Hustler Z Parts Manual ••••••• Hustler Turf Equipment ••••• P.O. Box 7000 ••• Hesston, Kansas • 67062-2097 375535 Rev.
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. Other states or federal areas may have similar laws. This spark ignition system complies with Canadian ICES-002.
Table of Contents Chapter 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Chapter 2 Contents Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Chapter 3 Contents Hydraulic System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Chapter 4 Contents Battery Installation. . . . . . . . . . . .
Tractor Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 72" and 60" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 52" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Chapter 10 Contents 72" and 60" Mulch Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 72" Mulch Kit–352419 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 1 General Information This Manual covers Hustler Z models 926667 24/60, 926675 24/60, 926881 23/52, 926915 23/60, 926923 23/60, 926931 25/60, 926949 25/60, 926964 25/72, 927111 27/60, 927160 27/72, and 927475 27/52. Frequently Ordered Parts PART NO. 027912 027920 768341 781443 784207 781310 782292 068478 785261 785279 772079 785634 747303 795526 795252 795260 DESCRIPTION LUBRIZOL 7 OZ. BOTTLE LUBRIZOL 10 OZ.
Hardware Description Codes & Abbreviations The following codes are used throughout this parts manual. Refer to this list when ordering parts.
Chapter 2 Contents Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Foot Rest Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rivet Nut Installation 1 2 INDEX NO. SERVICE PART NO. MFG. PART NO.
Footrest Assembly 1 2 3 4 5 6 5 7 2 3 1 INDEX NO. SERVICE PART NO. MFG. PART NO. QTY 1 359547 359547 2 STEP TREAD 2 348276 348276 1 FLOOR 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 .406 X .812 X .060 SAE HD ZN 6 781880 781880 2 RUBBER BUMPER 7 052860 052860 2 CS .375-16 X 1.250 HX G5 ZN DESCRIPTION NOTES: 1.
2-4 375535 6/06
Chapter 3 Contents Hydraulic System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic System Installation 4 2 3 17 1 16 19 15 20 5 31 18 17 8 6 FRONT 10 14 11 23 7 21 22 12 24 20 30 26 18 25 17 10 11 29 9 28 27 12 11 13 24 3-2 375535 6/06
Hydraulic System Installation ITEM NO. SERVICE PART NO. MFG. PART NO. 1 768515 768515 2 FW .281 X .625 X .051/.080 HD ZN/YL 2 055947 055947 2 CS .250-20 X .500 HX G5 ZN 3 032771 032771 1 STRAINER 4 032763 032763 1 BREATHER CAP 5 349860 349860 1 RESERVOIR 6 034272 034272 4 NT .312-18 HX G5 ZN 7 768523 768523 4 FW .343 X .687 X .051/.
HYDRAULIC SYSTEM CHARGING PROCEDURE 1. 2. 3. 4. 5. Set handles in the neutral position. Start engine at idle. Let run for a minimum of 30 seconds. Stroke handles to forward position. If motors do not turn in 15 seconds return 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.
Chapter 4 Contents Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Steering and Brake Assembly (Centering Damper). . . . . . . . . . . . . . 4-6 Steering and Park Brake Assembly (With Anti Reverse) . . . . . . . . . 4-10 Pump Belt and Pulley Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Installation 1 BLACK WIRE, PART OF WIRE HARNESS 2 3 1 5 6 5 1 7 8 9 9 4 RED WIRE, PART OF WIRE HARNESS TRACTOR FRAME 10 8 3 1 11 14 12 11 5 13 4-2 375535 6/06
Battery Installation INDEX NO. SERVICE PART NO. MFG. PART NO. QTY 1 024927 024927 2 2 771428 771428 1 RED BATTERY CABLE BOOT 3 768820 768820 1 BATTERY GROUND CABLE 4 744276 744276 1 POSITIVE BATTERY CABLE 5 768523 768523 3 FW .343 X .687 X .051/.080 HD ZN/YL 6 058776 058776 2 NT .312-18 HX NL ZN 7 348417 348417 1 BATTERY CLAMP STRAP 8 055939 055939 2 CS .250-20 X .750 HX G5 ZN 9 029868 029868 4 LW .
Deck Lift Assembly 1 2 4 TRACTOR FRAME 6 5 3 4 5 5 11 12 10 4 1 5 6 5 10 1 7 13 10 8 4 1 4 5 4 10 1 9 8 9 4 14 8 4 9 4-4 375535 6/06
Deck Lift Assembly 2 ITEM NO. SERVICE PART NO. MFG. PART NO. QTY 1 348318 348318 1 STOP HANDLE 2 600437 600437 1 DECK HEIGHT PIN - 1/2" DIA 348284 N/A 1 HEIGHT ADJ STOP - 3/8" DIA { DESCRIPTION 3 783001 783001 1 DECK LIFT INDICATOR SUBASSEMBLY 4 704643 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.
Steering and Park Brake Assembly (Centering Damper) 1 6 11 12 13 10 2 3 20 19 8 6 3 21 14 6 7 16 5 21 22 6 7 7 4 7 23 30 17 3 3 7 25 18 3 24 38 5 3 15 9 11 4 27 3 26 37 3 10 36 28 40 35 6 3 29 7 28 36 30 7 34 30 3 31 1 39 33 29 3 41 15 TRACTOR FRAME 32 2 4-6 375535 6/06
Steering and Park Brake Assembly (Centering Damper) 5 3 4 ITEM NO. SERVICE PART NO. MFG. PART NO. QTY 1 2 781260 N/A 2 348755 348755 2 STEERING BAR 3 767954 767954 48 FW .406 X .812 X .060 SAE HD ZN 4 036244 036244 10 CS .375-16 X 1.000 HX G5 ZN 5 705178 705178 6 CS .375-16 X 1.750 HX G5 ZN 6 041152 041152 8 NT .312-24 HX ZN 7 768523 768523 18 FW .343X .687 X .051/.
1. 2. 3. 4. 5. 6. Torque to 350-375 ft.-lbs. Included with wheel motor. Torque brake assembly mounting bolts to 100 ft.-lbs. 781112 used on left wheel. 781351 used on right wheel. Includes item 1 (781260). Used on tractors with serial number 03012522 and higher.
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Steering and Park Brake Assembly (With Anti Reverse) 1 5 11 12 13 10 2 3 22 23 8 6 3 24 14 7 7 6 17 18 16 5 26 20 3 3 7 19 21 3 25 33 6 3 7 4 24 7 27 28 43 5 3 15 9 11 4 30 3 29 40 3 10 39 31 45 3 41 42 38 3 32 31 33 7 37 3 6 39 7 33 3 34 1 44 36 32 3 46 15 TRACTOR FRAME 35 2 4-10 375535 6/06
Steering and Park Brake Assembly (With Anti Reverse) 3 4 375535 6/06 ITEM NO. SERVICE PART NO. MFG. PART NO. QTY 1 781260 781260 2 2 348755 348755 2 STEERING BAR 3 767954 767954 48 FW .406 X .812 X .060 SAE HD ZN 4 036244 036244 10 CS .375-16 X 1.000 HX G5 ZN 5 705178 705178 6 CS .375-16 X 1.750 HX G5 ZN 6 041152 041152 8 NT .312-24 HX ZN 7 768523 768523 18 FW .343X .687 X .051/.
ITEM NO. SERVICE PART NO. MFG. PART NO. QTY 46 064337 N/A 2 DESCRIPTION ROSS KEY NOTES: 1. 2. 3. 4. 5. Torque to 350-375 ft.-lbs. Included with wheel motor. Torque brake assembly mounting bolts to 100 ft.-lbs. 781112 used on left wheel. 781351 used on right wheel. Used on tractors with serial prior to 03012522.
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Pump Belt and Pulleys Installation TRACTOR FRAME 37 34 1 38 2 23 2 4 33 25 25 13 39 24 30 LOCATION OF RUBBER BUMPER 31 26 27 28 29 3 6 6 8 8 10 7 SEE NOTE 5 9 1 2 11 10 7 3 3 34 36 4 1 1 7 10 13 9 14 18 19 2 16 2 15 17 20 28 32 35 2 6 12 10 5 24 25 13 3 21 25 22 31 5 SEE NOTE 6 4-14 375535 6/06
Pump Belt and Pulleys Installation 4 7 7 5 6 INDEX NO. SERVICE PART NO. MFG. PART NO. 1 779876 779876 1 ENGINE SC SINGLE PULLEY 2 212076 212076 1 KEY 1/4 SQ X 1.50 LONG 3 787366 787366 1 WARNER CLUTCH QTY DESCRIPTION 4 783829 783829 1 FW .460 X 1.750 X .250 ZNYC 5 785659 785659 1 CS .437-20 X 2.50 HX G5 ZNYC 6 083196 083196 4 SS .312-18 X .750 SQ-HD ZN 7 768127 768127 2 KEY 5MM X 30MM RADIUS ENDS 8 325308 325308 2 PULLEY & FAN 9 008193 008193 2 NT .
4. 5. 6. 7. 8. Included with Honda 24 HP engine (785014). Alternative use clutch (Ogura GT2). Alternative use clutch (Ogura GT3). Order 781039K for replacement clutch. Electric clutch burnishing procedure: After installing a new clutch it is important to burnish the clutch to insure maximum deck clutch life. In an open area with no bystanders set the engine speed to half throttle. Cycle the deck clutch on for 15 seconds, and then off for 15 seconds.
Chapter 5 Contents Kawasaki Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Honda Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Kohler Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Fuel System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Instrument Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kawasaki Engine Installation 1 TO BULLET 2 TERMINALS 30 14 12 10 36 15 11 33 16 TO SPADE 2 TERMINAL TO STARTER SOLENOID BLK 2 18 2 TAN/RED 16 17 RED/BLK 2 11 33 34 35 30 16 15 HOUR METER CONNECTION 19 31 11 31 13 29 30 37 15 16 32 POSITIVE BATTERY CABLE PURPLE 2 TO ENGINE SENSOR 2 YELLOW P/O ENGINE 20 TRACTOR FRAME 2 21 5 3 7 1 17 8 4 6 16 27 9 28 22 23 24 16 25 26 5-2 375535 6/06
Kawasaki Engine Installation 5 6 7 9 375535 6/06 ITEM NO. SERVICE PART NO. MFG. PART NO. QTY 1 777656 777656 1 KAWASAKI 23 HP ENGINE 782318 782318 1 KAWASAKI 25 HP ENGINE (FH721V, 3600 RMP) DESCRIPTION 2 781724 781724 1 MUFFLER 3 720177 720177 2 CS M 8-1.25 X 20 10.9 HXFL ZN 4 782649 782649 1 KAW (23) EXHAUST PIPE CLAMP 5 780841 780841 2 KAW (23) MUFFLER GASKET 6 781732 781732 1 MUFFLER MANIFOLD 7 360693 360693 1 HEAT SHIELD 8 017004 017004 4 LW .
NOTES: 1. 2. 3. 4. Includes mounting hardware. Part of Item 37 (783984 Tractor Wire Harness). Engine oil capacity; 2 US quarts. Engine RPM to be set at 3600± 50. 5. 6. 7. 8. 23 HP engine used in 926881, 926915, 926923, only. 25 HP engine used in 926931, 926949, and 926964 only. Includes one (1) of Item 11 (057661 Hose Clamp). When installing lower hose clamp on air cleaner hose, install as low as possible (against carburetor inlet). 9. Used on mowers with serial numbers 05031839 and higher.
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Honda Engine Installation 1 6 11 12 15 14 2 16 13 3 18 31 10 3 1 6 9 7 7 8 7 16 7 33 14 16 2 19 15 BLK 2 TAN/RED 32 17 27 14 30 15 16 4 HOUR METER CONNECTION 5 20 PART OF 9 WIRE HARNESS 35 24 16 23 17 ORG 21 22 2 29 RED/BLK 7 7 7 7 28 BRN 2 GRA 2 PUR 2 POSITIVE BATTERY CABLE 25 34 26 16 17 5-6 375535 6/06
Honda Engine Installation ITEM NO. 5 SERVICE PART NO. MFG. PART NO. QTY 1 785014 785014 1 HONDA 24HP ENGINE 2 784843 784843 1 MUFFLER 3 720177 720177 2 CS M 8-1.25 X 20 10.9 HXFL ZN 4 787689 787689 1 HONDA OIL DRAIN VALVE 5 787713 787713 1 0.50" LOW PRESSURE HOSE, 3.00" LONG 6 785378 785378 1 1.50" MUFFLER CLAMP 7 017004 N/A 5 LW .312 MED SPRING ZN 8 782664 N/A 4 NT M8-1.
8. When installing lower hose clamp on air cleaner hose, install as low as possible (against carburetor inlet). 9. This connector used for optional hydraulic oil cooler fan. 10.
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Kohler Engine Installation 2 6 5 11 8 1 9 13 28 14 6 12 10 3 1 2 14 15 4 BLK 2 TAN/RED 9 16 14 13 HOUR METER CONNECTION 9 13 14 6 17 7 19 18 26 15 23 20 21 14 22 27 6 2 RED/BLK 24 2 25 POSITIVE BATTERY CABLE 14 15 PUR (P/O ENGINE) 5-10 375535 6/06
Kohler Engine Installation ITEM NO. 5 SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 788216 788216 1 KOHLER 27HP ENGINE 2 788018 788018 1 MUFFLER 3 788026 788026 1 MUFFLER MANIFOLD 4 785378 785378 1 1.50" MUFFLER CLAMP 5 029751 029751 2 CS .375-16 X 1.00 HXFLK ZNYC 6 705137 705137 4 FW .391 X 1.250 X .060 ZNYC 7 016899 016899 2 NT .
9.
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3 Fuel System Installation 1 2 10 1 4 2 11 6 5 2 7 19 12 1 2 13 5 4 3 2 15 14 13 6 8 6 12 16 12 9 17 19 18 1 11 6 13 1 15 16 TRACTOR FRAME WITH ENGINE 19 13 1 5-14 375535 6/06
3 Fuel System Installation ITEM NO. SERVICE PART NO. MFG. PART NO. QTY 1 779306 779306 2 3.5" FUEL CAP 2 793240 793240 1 LEFT SIDE FUEL TANK 3 793232 793232 1 RIGHT SIDE FUEL TANK 4 792986 N/A 2 SITE-LINE FUEL FITTING (90°) 5 785295 N/A 2 GROMMET 6 000323 000323 6 CLIP 7 015818 015818 1 FUEL LINE 45.5" 8 015818 015818 1 FUEL LINE 26.5" 9 015818 015818 1 FUEL LINE 22.
4 Fuel System Installation 1 2 5 1 4 6 5 5 1 9 3 7 11 10 14 2 8 13 17 15 2 10 5 14 14 8 1 6 5 18 12 16 5 6 17 14 1 14 15 16 5 6 1 TRACTOR FRAME WITH ENGINE 5-16 375535 6/06
4 Fuel System Installation ITEM NO. SERVICE PART NO. MFG. PART NO. QTY 1 784181 N/A 2 FUEL TANK CAP 2 796326 N/A 1 LEFT SIDE FUEL TANK 3 796318 N/A 1 RIGHT SIDE FUEL TANK 4 349944 N/A 1 REAR SEAT SUPPORT 5 767954 N/A 15 FW .406 X .812 X .060 SAE HD ZN 6 055822 N/A 12 CS .375-16 X .750 HX G5 ZN 7 000398 N/A 1 CLAMP 8 036244 N/A 3 CS .375-16 X 1.
Instrument Panel Assembly 1 14 2 4 3 8 10 1 7 5 1 8 6 14 3 7 1 7 9 4 11 12 RIGHT SIDE FUEL TANK 15a 13 12 11 5a (KAW) 10a (HONDA) 15a (KOHLER) 20a FUSE SIZE AND LOCATION 5-18 375535 6/06
Instrument Panel Assembly ITEM NO. SERVICE PART NO. MFG. PART NO. QTY 1 776476 776476 1 PTO SWITCH 2 083022 N/A 2 IGNITION KEY 2 785808 785808 1 INDAK COATED KEY 3 045898 045898 1 KEY SWITCH 4 059832 059832 6 NT #10-24 HX NL ZN 5 026237 N/A 3 RELAY 6 762195 N/A 1 DELAY MODULE 7 704932 704932 6 FW .219 X .500 X .048 ZN 8 714998 714998 3 MS #10-24 X .
Electrical Schematic - Kawasaki (783894) 5-20 375535 6/06
Electrical Schematic - Kawasaki (783894) 375535 6/06 5-21
Electrical Schematic - Honda (787200) OPTIONAL FAN 5-22 375535 6/06
Electrical Schematic - Honda (787200) 375535 6/06 5-23
Electrical Schematic - Kohler (788000) 5-24 375535 6/06
Electrical Schematic - Kohler (788000) 375535 6/06 5-25
5-26 375535 6/06
Chapter 6 Contents Front Wheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Front Wheel Breakdown—747782. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Option Semi-Pneumatic Tire/Wheel Breakdown—789537 . . . . . . . . 6-5 Drive Wheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Anti-Rollover Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Wheel Assembly 1 2 TRACTOR FRAME 3 3 4 1 2 3 3 4 5 3 4 6 7 8 5 9 9 3 2 4 10 6 7 9 9 11 8 1 11 6-2 1 375535 6/06
Front Wheel Assembly INDEX NO. SERVICE PART NO. MFG. PART NO. QTY 1 705954 705954 2 CS .500-13 X 1.25 HX G5 ZN 2 344267 344267 2 FW .510 X 2.15 X .187 SPL ZN 3 712976 712976 2 FW .531 X 1.375 X .125 ZNYC 4 784223 784223 4 BEARING 5 387035 387035 2 SPACER, 1.07 X 1.312 X 2.793 6 045765 045765 2 FW 1.030 X 1.500 X.134 ZN 7 349266 349266 2 FORK 8 041475 041475 2 CS .750-10 X 9.50 HX ZN 9 025296 025296 4 FW .760 X 1.625 X .08 10 061101 061101 2 NT .
Front Wheel Breakdown—747782 1 2 1 3 4 1 5 6 ITEM NO. SERVICE PART NO. MFG. PART NO. QTY 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 TIRE VALVE 6 015511 N/A 1 GREASE FITTING 45 DEG 1/4 DESCRIPTION NOTES: 1. Inflate tire to 8-10 psi.
Optional Semi-Pneumatic Tire/Wheel—789537 2 1 3 4 1 ITEM NO. SERVICE PART NO. MFG. PART NO.
Drive Wheel Assembly Installation 1 6 1 5 2 3 4 2 INDEX NO. SERVICE PART NO. PART NO. QTY 1 784058 784058 2 2 781245 N/A 3 784066 N/A WHEEL ASSEMBLY 12 X 8.50 FOR 72” 4 019521 N/A TIRE VALVE 5 061077 061077 5 1 781237 781237 2 2 781245 N/A 3 781252 N/A 2 WHEEL ASSEMBLY 12 X 8.
Anti-Rollover Wheel Assembly 1 3 3 4 1 2 3 TRACTOR FRAME 1 3 2 INDEX NO. SERVICE PART NO. MFG. PART NO. QTY 1 068239 068239 2 CS .500-13 X 4.500 HX G5 ZN 2 031997 031997 2 ANTI-SCALP WHEEL 3 767962 767962 4 FW .531 X 1.063 X .090 SAE HD ZN 4 781567 781567 2 NT .50-13 HX LK NY DESCRIPTION NOTES: 1. Do not torque, wheel must turn freely.
6-8 375535 6/06
Chapter 7 Contents 72" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 72" Deck Pulley Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 60" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 60" Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 52" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72" Deck Assembly 2 3 4 5 1 5 4 4 10 6 14 7 8 1 9 4 17 14 16 8 12 15 12 13 8 11 9 17 8 12 4 15 13 12 11 9 5 12 15 12 13 11 12 15 7-2 12 9 375535 6/06
72" Deck Assembly INDEX NO. 3 2 SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 545764 348052 1 72" DECK CRATED 2 349324 349324 1 DISCHARGE CHUTE 3 052860 052860 2 CS .375-19 X 1.250 HX G5 ZN 4 767954 767954 18 FW .406 X .812 .060 SAE HD ZN 5 054502 054502 8 NT .375-16 HX G5 ZN 6 349522 349522 1 DISCHARGE CHUTE MOUNT BRACKET 7 086660 086660 2 NT .375-16 HX LK NY 8 808485 808485 4 5/16-18 THREAD RIVET NUT 9 781708 N/A 4 CS .500-13 X 4.
72" Deck Pulley Assembly 1 2 4 10 APPROXIMATE LOCATION OF BUMPERS 4 3 11 5 6 15 12 7 3 13 8 9 3 16 14 17 18 2 4 3 2 19 21 20 22 18 23 21 18 24 25 28 BELT GUIDE POSITIONING 18 26 27 29 28 1 7-4 30 375535 6/06
72" Deck Pulley Assembly ITEM NO. SERVICE PART NO. MFG. PART NO. QTY 1 784207 784207 1 B-SECTION BELT 2 016972 016972 2 NT .625-11 HX G5 028118 028118 3 FW .62 X 1.00X.134 ZN 4 781385 781385 2 6.00" IDLER PULLEY, 5 008573 008573 1 CS .500-13 X 2.500 HX G5 ZN 6 070037 070037 1 FW .530 X 1.06 X .
7. Used on mowers with serial number prior to 04032000. 8. Used on mowers with serial number pior to 05011098.
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60" Deck Assembly 3 2 1 4 5 4 5 6 4 7 10 14 8 16 9 17 4 1 14 8 12 15 12 8 11 13 17 9 8 13 15 12 15 13 12 11 5 12 4 11 9 13 12 11 12 15 9 7-8 375535 6/06
60" Deck Assembly INDEX NO. SERVICE PART NO. 1 545277 349100 1 60" DECK CRATED 2 349324 349324 1 DISCHARGE CHUTE 3 052860 052860 2 CS .375-16 X 1.250 HX G5 ZN 4 767954 767954 18 FW .406 X .812 X .060 SAE HD ZN 5 054502 054502 8 NT .375-16 HX GRD 5 ZN 6 349522 349522 1 DISCHARGE CHUTE MOUNT BRACKET 7 086660 086660 2 NT .375-16 HX LK NY 8 808485 808485 4 5/16-18 THREAD RIVET NUT 9 781708 N/A 4 CS .500-13 X 4.25 HX G5 ZN 10 349803 349803 1 PUSHER NT .
60" Deck Pulley Assembly 1 2 7 5 28 6 10 3 17 4 11 12 3 13 4 5 16 14 15 19 18 26 6 2 2 5 8 20 9 19 21 26 27 19 60" DECK 19 22 25 23 29 24 25 BELT GUIDE POSITIONING 1 30 7-10 APPROXIMATE LOCATION OF BUMPERS 375535 6/06
60" Deck Pulley Assembly INDEX NO. SERVICE PART NO. MFG. PART NO. QTY. 1 781310 781310 1 B-SECTION BELT 2 016972 016972 2 NT .625-11 HX G5 3 794446 794446 1 CS .625-11 X 1.50 HX G5 ZN 4 347443 347443 1 TOP IDLER DECK BELT GUIDE 5 028118 028118 3 FW .62 X 1.00X.134 ZN 6 781385 781385 2 6.00" IDLER PULLEY, 7 008573 008573 1 CS .500-13 X 2.500 HX G5 ZN 8 784199 784199 3 CS .312-18X1.250 FLT SH ZNYC 9 783878 783878 1 IDLER CLAMP 10 070037 070037 1 FW .
7. Used on mowers with serial number prior to 04032000. 8. Used on mowers with serial number prior to 05011098.
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52" Deck Assembly 2 4 3 1 5 4 15 4 6 8 1 17 4 14 16 8 13 9 10 8 11 12 9 16 13 8 12 12 10 13 13 11 12 11 10 11 10 5 9 7-14 4 9 375535 6/06
52" Deck Assembly INDEX NO. 3 2 SERVICE PART NO. MFG. PART NO. QTY. DESCRIPTION 1 545343 347195 1 52" DECK CRATED 2 347971 347971 1 52" DISCHARGE CHUTE 3 052860 052860 2 CS .375-16 X 1.25 HX G5 ZN 4 767954 767954 18 FW .406 X .812 X .060 SAE HD ZN 5 054502 054502 8 NT .375-16 HX GRD 5 ZN 6 086660 086660 2 NT .375-16 HX LK NY 7 317073 317073 1 DISCHARGE CHUTE MOUNT BRACKET 8 N/A 808485 4 5/16-18 THREAD RIVET NUT 9 781708 N/A 4 CS .500-13 X 4.
52" Deck Pulley Assembly 1 2 4 5 4 12 6 13 3 7 14 3 9 8 4 10 11 15 2 16 17 2 18 19 4 5 21 28 29 17 16 16 20 52" DECK 4 16 22 26 23 25 27 BELT GUIDE POSITIONING 24 1 7-16 30 25 375535 6/06
52" Deck Pulley Assembly INDEX NO. SERVICE PART NO. MFG. PART NO. QTY. 1 782292 782292 1 B-SECTION BELT 2 016972 016972 2 NT .625-11 HX G5 ZNYC 3 794446 794446 1 CS .625-11 X 1.50 HX G5 ZN 4 028118 028118 6 FW .62 X 1.00 X .134 ZN 5 781385 781385 2 6.00" IDLER PULLEY 6 008573 008573 1 CS .500-13 X 2.50 HX G5 ZN 7 070037 070037 1 FW .530 X 1.06 X .
breakdown. 7. Used on mowers with serial number prior to 04032000. 8. Used on mowers with serial number prior to 05011098. 9. Used with mulch kit only.
Spindle Assembly - 350595K 1 1 2 3 4 1 2 5 6 INDEX NO. SERVICE PART NO. MFG. PART NO. QTY. 1 077123 N/A 2 2 766204 N/A 1 BLADE SPINDLE BUSHING 3 034843 N/A 1 CAST SPINDLE HOUSING DESCRIPTION BEARING W/O COLLAR 4 012005 N/A 1 GREASE FITTING 5 072272 N/A 1 FW 1.06 X 2.00 X.134 SAE ZN 6 788547 N/A 1 SADDLELESS SPINDLE SHAFT NOTES: 1. Install upper bearing with extended inner race up. 2. Install lower bearing with extended inner race down. 3.
Spindle Assembly - 796235 1 1 2 3 4 1 2 5 6 INDEX NO. SERVICE PART NO. MFG. PART NO. QTY. 1 077123 N/A 2 BEARING W/O COLLAR 2 766204 N/A 1 BLADE SPINDLE BUSHING 3 034843 N/A 1 CAST SPINDLE HOUSING 4 012005 N/A 1 GREASE FITTING 5 072272 N/A 1 FW 1.06 X 2.00 X.134 SAE ZN 6 796227 N/A 1 SADDLELESS SPINDLE SHAFT DESCRIPTION NOTES: 1. Install upper bearing with extended inner race up. 2. Install lower bearing with extended inner race down.
Chapter 8 Contents Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Deck Belt Routing and Tensioning. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deck Installation TRACTOR ASSEMBLY 1 1 2 4 3 5 DECK ASSEMBLY 5 8-2 375535 6/06
Deck Installation ITEM NO. SERVICE PART NO. MFG. PART NO. 1 055749 055749 4 CS .437-14 X 1.750 HX G5 ZN 2 061101 061101 2 NT .750-10 HX NL ZN 3 025296 025296 4 FW .760 X 1.625 X.08 ZN 4 051169 051169 2 CS .750-10 X 3.000 HX G5 ZN 5 704643 704643 8 NT .437-14 HX FLG ZN QTY DESCRIPTION NOTES: 1. 60" Deck installation is shown, 52" and 72" Deck installations are similar.
Deck Belt Routing and Tensioning 1 DECK ASSEMBLY 8-4 375535 6/06
NOTES: 1. Spring length after tensioning belt. Measure spring from outside of hook to outside of hook. 2. Route belt as shown.
Seat Installation 8 17 14 16 5 15 1 3 4 3 4 2 1 5 1 7 6 8 13 4 10 11 12 12 5 9 5 8-6 375535 6/06
Seat Installation 2 3 4 INDEX NO. SERVICES PART NO. MFG. PART NO. QTY 1 793661 793661 1 MICHIGAN STANDARD SEAT 792051 792051 1 MICHIGAN SUSPENSION SEAT 2 350041 350041 1 SEAT PAN 3 000331 000331 3 BLACK CABLE TIE 4 086660 086660 3 NT .375-16 HX LK NY 5 767954 767954 7 FW .406 X .812 X .060 SAE HD ZN 6 724716 724716 1 FIBER WASHER 7 350421 350421 1 SEAT PAN STOP 8 036244 036244 3 CS .375-16 X 1.000 HX G5 ZN 9 052860 052860 2 CS .375-16 X1.
DESCRIPTION PART NO. 793273 ARMREST STOP ASSEMBLY 797571 SEAT BACK PANEL KIT 7. Service parts available for Milsco seats: DESCRIPTION PART NO.
Chapter 9 Contents Tractor Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 72" and 60" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 52" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tractor Decals A 17 2 4 6 8 1 A 3 TOP OF SEAT PAN 5 9 10 BOTTOM OF SEAT PAN 11 12 13 14 15 7 9-2 375535 6/06
Tractor Decals 16 INDEX NO. SERVICE PART NO. MFG. PART NO. QTY.
72" and 60" Deck Decals 1 2 7 8 6 3 4 4 5 3 INDEX NO. SERVICE PART NO. MFG. PART NO. QTY. 1 786277 786277 1 60" SIDE DISCHARGE DECK ID DECAL 786285 786285 1 72" SIDE DISCHARGE DECK ID DECAL 2 781419 781419 1 BELT ROUTING DECAL 3 727438 727438 2 WHIRLING BLADES DECAL 4 727453 727453 2 BELT & PULLEY DECAL 5 727420 727420 1 DEFLECTOR SHIELD DECAL 6 727172 727172 1 "MADE IN U.S.A.
52" Deck Decals 2 1 7 6 8 4 5 3 4 3 INDEX NO. SERVICE PART NO. MFG. PART NO. QTY. 1 785535 785535 1 52" SIDE DISCHARGE DECK ID DECAL 2 781419 781419 1 BELT ROUTING DECAL 3 727438 727438 2 WHIRLING BLADES DECAL 4 727453 727453 2 BELT & PULLEY DECAL 5 727420 727420 1 DEFLECTOR SHIELD DECAL 6 727172 727172 1 "MADE IN U.S.A.
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Chapter 10 Contents 72" and 60" Mulch Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 72" Mulch Kit–352419 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 60" Mulch Kit–352427 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 52" Mulch Kit - 344929 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 52" Mulch Kit–352435 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72" and 60" Mulch Kits 3 1 2 2 1 2 3 4 1 2 5 6 6 1 2 INDEX NO. SERVICE PART NO. MFG. PART NO. QTY. 1 054502 054502 7 2 767954 767954 9 FW .406 X .812 X.060 SAE HD ZN 3 036244 036244 2 CS .375-16 X 1.00 HX G5 ZN DESCRIPTION NT .375-16 HX GRD 5 ZN 4 011320 011320 1 CB .375-16 X .750 STD ZN 5 346056 346056 1 RIGHT MULCH BAFFLE 346023 346023 2 60" COMMON MULCH BAFFLE 348599 348599 2 72” COMMON MULCH BAFFLE 6 NOTES: 1. 60" Mulch Kit - 346411 2.
72" Mulch Kit–352419 1 1 2 72" DECK 3 2 6 2 5 5 2 EXISTING HARDWARE 1 3 4 2 INDEX NO. SERVICE PART NO. MFG. PART NO. 1 054502 054502 7 NT .375-16 HX GRD 5 ZN 2 767954 767954 10 FW .406 X .812 X.060 SAE HD ZN 3 036244 036244 3 CS .375-16 X 1.00 HX G5 ZN 4 100891 100891 1 RIGHT MULCH BAFFLE 5 348599 348599 2 72” COMMON MULCH BAFFLE 6 793398 793398 3 BLADE,23.86"-MUL-F-CW QTY. DESCRIPTION NOTES: 1. Used on mowers with serial number 05011098 and later.
60" Mulch Kit–352427 1 1 2 60" DECK 3 2 2 2 5 5 1 EXISTING HARDWARE 3 6 2 4 INDEX NO. SERVICE PART NO. MFG. PART NO. 1 054502 054502 7 NT .375-16 HX GRD 5 ZN 2 767954 767954 10 FW .406 X .812 X.060 SAE HD ZN 3 036244 036244 3 CS .375-16 X 1.00 HX G5 ZN 4 100420 100420 1 RIGHT MULCH BAFFLE 5 348599 348599 2 72” COMMON MULCH BAFFLE 6 793380 793380 3 BLADE,23.86"-MUL-F-CW QTY. DESCRIPTION NOTES: 1. Used on mowers with serial number 05011098 and later.
52" Mulch Kit–344929 1 1 2 3 2 4 2 5 6 2 1 INDEX NO. SERVICE PART NO. MFG. PART NO. QTY. 1 054502 054502 5 2 767954 767954 7 FW .406 X .812 X.060 SAE HD ZN 3 036244 036244 2 CS .375-16 X 1.00 HX G5 ZN DESCRIPTION NT .375-16 HX GRD 5 ZN 4 011320 011320 1 CB .375-16 X .750 STD ZN 5 344796 344796 1 RIGHT MULCH BAFFLE 6 344945 344945 2 COMMON MULCH BAFFLE, NOTES: 1. Used on mowers with serial number prior to 05011098.
52" Mulch Kit–352435 1 1 2 52" DECK 3 2 2 5 2 5 1 4 3 6 EXISTING HARDWARE 2 INDEX NO. SERVICE PART NO. MFG. PART NO. QTY. 1 054502 054502 5 NT .375-16 HX GRD 5 ZN 2 767954 767954 8 FW .406 X .812 X.060 SAE HD ZN 3 036244 036244 3 CS .375-16 X 1.00 HX G5 ZN 4 100446 100446 1 RIGHT MULCH BAFFLE 5 344945 344945 2 72” COMMON MULCH BAFFLE 6 794198 794198 3 BLADE,17.86"-MUL-F-CW DESCRIPTION NOTES: 1. Used on mowers with serial number 05011098 and later.
Chapter 11 Contents Maintenance & Adjustments Safety Precautions . . . . . . . . . . . . . . .11-3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-7 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-2 375535_0606
SAFETY PRECAUTIONS ▲ ▲ This safety alert symbol is used to call attention to a message intended to provide a reasonable degree of PERSONAL SAFETY for operators and other persons during the normal operation and servicing of this equipment. DANGER – denotes immediate hazards which WILL result in severe personal injury or death. ▲ WARNING - denotes a hazard or unsafe practice which COULD result in severe personal injury or death. ▲ ▲ This manual uses two other words to highlight information.
Using a ramp regularly. ▲ Grass collection system components are subject to wear, damage and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check components and replace with manufacturer’s recommended parts, when necessary. ▲ Use only genuine Hustler replacement parts to ensure that original standards are maintained ▲ Use extreme caution when loading and unloading a unit with a ramp.
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 explanation is shown to help the operator understand the meanings of these decals. Do not smoke while refueling. Do not fill tank with engine running, or while the engine is hot.
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MAINTENANCE MAINTENANCE LOCATOR CHART 6 7 12 11 5 11 9 3 10 4 1a 6 1b 1a. Engine Oil Fill & Dipstick (Kawasaki & Honda) 1b. Engine Oil Fill & Dipstick (Kohler) 2. Fuel Filter 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 11. Deck Height Pivot Zerks (4) 12. Park Brake Switch 13. Drive Tire 14. Pump Idler Zerk (1) 15.
MAINTENANCE LOCATOR CHART 4 2 5 3 4 4 1 2 5 1. 2. 3. 4. 5.
Some repairs require the assistance of a trained service mechanic and should not be attempted by unskilled personnel. Consult your Hustler service center when assistance is needed. Battery Torque values WARNING: Particular attention must be given to tightening the drive wheel lug nuts, wheel motor nuts, and blade spindle bolts. Failure to correctly torque these items may result in the loss of a wheel or blade, which can cause serious damage or personal injury. Torque values given below: Ft-lbs.
Hydraulic reservoir Seat platform catch Seat platform Control lever Hydraulic filter Figure 11-5 Figure 11-4 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.
possible, then refuel the equipment on the truck or trailer using a portable container and not a gasoline dispenser nozzle. If a gasoline dispenser nozzle must be used, keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. WARNING: Gasoline is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness. Avoid prolonged breathing of vapors. Keep face away from nozzle and gas tank or conditioner opening.
Do not clean element, replace with a new element only. Cleaning used air filter elements, through improper cleaning procedures, can get dust on the inside of the filter causing dirt ingestion and engine failure. It is important to note that whenever an air filter element is cleaned by any method, the person or company performing the cleaning assumes responsibility for the integrity of the filter from then on.
WARNING: If the pump belt fails, loss of control will occur especially when operating on a slope. If you lose steering control while operating the machine, place the steering control levers in the park brake position immediately. Inspect the machine and involve your Hustler dealer to resolve the problem before continuing to operate. Inspect the belt pulley grooves and flanges for wear. A new belt, or one in good condition, should never run against the bottom of the groove.
Warped Blade (Replace) Cutting Plane Straight Blade Comparison of Warped and Straight Blades Figure 11-15 Resharpening Pattern Do not sharpen to original pattern (below). It is easier to get a straight cutting edge following the resharpening pattern shown above. Cutting Edge Twisted Blade Edge (Replace) Cutting Plane Cutting Edge Straight Blade Edge End view of blades, comparing twisted and straighten blades.
ADJUSTMENTS Introduction Control lever in the neutral position 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. A good time to detect potential problems is while performing scheduled maintenance service.
the control levers are pushed forward against the stops. To keep the pumps from bottoming out internally use the following procedure: 1. To make the first adjustment the tractor engine must NOT be running. 2. Check to make sure the control levers are against the stops before the pumps are bottomed out internally. To do this, gently and slowly move the control levers forward and feel if there is some resistance on the pump lever before the control levers hit the stops. Check one side at a time.
Hustler Z shown Control lever Park brake slot Outside edge Travel slot Bypass valve Figure 11-24 Figure 11-23 5. 6. 7. 8. 9. 10. 11. 12. 13. at this point. Move the control lever to where it is touching the outside edge of the lever’s travel slot. Fig. 11-24 NOTE: When the control lever is against the outside edge of the the slot, the brakes should not be engaged. Rotate the tire. If the brake is adjusted properly the tire will still rotate but friction will start to become noticeable here.
9. Set the amount of threads protruding on the deck lift rod from the lift block at approximately 1". Fig. 11-35 10. Jam both nuts against the block. 11. Push or pull on the deck lift foot pedal until the chain on the left front just becomes tight, making sure that the deck stays tight against the 3" block. 12. While keeping the chain tight, tighten the nuts against the deck lift block on the height indicator rod. Fig. 11-34 13. Go to the right front of the tractor. 14.
Deck lift threaded rod Nut Foot pedal Nut Chains Nuts Figure 11-31 Figure 11-34 Deck lift threaded rod Deck lift assist springs Lift block 1” 1” Nut Nut Chains Deck lift rod Figure 11-32 Figure 11-35 5/16” bolt Adjuster Jam nut Hardware Figure 11-33 375535_0606 11-19
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INDEX PAGE Access to engine and hydraulic pump..........................11-10 Adjustment introduction...............................................11-15 Belt replacement...........................................................11-12 Control lever adjustment ..............................................11-16 Control lever stops .......................................................11-15 Decals.............................................................................11-5 Deck drive belt adjustment.....
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Part Number Index Part No. Page No. Part No. Page No. Part No. Page No.
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