Manuals / Hustler Turf / Lawn and Garden / Lawn Mower

Hustler Turf Diesel Z manual Assembly Pictures and Aids, General Information for all models

Models: Diesel Z

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Assembly Pictures and Aids

General Information for all models

Instrument panel and wire connections (FIG. 1).

OIL PRESSURE LIGHT

GLOW PLUG LIGHT

FUEL

GAUGE

COOLANT TEMP. GAUGE

PTO CLUTCH SWITCH

COOLANT	CHARGE
TEMP. LIGHT	LIGHT

HOUR

METER

YEL/RED

GRN/BLK

ORANGE

YEL/BLK

WHT/YEL

YEL/WHT

ORANGE

BLACK

CONNECT LONG

SENSOR WIRE TO

SHORT WIRE HARNESS

CONNECTOR

BLACK

ORANGE

CONNECT

SHORT

SENSOR WIRE TO

LONG WIRE HARNESS

CONNECTOR

FIG. 1

Oil Pressure Light

Orange

Yellow w/ Black stripe

Glow Plug Light

Orange

Green w/ Black stripe

Coolant Temperature Light

Orange

Yellow w/ White stripe

Charge Light

Orange

Yellow w/ Red stripe

Hour Meter

Orange

Black

Coolant Temperature Gauge

Orange ring & Black

White w/ Yellow stripe ring

spade

10-3	109706 10/08

Page 117

Image 117

Hustler Turf Diesel Z manual Assembly Pictures and Aids, General Information for all models

Contents

Hustler Turf Equipment Hustler Diesel Z Parts ManualP.O. Box Hesston, Kansasowner’s manual Chapter Table of ContentsChapter ChapterChapter 72 Rear Discharge Deck Pulley AssemblyChapter ChapterChapter Service LiteratureGeneral Information Frequently Ordered PartsSIZE Using this manualFT-LBS Hardware Description Codes & AbbreviationsChapter 2 Contents Footrest Assembly 9 7109706 10/08 Footrest Assembly 2. Service part includes Items 1 and 2 step treadsSERVICE INDEX NOSERVICE Rivet Nut InstallationINDEX NO DESCRIPTIONChapter 3 Contents Hydraulic Component Fittings Hydraulic Component MountingHydraulic Line Connections 109706 10/08 Hydraulic Component Fittings1. Hydraulic system capacity is 7 US quarts. Fill reservoir to within 1 of top of Item 4 032771 Strainer Hydraulic Component FittingsTANDEM PUMPS Hydraulic Component MountingRESERVOIR LEFT WHEEL MOTORSERVICE 1. Part of wheel motors 601556 andHydraulic Component Mounting INDEX NOTANDEM PUMPS Hydraulic Line ConnectionsRIGHT WHEEL MOTOR FIREWALL OIL COOLER MANIFOLDSERVICE 1. See “Hydraulic routing” on pageHydraulic Line Connections INDEX NO109706 10/08 Deck Lift Assembly Steering Sub-Assembly Steering System Brake System Chapter 4 ContentsDeck Lift Assembly TRACTOR FRAME109706 10/08 Deck Lift Assembly 1. Apply grease to zerks see owner’s manualSERVICE DESCRIPTION1. Includes Item 1 781260 Steering Bar Grip Steering Sub-AssemblySERVICE INDEX NO109706 10/08 This page intentionally left blankSee “Steering Sub-Assembly” on page Sub-Assembly”Steering System See “SteeringSteering System 3. Torque to 180-200 in-lbsSee “Steering Sub-Assembly” on page Brake SystemSERVICE Brake SystemDESCRIPTION 109706 10/08 4-10Engine Sub-Assembly Belt Drive System Firewall & ROPS Assembly Chapter 5 ContentsAir Filter Installation Cooling System Installation Engine Cover Installation Fuel System7 12 Engine Sub-Assembly4826 FUEL FILTER DETAIL 109706 10/08SERVICE Engine Sub-Assembly109706 10/08 INDEX NO4. Engine oil capacity See engine owner’s manual 1. Supplied with engine 2. Torque to 33 ft-lbs 3. Torque to 78 ft-lbs5. Engine RPM to be set at 2950±50 6. Included in 601498 Hydro Kit 7. Torque to 64 ft-lbs109706 10/08 This page intentionally left blankDECK BELT Belt Drive System3. Apply grease to zerks 4. Torque to 100 ft-lbs 1. Torque to 41 ft-lbs 2. Torque to 21 ft-lbs6. Torque to 45-48 ft-lb 7. Torque to 12-15 ft-lb SERVICE109706 10/08 109706 10/08 This page intentionally left blankFRONT OF FIREWALL DETAIL Firewall & ROPS Assembly5-10 109706 10/081. Assemble Item 6 ROPS Stop on right post of ROPS only 2. Service part includes decals. See “Tractor Decals” on pageFirewall & ROPS Assembly SERVICEAIR FILTER DETAIL Air Filter InstallationAir Filter Installation 4. Service part includes decals. See “Tractor Decals” on pageSEE RADIATOR DETAIL FOR ASSEMBLY Cooling System InstallationRADIATOR DETAILCooling System Installation 1. Coolant capacity 6.0 US quarts2. Service part includes decals. See “Tractor Decals” on page SERVICE3215 Engine Cover Installation5-16 109706 10/08SERVICE Engine Cover Installation109706 10/08 5-17Fuel System 5-18109706 10/08 3. Right side fuel sensor terminal of wire harness connects here 2. Left side fuel sensor terminal of wire harness connects here7. Service parts for fuel tanks not shown 1. Includes Item 6 601375 O-RingPOSITIVE BATT. CABLE DETAIL Battery and Electrical ConnectionsTRACTOR FRAMEBattery and Electrical Connections 2. Battery is not installed in export models 3. Part of wire harnessTHROTTLE Instrument PanelFIREWALL21 15A 25A FUSE SIZE LOCATION DETAIL3. Service part includes decals. See “Tractor Decals” on page 1. Part of wire harnessSERVICE Instrument PanelElectrical Schematic-601367 5-24109706 10/08 Front Wheel Assembly Front Wheel Breakdown-747782 Chapter 6 ContentsDrive Wheel Assembly Installation Anti-Rollover Wheel Assembly Optional Semi-Pneumatic Tire/Wheel-789537TRACTOR FRAME Front Wheel AssemblyFront Wheel Assembly 1. Apply grease to zerks 2. Torque to 100 ft.-lbsSERVICE INDEX NO1. Inflate tire to 8-12 psi Front Wheel Breakdown-747782SERVICE DESCRIPTIONSERVICE Optional Semi-Pneumatic Tire/Wheel-789537109706 10/08 DESCRIPTION1. Torque to 65-75 ft. lbs 2. Inflate tire to 8-12 psi Drive Wheel Assembly InstallationSERVICE DESCRIPTION1. Do not torque, wheel must turn freely Anti-Rollover Wheel AssemblySERVICE DESCRIPTION109706 10/08 Chapter 7 Contents 72 Side Discharge XR7 Deck Assembly 5 4 8109706 10/08 2. Includes items 7, 8, 9, and 1. Do not torque, Item 2 798694 Discharge Chute must pivot freely72 Side Discharge XR7 Deck Assembly SERVICE72 DECK ASSY 72 Side Discharge XR7 Deck Pulley AssemblyBELT GUIDE INDEXING 109706 10/081. Torque to 118 ft. lbs 2. Torque to 67-75 ft. lbs 5. See ‘‘Spindle Assembly-796235X’’ on page 7-34 for breakdown3. Apply grease to zerk see owner’s manual 72 Side Discharge XR7 Deck Pulley Assembly109706 10/08 66 Side Discharge XR7 Deck AssemblySERVICE 66 Side Discharge XR7 Deck Assembly1. Do not torque, Item 2 798694 Discharge Chute must pivot freely 2. Includes items 7, 8, 9, and66 DECK ASSY 66 Side Discharge XR7 Deck Pulley Assembly2 20 BELT GUIDE5. See ‘‘Spindle Assembly-796235X’’ on page 7-34 for breakdown 66 Side Discharge XR7 Deck Pulley AssemblySERVICE 1. Torque to 118 ft. lbs 2. Torque to 67-75 ft. lbs9 11 60 Side Discharge XR7 Deck Assembly7-10 109706 10/08SERVICE 60 Side Discharge XR7 Deck Assembly1. Do not torque, Item 2 798694 Discharge Chute must pivot freely 2. Includes items 7, 8, 9, and60 DECK ASSY 60 Side Discharge XR7 Deck Pulley AssemblyBELT GUIDE INDEXING 7-121. Torque to 118 ft. lbs 2. Torque to 65-75 ft. lbs 5. See‘‘Spindle Assembly-796235X’’ on page 7-34 for breakdown60 Side Discharge XR7 Deck Pulley Assembly SERVICE10 8 54 Side Discharge XR7 Deck Assembly7-14 109706 10/0854 Side Discharge XR7 Deck Assembly 2. Includes items 9, 10, 11, andSERVICE 1. Do not torque, Item 2 798694 Discharge Chute must pivot freely54 DECK ASSY 54 Side Discharge XR7 Deck Pulley AssemblyBELT GUIDE POSITIONING 24 2954 Side Discharge XR7 Deck Pulley Assembly 3. Apply grease to zerk5. See‘‘Spindle Assembly-796235X’’ on page 7-34 for breakdown SERVICEDECK ASSEMBLY Side Discharge Deck-A Adaptors7-18 109706 10/08Side Discharge Deck-A Adaptors SERVICE109706 10/08 7-19Assembled Detail Side Discharge Deck-B AdaptorsSERVICE 1. Service part includes rivet nutsSide Discharge Deck-B Adaptors ITEM NO23 4 72 Rear Discharge Deck AssemblyDEFLECTOR DETAIL 7-221. Factory assembled in top hole for shipping purposes 4. When installing Items 22 and 24, Item 24 should be on top of Item2. Includes Items 15 through 17 and 72 Rear Discharge Deck Assembly72 Rear Discharge Deck Pulley Assembly 7-24109706 10/08 5. See ‘‘Spindle Assembly-796680X’’ on page 7-35 for breakdown 4. See ‘‘Spindle Assembly-796235X’’ on page 7-34 for breakdown72 Rear Discharge Deck Pulley Assembly SERVICEDEFLECTOR DETAIL 60 Rear Discharge Deck Assembly1. Includes Items 13 through 15 and 4. When installing Items 20 and 22, Item 22 should be on top of Item2. Factory assembled in top hole for shipping purposes 60 Rear Discharge Deck Assembly5 19 22 6 60 Rear Discharge Deck Pulley Assembly7-28 109706 10/084. See ‘‘Spindle Assembly-796235X’’ on page 7-34 for breakdown 60 Rear Discharge Deck Pulley Assembly5. See ‘‘Spindle Assembly-796680X’’ on page 7-35 for breakdown SERVICE121 13 14 54 Rear Discharge Deck AssemblyDEFLECTOR DETAIL 29 32. Includes Items 12 through 14 and 4. When installing Items 19 and 21, Item 21 should be on top of Item54 Rear Discharge Deck Assembly SERVICE54 Rear Discharge Deck Pulley Assembly 7-32109706 10/08 54 Rear Discharge Deck Pulley Assembly 4. See ‘‘Spindle Assembly-796680X’’ on page 7-35 for breakdown5. See ‘‘Spindle Assembly-796235X’’ on page 7-34 for breakdown SERVICE1. Install upper bearing with extended inner race up Spindle Assembly-796235X2. Install lower bearing with extended inner race down SERVICE1. Install upper bearing with extended inner race up Spindle Assembly-796680X2. Install lower bearing with extended inner race down SERVICE109706 10/08 7-36Chapter 8 Contents 109706 10/08 Deck InstallationDeck Installation 1. Install front deck hanger chains in lower holes onlySERVICE INDEX NOTRACTOR FRAME Seat Installation10 11 109706 10/081. Must pivot freely 2. Service part number includes decals see “Tractor Decals” on pageSeat Installation SERVICE2. Route belt as shown 72, 66 & 54 Side Disch. Deck Belt Routing/Tensioning2. Route belt as shown 60 Side Disch. XR7 Deck Belt Routing/Tensioning2. Route belt as shown 72, 60 & 54 Rear Discharge Deck Belt Routing/TensioningChapter 9 Contents Tractor Decals TOP OF SEAT PANBOTTOM OF SEAT PAN Tractor Decals SERVICE109706 10/08 INDEX NOSERVICE 72 Side Discharge XR7 Deck Decals109706 10/08 INDEX NOSERVICE 66 Side Discharge XR7 Deck Decals109706 10/08 INDEX NOSERVICE 60 Side Discharge XR7 Deck Decals109706 10/08 INDEX NOSERVICE 54 Side Discharge XR7 Deck Decals109706 10/08 INDEX NOSERVICE 72 Rear Discharge Deck Decals109706 10/08 INDEX NOSERVICE 60 Rear Discharge Deck Decals109706 10/08 INDEX NO54 Rear Discharge Deck Decals SERVICEDESCRIPTION Chapter 10 Contents Belt replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27 Mower blade maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 10-28 Mower blade removal General Information for all models Assembly Pictures and AidsWire harness and cable routings THROTTLE CABLE FUEL SENSOR CONNECTOR TIE STRAP WIRE HARNESS Fuel sensors and wire harness routing FIG. 8, FIG. 9 & FIGCONNECTOR WIRE HARNESSFuel lines WIRE HARNESS WIRE HARNESSOIL COOLER TIE STRAP FUEL LINES TIED WITH WIRE HARNESS TIE STRAP ARROW UPFUEL VALVE Hydraulic routingTIE STRAP Engine oil hose routingADAPTOR TIE STRAP OIL HOSES TO REMOTE FILTER SEAT LATCHSafe Maintenance & Adjustment Practices Maintenance & Adjustment SafetySafety and Instruction Decals Using a rampKeep shields or covers in place while machine is in operation Whirling blades! Keep hands and feet away Beware of thrown objectsKeep hands away from rotating pulleys and belts Part Number 727016727818 Part Number 600899 Part Number 727008 Part Number 779280 Part NumberMaintenance Locator Chart Maintenance12. Park Brake Switch Viewed from top of unit 6NOTE After completing maintenance cycle 500 hours, repeat cycle SERVICE AT INTERVALS INDICATEDa --Refer to Engine Owner’s Manual WEEKLYIntroduction General engine maintenanceTorque values TiresLubrication Hour meterElectrical system Access to engine and hydraulic pumps Hydraulic systemSEAT PLATFORM CHECK SEAT PLATFORM CONTROL LEVER HYDRAULIC RESERVOIR HYDRAULIC FILTER Fuel system DANGER Observe usual fuel handling precautionsPRIMING BULB CLOSED POSITION LEFT TANK POSITION FUEL SHUT-OFF VALVE RIGHT TANKPOSITION SHOWN Changing the oil Engine oil and filterENGINE OIL FILLER TUBE ENGINE OIL DIPSTICKREFER TO FIG. 39 FOR THIS PROCEDURE PRE-CLEANEREngine air filter OIL REMOVAL FROM THE ENGINE BREATHER VALVE SYSTEMINCORRECT AIR CLEANER ELEMENT IMPROPER INSTALLATION OF AN AIR FILTER ELEMENTRECOMMENDED SERVICE PROCEDURE OVERSERVICINGINDICATOR RESET INDICATOR SAFETY FILTERSAFETY AIR CLEANER FILTER AIR RESTRICTION INDICATORSpindle drive belt Belt replacementSpindle belt tension idler spring Deck belt idler pulleyElectric deck clutch Mower blade maintenanceDeck drive belt Fixed pulleyMower blade removal CONTROL LEVER NEUTRAL ADJUSTMENT AdjustmentSteering linkage IntroductionJAM NUT Control lever stopsCONTROL PANEL STOP CONTROL LEVER controls the right hydraulic pumpSteering dampener SPRING HOUSING FRONT BALL STUDControl lever adjustment Park brake spring adjustmentALIGN HANDLES ±.125” Deck drive belt adjustment Hydraulic pump belt adjustmentEngine RPM setting Deck leveling and height adjustmentDECK LEVEL ADJUSTMENTS Page 25. Tighten the appropriate nut until the chain just becomes tight 23. Go to the left rear of the tractor10-37 109706 10/08109706 10/08 10-38Index Numerical IndexPart Numbers PartPart Page PartPart PagePart