601569 601476 787473 771337 601524 781534 601318 1. Hydraulic system capacity is 7 US quarts. Fill reservoir to within 1" of top of Item 4 (032771 Strainer).

  • Page 14: Hydraulic Component Mounting

    Hydraulic Component Mounting LEFT WHEEL MOTOR TANDEM PUMPS RESERVOIR MANIFOLD RIGHT WHEEL MOTOR 109706 10/08...
  • Page 15 Hydraulic Component Mounting SERVICE INDEX NO. PART NO. 036236 768523 036244 767954 767962 008193 034272 064345 028274 601427 054502 601247 1. Part of wheel motors (601556 and 601557). 109706 10/08 MFG. PART QTY. 036236 CS .312-18X1.000 HX G5 768523 FW .343X.687X.051/.080H 036244 CS .375-16X1.000 HX G5 767954...

  • Page 16: Hydraulic Line Connections

    Hydraulic Line Connections FIREWALL & OIL COOLER RIGHT WHEEL MOTOR TANDEM PUMPS MANIFOLD TANDEM PUMPS LEFT WHEEL MOTOR RESERVOIR LEFT WHEEL MOTOR RIGHT WHEEL MOTOR 109706 10/08...

  • Page 17: Hydraulic Line Connections

    Hydraulic Line Connections SERVICE INDEX NO. PART NO. 601521 601583 601001 601522 601584 601617 601519 601518 601570 601520 700484 601517 601494 601495 601496 601497 1. See “Hydraulic routing” on page 10-8. 109706 10/08 MFG. PART QTY. HOSE MANIFOLD BLOCK TO OIL COOLER HOSE MANIFOLD BLOCK 601001 SPRING CLAMP .75"...
  • Page 18 109706 10/08...
  • Page 19 Chapter 4 Contents Deck Lift Assembly ........4-2 Steering Sub-Assembly .

  • Page 20: Deck Lift Assembly

    Deck Lift Assembly TRACTOR FRAME 109706 10/08...
  • Page 21 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). 109706 10/08 MFG. DESCRIPTION PART NO. 348318 STOP HANDLE 600437 DECK HEIGHT 1/2" PIN W/A 783001 DECK LIFT INDICATOR SUBASSEMBLY 704643...

  • Page 22: Steering Sub-Assembly

    Steering Sub-Assembly SERVICE INDEX NO. PART NO. 781260 109839 767954 036244 705178 348946 348862 109260 109259 781153 047456 781716 086660 601087 1. Includes Item 1 (781260 Steering Bar Grip). MFG. PART QTY. STEERING BAR GRIP 109839 HANDLE Z W/A 767954 FW .406X .812 X.060 SAE 036244 CS .375-16X1.000 HX G5...
  • Page 23 This page intentionally left blank. 109706 10/08...

  • Page 24: Steering System

    Steering System See “Steering Sub-Assembly” on page 4-4. TRACTOR FRAME See “Steering Sub-Assembly” on page 4-4. 109706 10/08...
  • Page 25 Steering System ITEM SERVICE PART NO. 348987 781716 053199 055822 767954 768523 023655 784439 108813 795377 795369 034272 109118 781286 781922 600221 029876 1. Tube ends to be clean and free of rust. Apply thin coat of grease prior to installing 781153 Bushing (item 9 on page 4-4).

  • Page 26: Brake System

    Brake System See “Steering TRACTOR Sub-Assembly” FRAME on page 4-4. WHEEL MOTOR 109706 10/08...
  • Page 27 Brake System ITEM SERVICE PART NO. 782979 767954 023655 768523 086660 712919 601566 767962 109718 781583 109109 109110 765339 016899 109355 058776 079186 1. Do not torque this fastener, should be snug but allow Item 11 (109109/ 109110 Brake Bell Crank) to pivot freely. 109706 10/08 MFG.
  • Page 28 4-10 109706 10/08...
  • Page 29 Chapter 5 Contents Engine Sub-Assembly ........5-2 Belt Drive System .

  • Page 30: Engine Sub-Assembly

    Engine Sub-Assembly 31 30 FUEL FILTER DETAIL 44 41 109706 10/08...
  • Page 31 Engine Sub-Assembly SERVICE INDEX NO. PART NO. 601355 108976 601361 601428 767962 768523 034272 011510820 314990013 036236 054502 767954 016410 008573 110466031 052100420 036244 601515 601516 086660 781567 055947 768515 792150 779132 601487 140517020 601546 601547 601526 601567 053678 109358 130306190 005116 109589...
  • Page 32 NOTES: 1. Supplied with engine. 2. Torque to 33 ft-lbs. 3. Torque to 78 ft-lbs. 4. Engine oil capacity: See engine owner’s manual. 5. Engine RPM to be set at 2950±50. 6. Included in 601498 (Hydro Kit). 7. Torque to 64 ft-lbs. 109706 10/08...
  • Page 33 This page intentionally left blank. 109706 10/08...

  • Page 34: Belt Drive System

    Belt Drive System DECK BELT 109706 10/08...
  • Page 35 Belt Drive System SERVICE INDEX NO. PART NO. 601279 038836 601278 767962 778217 601478 768515 055939 068551 109725 767954 036244 781385 796714 796714 028118 025007 054502 601424 601084 025296 015495 109127 601016 601486 016972 601488 047712 601713 601422 600122 004317 601423 791251 601722...
  • Page 36 8. For mowers with serial numbers prior to 08051277, shims are required between item 32 (pulley) and the engine. Use quantity (3) of 601662 (Arbor Shim 0.020 Thk). 109706 10/08...
  • Page 37 This page intentionally left blank. 109706 10/08...

  • Page 38: Firewall & Rops Assembly

    Firewall & ROPS Assembly FRONT OF FIREWALL DETAIL 5-10 109706 10/08...
  • Page 39 Firewall & ROPS Assembly SERVICE INDEX NO. PART NO. 601443 601470 601471 061812 023317 601472 077859 055939 768515 549352 109401 068551 601356 601357 601538 056077 601069 781567 767962 601559 1. Assemble Item 6 (ROPS Stop) on right post of ROPS only. 2.

  • Page 40: Air Filter Installation

    Air Filter Installation 5-12 AIR FILTER DETAIL 109706 10/08...
  • Page 41 Air Filter Installation SERVICE INDEX NO. PART NO. 782763 079186 768523 785741 795138 057661 601359 601360 034272 016253 036236 775353 794644 706531 549394 109341 791384 785279 785261 1. Orient the hose clamp on the air filter to engine hose so that it is accessible for maintenance (See FIG.

  • Page 42: Cooling System Installation

    Cooling System Installation SEE RADIATOR DETAIL FOR ASSEMBLY 13 2 5-14 RADIATOR DETAIL 109706 10/08...
  • Page 43 Cooling System Installation SERVICE INDEX NO. PART NO. 036236 768523 109559 601069 794644 706531 016253 549360 109137 601295 109144 068346 108977 034272 713040 601353 601354 549402 601358 041483 033035 033035 033035 713198 713198 601558 600320 1. Coolant capacity: 6.0 US quarts. 2.

  • Page 44: Engine Cover Installation

    Engine Cover Installation 2 10 5-16 109706 10/08...
  • Page 45 Engine Cover Installation SERVICE INDEX NO. PART NO. 601363 767954 068551 712927 601364 601503 768515 601379 109745 063297 601564 034272 768523 601089 010306 109136 758821 109413 031666 109105 767962 016527 055939 601373 024927 109721 029868 036236 781880 109722 058776 033035 033035 033035 713198...

  • Page 46: Fuel System

    Fuel System 5-18 109706 10/08...
  • Page 47 Fuel System SERVICE INDEX NO. PART NO. 798470 601699 601366 601698 601365 000323 601369 601375 015818 015818 015818 015818 015818 015818 015818 015818 795542 041483 041491 038398 791400 791400 767954 055822 601378 060889 601693 1. Includes Item 6 (601375 O-Ring). 2.

  • Page 48: Battery And Electrical Connections

    Battery and Electrical Connections YEL/WHT WHT/YEL RED/BLK POSITIVE BATT. CABLE DETAIL ALTERNATOR CONNECTOR 5-20 YEL/BLK GRN/BLK ORG/GRN TRACTOR FRAME 109706 10/08...
  • Page 49 Battery and Electrical Connections SERVICE INDEX NO. PART NO. 601291 793489 109108 068551 768515 053678 029876 601540 601380 005231 601539 767954 054502 601319 045336 768523 601381 601367 023100004 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 50: Instrument Panel

    Instrument Panel FIREWALL FUSE SIZE & LOCATION 5-22 THROTTLE DETAIL 24 25 31 32 109706 10/08...
  • Page 51 Instrument Panel SERVICE INDEX NO. PART NO. 109557 109729 601089 769166 385710011 601370 712257 776476 055947 768515 785808 045898 601098 601053 059832 794347 063198 601368 601371 109420 036236 768523 601069 549378 549386 052860 767954 601507 712919 109421 016816 056077 601493 601362 054502 034272...

  • Page 52: Electrical Schematic-601367

    Electrical Schematic—601367 5-24 109706 10/08...
  • Page 53 Chapter 6 Contents Front Wheel Assembly........6-2 Front Wheel Breakdown—747782.

  • Page 54: Front Wheel Assembly

    Front Wheel Assembly TRACTOR FRAME 109706 10/08...
  • Page 55 Front Wheel Assembly SERVICE INDEX NO. PART NO. 705954 344267 712967 784223 387035 045765 349266 025296 041475 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 56: 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: 109706 10/08...

  • Page 57: Optional Semi-Pneumatic Tire/Wheel-789537

    Optional Semi-Pneumatic Tire/Wheel—789537 ITEM SERVICE PART NO. 039677 789537 015511 782771 109706 10/08 MFG. DESCRIPTION PART NO. WHEEL BEARING TIRE/WHEEL ASSEMBLY GREASE FITTING 45 DEG 1/4 BEARING SPACER NOTES:...

  • Page 58: Drive Wheel Assembly Installation

    Drive Wheel Assembly Installation ITEM SERVICE PART NO. PART NO. 601238 601238 781245 796250 019521 061077 061077 770859 782078 782078 782284 782086 019521 061077 061077 770859 784058 784058 781245 784066 019521 061077 061077 770859 1. Torque to 65-75 ft. lbs. 2.

  • Page 59: 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. 109706 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 .500-13 HX G8 ZY NL NOTES:...
  • Page 60 109706 10/08...
  • Page 61 Chapter 7 Contents 72" Side Discharge XR7 Deck Assembly ..... 7-2 72" Side Discharge XR7 Deck Pulley Assembly ....7-4 66"...

  • Page 62: 72" Side Discharge Xr7 Deck Assembly

    72" Side Discharge XR7 Deck Assembly 109706 10/08...
  • Page 63 72" Side Discharge XR7 Deck Assembly INDEX SERVICE PART NO. 549170 798694 052860 767954 086660 103010 781708 767962 031997 053199 781567 005116 314104 015495 103184 025395 788166 1. Do not torque, Item 2 (798694 Discharge Chute) must pivot freely. 2. Includes items 7, 8, 9, and 10. 3.

  • Page 64: 72" Side Discharge Xr7 Deck Pulley Assembly

    72" Side Discharge XR7 Deck Pulley Assembly 72" DECK ASSY BELT GUIDE INDEXING 109706 10/08...
  • Page 65 72" Side Discharge XR7 Deck Pulley Assembly ITEM SERVICE PART NO. 601531 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 1.

  • Page 66: 66" Side Discharge Xr7 Deck Assembly

    66" Side Discharge XR7 Deck Assembly 109706 10/08...
  • Page 67 66" Side Discharge XR7 Deck Assembly ITEM SERVICE PART NO. 549162 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 68: 66" Side Discharge Xr7 Deck Pulley Assembly

    66" Side Discharge XR7 Deck Pulley Assembly 66" DECK ASSY BELT GUIDE INDEXING 109706 10/08...
  • Page 69 66" Side Discharge XR7 Deck Pulley Assembly ITEM SERVICE PART NO. 601528 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 70: 60" Side Discharge Xr7 Deck Assembly

    60" Side Discharge XR7 Deck Assembly 7-10 109706 10/08...
  • Page 71 60" Side Discharge XR7 Deck Assembly SERVICE ITEM NO. PART NO. 549154 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 72: 60" Side Discharge Xr7 Deck Pulley Assembly

    60" Side Discharge XR7 Deck Pulley Assembly 60" DECK ASSY BELT GUIDE INDEXING 7-12 109706 10/08...
  • Page 73 60" Side Discharge XR7 Deck Pulley Assembly ITEM SERVICE PART NO. 601466 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 74: 54" Side Discharge Xr7 Deck Assembly

    54" Side Discharge XR7 Deck Assembly 7-14 109706 10/08...
  • Page 75 54" Side Discharge XR7 Deck Assembly SERVICE ITEM NO. PART NO. 549105 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 76: 54" Side Discharge Xr7 Deck Pulley Assembly

    54" Side Discharge XR7 Deck Pulley Assembly 54" DECK ASSY BELT GUIDE POSITIONING 7-16 109706 10/08...
  • Page 77 54" Side Discharge XR7 Deck Pulley Assembly ITEM SERVICE PART NO. 601525 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 78: Side Discharge Deck-"A" Adaptors

    Side Discharge Deck—"A" Adaptors DECK ASSEMBLY 7-18 109706 10/08...
  • Page 79 Side Discharge Deck—"A" Adaptors SERVICE ITEM NO. PART NO. 108661 108531 108516 108619 025395 767954 086660 109706 10/08 MFG. QTY. DESCRIPTION PART NO. 108661 AIR FLOW FLOOR (72" DECKS) 108531 AIR FLOW FLOOR (66" DECKS) 108516 AIR FLOW FLOOR (60" DECKS) 108619 AIR FLOW FLOOR (54"...

  • Page 80: Side Discharge Deck-"B" Adaptors

    Side Discharge Deck—"B" Adaptors Deck Assembly Assembled Detail 7-20 109706 10/08...
  • Page 81 Side Discharge Deck—"B" Adaptors SERVICE ITEM NO. PART NO. 108663 108533 108518 108621 108662 108532 108517 108620 108241 108221 108212 108254 025395 767954 086660 029751 1. Service part includes rivet nuts. 109706 10/08 MFG. QTY. DESCRIPTION PART NO. 108663 AIR FLOW BAFFLE, "B" RIGHT SIDE (72" DECKS) 108533 AIR FLOW BAFFLE, "B"...

  • Page 82: 72" Rear Discharge Deck Assembly

    72" Rear Discharge Deck Assembly 7-22 DEFLECTOR DETAIL 109706 10/08...
  • Page 83 72" Rear Discharge Deck Assembly ITEM SERVICE PART NO. 549667 109484 109485 768523 086660 767954 110471 110472 710194 808485 015495 349803 036244 101477 781708 767962 053199 781567 031997 109486 109487 601483 107712 600930 109482 109483 778399 016253 037887 058776 601069 025395 788166 1.

  • Page 84: 72" Rear Discharge Deck Pulley Assembly

    72" Rear Discharge Deck Pulley Assembly 24 30 7-24 109706 10/08...
  • Page 85 72" Rear Discharge Deck Pulley Assembly ITEM SERVICE PART NO. 797167 110459 110458 781872 028118 796714 600296 781567 767962 770867 109549 109948 781302 259812 704759 601779 797910 016972 016527 752386 538850 792002 782474 783738 796680X 796508 212472 796722 768523 058776 796235X 796839 029934...

  • Page 86: 60" Rear Discharge Deck Assembly

    60" Rear Discharge Deck Assembly DEFLECTOR DETAIL 7-26 109706 10/08...
  • Page 87 60" Rear Discharge Deck Assembly INDEX SERVICE PART NO. 549592 109484 768523 086660 767954 710194 601069 792887 015495 349803 036244 352591 781708 767962 053199 781567 031997 109486 109487 601483 110182 601717 110180 110181 025395 109482 109483 778399 016253 058776 025296 037887 109485 788166...

  • Page 88: 60" Rear Discharge Deck Pulley Assembly

    60" Rear Discharge Deck Pulley Assembly 7-28 109706 10/08...
  • Page 89 60" Rear Discharge Deck Pulley Assembly INDEX SERVICE PART NO. 601673 110411 110412 781872 028118 796714 781567 767962 770867 109549 600296 109948 601779 797910 704759 781302 259812 016972 016527 752386 770842 792002 782474 783738 796680X 796235X 212472 600901 795633 796722 029934 768523 058776...

  • Page 90: 54" Rear Discharge Deck Assembly

    54" Rear Discharge Deck Assembly DEFLECTOR DETAIL 7-30 29 3 109706 10/08...
  • Page 91 54" Rear Discharge Deck Assembly ITEM SERVICE PART NO. 549584 109490 768523 086660 767954 710194 601069 015495 349803 036244 107975 781708 767962 053199 781567 031997 109486 109487 601483 108816 601017 109543 109542 025395 109482 109483 778399 016253 058776 107978 037887 109491 600994 788166...

  • Page 92: 54" Rear Discharge Deck Pulley Assembly

    54" Rear Discharge Deck Pulley Assembly 13 12 7-32 109706 10/08...
  • Page 93 54" Rear Discharge Deck Pulley Assembly ITEM SERVICE PART NO. 601691 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 768523 058776 029934...

  • Page 94: Spindle Assembly-796235X

    Spindle Assembly—796235X 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. MFG. QTY. DESCRIPTION PART NO. BEARING W/O COLLAR BLADE SPINDLE BUSHING CAST SPINDLE HOUSING GREASE FITTING BEARING DUST COVER...

  • Page 95: Spindle Assembly-796680X

    Spindle Assembly—796680X 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. 109706 10/08 MFG. QTY. DESCRIPTION PART NO. BEARING W/O COLLAR BLADE SPINDLE BUSHING CAST SPINDLE HOUSING GREASE FITTING...
  • Page 96 7-36 109706 10/08...
  • Page 97 Chapter 8 Contents Deck Installation ........8-2 Seat Installation .

  • Page 98: Deck Installation

    Deck Installation 109706 10/08...
  • Page 99 Deck Installation SERVICE INDEX NO. PART NO. 055749 061101 025296 051169 704643 1. Install front deck hanger chains in lower holes only. 109706 10/08 MFG. PART QTY. 055749 CS .437-14X1.750 HX G5 061101 NT .750-10 HXZY NL 025296 FW .760X 1.625X.08 ZNYC 051169 CS .750-10X3.000 HX G5 704643...

  • Page 100: Seat Installation

    Seat Installation TRACTOR FRAME 109706 10/08...
  • Page 101 Seat Installation SERVICE INDEX NO. PART NO. 792051 601444 017129 797076 549188 000331 350421 036244 724716 767954 086660 601650 768523 034272 109684 795583 054502 080358 052860 722199 1. Must pivot freely. 2. Service part number includes decals; see “Tractor Decals” on page 9-2. 109706 10/08 MFG.

  • Page 102: 72", 66" & 54" Side Disch. Deck Belt Routing/Tensioning

    72", 66" & 54" Side Disch. Deck Belt Routing/Tensioning NOTES: 1. Tension spring in deck leveling position. Measure spring from outside of hook to outside of hook. Spring length after tensioning new belt. 2. Route belt as shown. 109706 10/08...

  • Page 103: 60" Side Disch. Xr7 Deck Belt Routing/Tensioning

    60" Side Disch. XR7 Deck Belt Routing/Tensioning 1. Spring length after tensioning belt. Measure spring from outside of hook to outside of hook. 2. Route belt as shown. 109706 10/08 NOTES:...

  • Page 104: 72", 60" & 54" Rear Discharge Deck Belt Routing/Tensioning

    72", 60" & 54" Rear Discharge Deck Belt Routing/Tensioning NOTES: 1. Tension spring in deck leveling position. Measure spring from outside of hook to outside of hook. Spring length after tensioning new belt. 2. Route belt as shown. 109706 10/08...
  • Page 105 Chapter 9 Contents Tractor Decals ......... . 9-2 72"...

  • Page 106: Tractor Decals

    Tractor Decals TOP OF SEAT PAN BOTTOM OF SEAT PAN 109706 10/08...
  • Page 107 Tractor Decals SERVICE INDEX NO. PART NO. 763805 785121 788968 601374 601372 600899 727008 779280 785188 727818 727016 771436 782128 601377 727172 782573 781427 600941 601246 793588 601596 786426 109706 10/08 MFG. PART QTY. 763805 FAN FINGER WARNING DECAL 785121 OPERATION RIGHT DECAL 788968 ENGINE COMPARTMENT DECAL...

  • Page 108: 72" Side Discharge Xr7 Deck Decals

    72" Side Discharge XR7 Deck Decals SERVICE INDEX NO. PART NO. 786285 760637 727420 727172 727453 727438 601597 799353 359547 797845 MFG. PART QTY. 786285 72" SIDE DISCHARGE DECK ID DECAL 760637 MOWER DECK QUICK REFERENCE DECAL 727420 DEFLECTOR SHIELD DECAL 727172 “MADE IN U.S.A.”...

  • Page 109: 66" Side Discharge Xr7 Deck Decals

    66" Side Discharge XR7 Deck Decals SERVICE INDEX NO. PART NO. 799189 760637 727420 727172 727453 727438 601597 799353 359547 797845 109706 10/08 MFG. PART QTY. 799189 66" SIDE DISCHARGE DECK ID DECAL 760637 MOWER DECK QUICK REFERENCE DECAL 727420 DEFLECTOR SHIELD DECAL 727172 “MADE IN U.S.A.”...

  • Page 110: 60" Side Discharge Xr7 Deck Decals

    60" Side Discharge XR7 Deck Decals SERVICE INDEX NO. PART NO. 786277 760637 727420 727172 727453 727438 601597 799353 359547 797845 MFG. PART QTY. 786277 60" SIDE DISCHARGE DECK ID DECAL 760637 MOWER DECK QUICK REFERENCE DECAL 727420 DEFLECTOR SHIELD DECAL 727172 “MADE IN U.S.A.”...

  • Page 111: 54" Side Discharge Xr7 Deck Decals

    54" Side Discharge XR7 Deck Decals SERVICE INDEX NO. PART NO. 799171 760637 727420 727172 727453 727438 781419 799353 359547 797845 109706 10/08 MFG. PART QTY. 799171 54" SIDE DISCHARGE DECK ID DECAL 760637 MOWER DECK QUICK REFERENCE DECAL 727420 DEFLECTOR SHIELD DECAL 727172 “MADE IN U.S.A.”...

  • Page 112: 72" Rear Discharge Deck Decals

    72" Rear Discharge Deck Decals SERVICE INDEX NO. PART NO. 786285 760637 727453 727438 727172 601690 797845 359547 MFG. PART QTY. 786285 72" DECK ID DECAL 760637 MOWER DECK QUICK REFERENCE DECAL 727453 BELT & PULLEY DECAL 727438 WHIRLING BLADES DECAL 727172 “MADE IN U.S.A.”...

  • Page 113: 60" Rear Discharge Deck Decals

    60" Rear Discharge Deck Decals SERVICE INDEX NO. PART NO. 786277 760637 727453 727438 727172 601690 797845 359547 109706 10/08 MFG. PART QTY. 786277 60" SIDE DISCHARGE DECK ID DECAL 760637 MOWER DECK QUICK REFERENCE DECAL 727453 BELT & PULLEY DECAL 727438 WHIRLING BLADES DECAL 727172...

  • Page 114: 54" Rear Discharge Deck Decals

    54" Rear Discharge Deck Decals ITEM SERVICE PART NO. 799171 760637 727438 727453 727172 601690 794503 797845 MFG. QTY. PART NO. 799171 54" REAR DISCHARGE DECK ID DECAL 760637 DECAL MOWER DECK QUICK REFERENCE 727438 DECAL WHIRLING BLADES 727453 DECAL BELT & PULLEY 727172 DECAL 'MADE IN U.S.A.' 601690...
  • Page 115 Assembly Pictures and Aids ......10-3 General Information for all models ....10-3 Wire harness and cable routings .
  • Page 116 Belt replacement ....... . 10-27 Mower blade maintenance ......10-28 Mower blade removal .

  • Page 117: Assembly Pictures And Aids

    Assembly Pictures and Aids General Information for all models Instrument panel and wire connections (FIG. 1). OIL PRESSURE LIGHT PTO CLUTCH SWITCH WHT/YEL ORANGE BLACK ORANGE CONNECT SHORT SENSOR WIRE TO LONG WIRE HARNESS CONNECTOR Oil Pressure Light Glow Plug Light Coolant Temperature Light Coolant Temperature Gauge GLOW PLUG...

  • Page 118: Wire Harness And Cable Routings

    PTO clutch wire routing (FIG. 2 & FIG. 3) TIE STRAP FIG. 2 Orient the hose clamp on the air filter to engine hose so that it is accessible for maintenance (FIG. 4). Orient the pre- cleaner cap with the vent notch facing downward and away from the operator (FIG. 5). AIR FILTER CLAMP FIG.
  • Page 119 Fuel sensors and wire harness routing (FIG. 8, FIG. 9 & FIG. 10) THROTTLE CABLE FUEL SENSOR CONNECTOR TIE STRAP WIRE HARNESS FIG. 8 FUEL SENSOR Oil cooler and wire harness routing (FIG. 11 & FIG. 12). OIL COOLER TIE STRAP WIRE HARNESS FIG.

  • Page 120: Fuel Lines

    Throttle cable connection (FIG. 14). THROTTLE CABLE FIG. 13 Fuel lines Fuel priming bulb (with arrow facing up) and right side fuel line routing (FIG. 15 & FIG. 16) TIE STRAP AIR HOSE TIE STRAP FUEL LINE FROM PRIMING BULB TO PUMP ON ENGINE CLIP THROTTLE CABLE...
  • Page 121 TIE STRAP ARROW UP PRIMING BULB TIE STRAP Left side fuel line routing (FIG. 17 & FIG. 18) TIE STRAP FUEL LINES TIE STRAP TO FAN SHROUD WIRE HARNESS FIG. 17 WIRE HARNESS HYDRAULIC HOSES FIG. 16 OIL COOLER TIE STRAP FUEL LINES TIED WITH WIRE HARNESS...

  • Page 122: Hydraulic Routing

    Fuel valve and fuel filter (FIG. 19 & FIG. 20) LEFT SIDE RETURN LINE RETURN LINE FROM ENGINE LEFT LINES SHOWN—RIGHT SIDE SIMILAR FIG. 19 Hydraulic routing Hydraulic hose routings (FIG. 21, FIG. 22 & FIG. 23) TIE STRAP HYDRO HOSE FROM LEFT WHEEL MOTOR TO MANIFOLD...

  • Page 123: Engine Oil Hose Routing

    Engine oil hose routing Route engine oil hoses behind the seat latch & through clamp to remote filter at rear of tractor (FIG. 24 & FIG. 25) ADAPTOR TIE STRAP FIG. 24 TIE STRAP FIG. 23 OIL HOSES TO REMOTE FILTER SEAT LATCH 10-9 FILTER...

  • Page 124: 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 PER- SONAL 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.

  • Page 125: Using A Ramp

    ▲ 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.
  • Page 126 The following illustrations show the various decals that are located on the machine. A brief explanation, for those requiring one, is shown to help the operator understand the meanings of these decals. Read Owner’s Manual and Quick Reference Decal before attempting to operate this machine. Avoid skin contact with battery acid.
  • Page 127 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. If pump belt fails, steering control will be lost. Refer to owner’s manual for inspection and Part Number replacement intervals and refer to above paragraph for emergency procedures.

  • Page 128: Maintenance

    Maintenance Locator Chart Viewed from top of unit Viewed from right side of unit Maintenance 1. Engine Oil Dipstick 2. Fuel Filter 3. Engine Air Cleaner 4. Engine Oil Drain Plug 5. Battery 6. Fuel Tanks 7. Hydraulic Oil Reservoir 8.
  • Page 129 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 130: Introduction

    It is important for level mowing that the tires have the same amount of air pressure. The recommended pressure are: Solid fill tires are not recommended for Hustler turf equipment. On any machine, with solid filled tires, the war- ranty claim will be denied.

  • Page 131: Hour Meter

    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.

  • Page 132: Electrical System

    Electrical system The electrical system is a 12-volt, negative ground. Recommended battery size is a garden tractor BCI group 45 with 480 or better cranking AMP rating. A maintenance-free battery is recommended. Otherwise, follow battery manu- facturer’s maintenance, safety, storing and charging specifications.The battery is located at the rear of the tractor, FIG.

  • Page 133: Access To Engine And Hydraulic Pumps

    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. 29) will prevent the seat from going all the way over.
  • Page 134 HYDRAULIC RESERVOIR 1. Smear a light coating of oil on filter’s o-rings. 2. Insert the filter element into the hydraulic reservoir housing. Tighten the oil filter 10 ft.- lbs. (13.56 Nm) — 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.

  • Page 135: 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 diesel fuel 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 136 4. Try and start the engine. If it will not start after 15 seconds of cranking, repeat Step 3. 5. If after trying several times and the engine still will not start, contact your Hustler Dealer. Hustler Z Diesel tractors are equipped with a fuel shutoff valve located on the lower right of the front engine guard (FIG.

  • Page 137: Engine Oil And Filter

    Engine oil and filter Check engine oil daily and after every 4 hours of operation. The crankcase dipstick is located at the front of the engine (FIG. 35) and oil filler tube is located on top of the engine (FIG. 36). Tractor must be sitting level when checking oil.

  • Page 138: Oil Removal From The Engine Breather Valve System

    OIL REMOVAL FROM THE ENGINE BREATHER VALVE SYSTEM IN THE EVENT THAT OIL ENTERS THE ENGINE BREATHER VALVE SYSTEM, THE OIL MUST BE REMOVED BEFORE CRANKING THE ENGINE. 1. If oil has entered the engine breather valve system, it may be found in the intake manifold.
  • Page 139 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.
  • Page 140 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. 3. Reinstall the dust cup. Make sure it seals all the way around the air cleaner body, then tighten the clamps.

  • Page 141: Belt Replacement

    Belt replacement FIG. 43, FIG. 44, FIG. 45, FIG. 46 and FIG. 47 show diagrams and descriptions of the unit’s belt drive systems. Deck Belt Drive Layout 1. Spindle drive belt 2. Deck blade spindle pulley 3. Spindle belt tension idler 4.

  • Page 142: Mower Blade Maintenance

    Viewed from right side of unit 1. Electric deck clutch 2. Deck drive belt 3. Fixed pulley FIG. 46 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 143: Mower Blade Removal

    Do not sharpen to original pattern (below). It is easier to get a straight cutting edge following the re sharpening pattern shown above FIG. 48 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.

  • Page 144: Adjustment

    Introduction Your Hustler Z Diesel 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 145: Control Lever Stops

    JAM NUT PUMP LINKAGE FIG. 52 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 146: Steering Dampener

    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.

  • Page 147: Control Lever Adjustment

    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. 56, 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.

  • Page 148: Hydraulic Pump Belt Adjustment

    Hydraulic pump belt adjustment The pump drive belt tension remains constant by means of a tension idler and spring (FIG. 58). There is no tension adjustment of this belt. NOTE: Replace the belt every 400 hours or every two (2) years whichever comes first.

  • Page 149: Engine Rpm Setting

    Engine RPM setting The Hustler Z Diesel is designed so that the engine will run at 2950 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.
  • Page 150 15. Be sure that adjuster is free to move up and down. 16. Tighten the adjuster bolt until the chain just becomes tight, making sure that the deck stays tight against the 3" block. 17. Tighten the adjuster bolt jam nut to prevent the adjuster bolt from moving (FIG. 65). 18.
  • Page 151 23. Go to the left rear of the tractor. 24. 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. 63). 25.
  • Page 152 10-38 109706 10/08...

  • Page 153: Index

    Numerical Index Part Page Index Part Numbers 000323 5-19 000331 004317 005116 7-11 7-15 005231 5-21 008193 008573 010306 5-17 011510820 011841 012005 7-34 7-35 015495 7-11 7-15 7-23 7-27 7-31 015511 015818 5-19 016253 5-13 5-15 7-23 7-27 7-31 016410 016527 5-17...
  • Page 154 Part Page 108607 7-15 108619 7-19 108620 7-21 108621 7-21 108649 108661 7-19 108662 7-21 108663 7-21 108813 108816 7-31 108932 108976 108977 5-15 109073 5-15 109104 109105 5-17 109106 109108 5-21 109109 109110 109118 109127 109136 5-17 109137 5-15 109144 5-15 109259...
  • Page 155 Part Page 601247 601278 601279 601291 5-21 601295 5-15 601318 601319 5-21 601353 5-15 601354 5-15 601355 601356 5-11 601357 5-11 601358 5-15 601359 5-13 601360 5-13 601361 601362 5-23 601363 5-17 601364 5-17 601365 5-19 601366 5-19 601367 5-21 5-23 601368 5-23...
  • Page 156 Part Page 767962 5-11 5-17 7-11 7-13 7-15 7-23 7-25 7-27 7-29 7-31 7-33 768515 5-11 5-17 5-21 5-23 768523 5-13 5-15 5-17 5-21 5-23 7-13 7-17 7-23 7-25 7-27 7-29 7-31 7-33 769166 5-23 769257 7-13 7-17 770842 7-13 7-29 770859 770867...

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