Hustler Super Z Parts Manual

Transcription

1 Hustler Super Z Parts Manual Hustler Turf Equipment P.O. Box 7000 Hesston, Kansas

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. NOTICE OF REQUIREMENT OF SPARK ARRESTER MUFFLER This equipment may create sparks that can start fires around dry vegetation. California Public Resources Code Section. provides that it is unlawful to use or operate an internal combustion engine on any forest-covered, brush-covered, or grass-covered land unless the engine is equipped with a spark arrester maintained in effective working order. A spark arrester is a device constructed of nonflammable materials specifically for the purpose of removing and retaining carbon and other flammable particles over 0.0 of an inch in size from the exhaust flow of an internal combustion engine that uses hydrocarbon fuels or which is qualified and rated by the United States Forest Service. Other states or federal areas may have similar laws. The Operator Should Contact Local Fire Agencies For Laws or Regulations Relating to Fire Prevention Requirements. THIS EQUIPMENT DOES NOT HAVE A SPARK ARRESTER AND YOU SHOULD CONTACT YOUR AUTHORIZED DEALER FOR THE PURCHASE OF A SPARK ARRESTER. Inspect spark arrester daily; replace every 00 hours or as needed. The Engine 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 s Manual with your unit. Should the Engine Owner s Manual become damaged or illegible, replace immediately. Replacements may be ordered per the information found in the Product Information section of the owner s manual. t /0

3 Table of Contents Section General Information Section Frame Rivet Nut Installation Seat Support Rivet Nut Installation Seat Support Rivet Nut Installation S/N Prior To Footrest Assembly Section Hydraulic System Installation Air Cooled Engines (Non HT) Hydraulic System Installation Air Cooled Engines (Non HT) Hydraulic System Installation Kawasaki HP Engine Hydraulic System Installation Kawasaki HP Engine Hydraulic System Installation Kawasaki HP Engine Hydraulic System Installation Kawasaki HP HT Engine Hydraulic System Installation Kohler 0HP HT Section Battery Installation Deck Lift Assembly Steering Assembly Park Brake Assembly Steering Sub-Assembly Pump Belt and Pulleys Installation Section Kawasaki HP Engine Installation Kawasaki HP Engine Installation Kawasaki HP Engine Installation Honda HP Engine Installation Kohler 7 & 0 HP Engine Installation Kohler 8 HP EFI Engine Installation Fuel System Air Cooled W/Carburetor Fuel System Liquid Cooled (S/N Higher Than 0800) Fuel System Liquid Cooled (S/N Prior To 0800) Fuel System With EFI Instrument Panel Assembly Air Cooled W/Carb Instrument Panel Liquid Cooled Instrument Panel Assembly With EFI Electrical Schematic Common Air Cooled (7990) Elec. Schematic Kaw LC (7998) S/N Higher Than Elec. Schematic Kaw LC (7999) S/N Prior To Electrical Schematic Kohler EFI (799) Section Front Wheel Assembly Front Wheel Breakdown /0 c-

4 Optional Semi-Pneumatic Tire/Wheel Drive Wheel Assembly Anti-Rollover Wheel Assembly Section 7 7" Side Discharge XR7 Deck Assembly " Side Discharge Deck Pulley Assembly (XR7) " Side Discharge Deck Pulley Assembly (XR7) " Side Discharge Deck Assembly (XR7) " Side Discharge Deck Pulley Assembly (XR7) " Side Discharge Deck Assembly (XR7) " Side Discharge Deck Pulley Assembly (XR7) Side Discharge Deck "A" Adaptors Side Discharge Deck "B" Adaptors " Rear Discharge Deck Assy S/N Higher Than " Rear Discharge Deck Assy S/N " Rear Discharge Deck Assy S/N Prior To " Rear Disch Deck Pulley Assy S/N Higher Than " Rear Disch. Deck Pulley Assy S/N Prior To " Rear Discharge Deck Assy S/N & Higher " Rear Discharge Deck Assy S/N " Rear Discharge Deck Assy S/N Prior To " Rear Disch. Deck Pulley Assy S/N & Higher " Rear Disch. Deck Pulley Assy S/N Spindle Assembly Spindle Assembly Section 8 Deck Installation ", ", & " Side Discharge Belt Routing and Tensioning " Side Discharge Belt Routing and Tensioning " & 0" Rear Discharge Belt Routing and Tensioning " & 0" Rear Disch. Belt Routing and Tensioning Seat Installation S/N Higher Than Seat Installation S/N Prior To ROPS Installation Section 9 Mower Decals ", " & 0" Side Discharge Deck Decals(XR7) " Side Discharge Deck Decals (XR7) " Rear Discharge Deck Decals " Rear Discharge Deck Decals Section 0 Assembly Pictures and Aids Maintenance & Adjustment Safety Safe Maintenance & Adjustment Practices Maintenance Adjustment c /0

5 General Information Section This Manual covers Hustler XR7 Super Z models: 977, 977EX, 97, 97EX, 977, 978, 9788A/B, 978A/B, 9787A/B, 97889A/B, 97897A/B, 979A/B, 979A/B, 9799A/B, 9797A/B, 97970A/B, 97988A/B, 97988EX, 9800A/B, 9800EX, 9808A/B, 9808EX, 980A/B, 980EX, 980A/B, 980EX, 980HTA/ B, 980HTEX, 980A/B, 980EX, 9809A/B, 9809EX, 98879A/B, 98879EX, 98887A/B, 98887EX, 98887HTA/B, 98887HTEX, 9889A/B, 9889EX, 989A/B, 989EX, 9899, 9899EX, 9897 & 9897EX with serial numbers higher than Frequently Ordered Parts Service Literature DESCRIPTON 789 Hydraulic Oil Filter 78 Pump Drive Belt Blade, F.0"-H-F-CW (7" Side Discharge Deck) 7989 Blade, F.0"-H-F-CW (" Side Discharge Deck) 798 Blade, F0.0"-H-F-CW (0" Side Discharge Deck) 7979 Blade, F8.0"-H-F-CW (" Side Discharge Deck) 7908 Blade, F.8-L-F-CCW (7" Rear Discharge Deck) 7989 Blade, F.8-L-F-CW (" Rear Discharge Deck) 79 Blade, F0.0"-L-F-CCW (0" Rear Discharge Deck) 0090 Blade, F0.0"-L-F-CW (0" Rear Discharge Deck) 7807 Belt, B-Section (7" Side Discharge Deck) 7979 Belt, B-Section (" Side Discharge Deck) Belt, B-Section (0" Side Discharge Deck) Belt, B-Section (" Side Discharge Deck) 7977 Belt, 7" Rear Discharge Deck 7978 Belt, 0" Rear Discharge Deck 0878 Fuel Filter 78 Main Air Filter Element 7879 Safety Air Filter Element 0 Main Air Filter Element (KAW only) (Prior to S/N 009) 0 Safety Air Filter Element (KAW only) (Prior to S/N 009) Kawasaki Engine Oil Filter 78 Honda Engine Oil Filter 770 Kohler Engine Oil Filter DESCRIPTION 0 Owner s Manual 78 Honda 8/0/ Engine Owner s Manual 778 Kawasaki 9 HP Engine Owner s Manual 78 Kohler Engine Owner s Manual 07 Kawasaki 9 HP Engine Owner s Manual 0 Kawasaki HP Engine Owner s Manual 7980 Kawasaki HP Engine Owner s Manual Note: When ordering parts, you must use the part number as shown for each part, not the index number. Always give the model and serial number to your parts and service representative. Note: Items sold in bulk such as seals and hoses are sold by the foot /0 -

6 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 necessary, 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 DESCRIPTION 087 "A" Baffles Kit XR7 (7" Side Discharge Deck) 08 "A" Baffles Kit XR7 (" Side Discharge Deck) 08 "A" Baffles Kit XR7 (0" Side Discharge Deck) 08 "A" Baffles Kit XR7 (" Side Discharge Deck) 08 "B" Baffles Kit XR7 (7" Side Discharge Deck) 08 "B" Baffles Kit XR7 (" Side Discharge Deck) 080 "B" Baffles Kit XR7 (0" Side Discharge Deck) 089 "B" Baffles Kit XR7 (" Side Discharge Deck) 08 Containment Baffles Kit (7" Side Discharge Deck) 08 Containment Baffles Kit (" Side Discharge Deck) 080 Containment Baffles Kit (0" Side Discharge Deck) 089 Containment Baffles Kit (" Side Discharge Deck) 08 Mulch Kit (/7" Side Discharge Deck) 08 Mulch Kit (/0" Side Discharge Deck) 0880 Stripe Kit (/7" Side Discharge Deck) 079 Stripe Kit (/0" Side Discharge Deck) Gator Blade,.0"-GAT-F-CW (7" Side Discharge Deck) 798 Gator Blade,.0"-GAT-F-CW (" Side Discharge Deck) 790 Gator Blade, 0.0"-GAT-F-CW (0" Side Discharge Deck) 7977 Gator Blade, 8.0"-GAT-F-CW (" Side Discharge Deck) Mulch Blade,.0"-MUL-F-CW (7" Side Discharge Deck) 7980 Mulch Blade,.0"-MUL-F-CW (" Side Discharge Deck) 79 Mulch Blade, 0.0"-MUL-F-CW (0" Side Discharge Deck) Mulch Blade, 8.0"-MUL-F-CW (" Side Discharge Deck) 08 Deck Lift Kit MMZ 07 Oil Cooler Screen 9 Steering Extension Kit 7897 Hitch Kit MMZ Flex Fork Kit 7897 Semi-Pneumatic Tire/Wheel Assy X.0-0 MMZ Foldable ROPS Kit 978 Snow Blade 988 Bac-Vac Catcher Assy (Requires additional kits for installation, see dealer) Hardware Description Codes & Abbreviations The following codes are used throughout this parts manual. Refer to this list when ordering parts. 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 /0

7 Standard Torques The following chart lists the standard torque values for the threaded fasteners found in this manual. Torque all cap screws, nuts and set screws to these values unless a different torque is shown in the Notes section next to the fastener. SIZE FT-LBS NM SIZE FT-LBS NM M.. 7 M M M M M M M M M0 0 M /0 -

8 /0

9 Section Frame Rivet Nut Installation Seat Support Rivet Nut Installation Seat Support Rivet Nut Installation S/N Prior To Footrest Assembly /0 -

10 Frame Rivet Nut Installation INDEX NO. SERVICE MFG. PART NO. QTY MOWER FRAME (") DESCRIPTION MOWER FRAME (0") MOWER FRAME (") MOWER FRAME (7") " RD MOWER FRAME " RD MOWER FRAME N/A /8- THREAD RIVET NUT NOTES: /0

11 Seat Support Rivet Nut Installation LIQUID COOL ONLY INDEX NO. SERVICE MFG. PART NO. QTY. DESCRIPTION XR7 MMZ SEAT SUPPORT N/A 8089 /8- THREAD RIVET NUT (FOR AIR COOLED) N/A 8089 /8- THREAD RIVET NUT (FOR LIQUID COOLED) N/A /- THREAD RIVET NUT (PER EACH SUPPORT) N/A /-0 THREAD RIVET NUT (KAWASAKI AIR COOLED ONLY) EXCEPT KAW N/A /-0 THREAD RIVET NUT (KAWASAKI LIQUID COOLED ONLY) HP KAWASAKI SEAT SUPPORT N/A 8088 /-8 THREAD RIVET NUT (KAWASAKI LIQUID COOLED ONLY) NOTES:. Used only on mowers with liquid cooled engines, serial numbers higher than 0800 (service part includes rivet nuts).. Used on all mowers with air cooled engines, serial numbers higher than 0800 (service part includes rivet nuts) /0 -

12 Seat Support Rivet Nut Installation S/N Prior To 0800 INDEX NO. SERVICE MFG. PART NO. QTY. DESCRIPTION XR7 MMZ SEAT SUPPORT HP KAWASAKI SEAT SUPPORT N/A 8088 /-8 THREAD RIVET NUT (KAWASAKI LIQUID COOLED ONLY) N/A 8089 /8- THREAD RIVET NUT (FOR AIR COOLED) N/A 8089 /8- THREAD RIVET NUT (FOR LIQUID COOLED) N/A /- THREAD RIVET NUT (PER EACH SUPPORT) N/A /-0 THREAD RIVET NUT (KAWASAKI AIR COOLED ONLY) EXCEPT KAW N/A /-0 THREAD RIVET NUT (KAWASAKI LIQUID COOLED ONLY) NOTES:. Used on all mowers with air cooled engines, serial numbers prior to 0800 (service part includes rivet nuts).. Used only on mowers with liquid cooled engines, serial numbers prior to 0800 (service part includes rivet nuts) /0

13 Footrest Assembly 7 INDEX NO. SERVICE MFG. QTY DESCRIPTION STEP TREAD 9 9 FLOOR 0 0 PLATFORM STEP TREAD NT.7- HX LK NY FW.0 X.8 X.00 SAE HD ZN RUBBER BUMPER CS.7- X.0 HX G ZN NOTES:. Do not tighten, Item (9 Floor) must be able to pivot on these bolts /0 -

14 /0

15 Section Hydraulic System Installation Air Cooled Engines (Non HT) Hydraulic System Installation Air Cooled Engines (Non HT) Hydraulic System Installation Kawasaki HP Engine Hydraulic System Installation Kawasaki HP Engine Hydraulic System Installation Kawasaki HP Engine Hydraulic System Installation Kawasaki HP HT Engine Hydraulic System Installation Kohler 0HP HT /0 -

16 Hydraulic System Installation Air Cooled Engines (Non HT) SUPER Z HOOD /0

17 Hydraulic System Installation Air Cooled Engines (Non HT) INDEX NO. SERVICE MFG. PART NO. QTY DESCRIPTION CS.0-0 X. HX G ZNYC FW.8 X. X.0/.080 HD ZNYC SEAL /8 X / X 7." LONG OIL COOLER NT.0-0 HX NL ZNYC BREATHER CAP STRAINER CS.0-0 X.0 HX G ZNYC SUPER Z RESERVOIR NT.-8 HX G ZNYC FW. X.87 X.0/.080 HD ZNYC PUMP, HYDRO-GEAR BDP-L NT.00- HX G ZNYC FW. X.0 X.090 SAE HD ZN ZAF SERIES FILTER HEAD FILTER ELEMENT CS.00-X.0 HX G MOTOR, WHITE RC8 CCW HOSE CLAMP 0 78 N/A RETURN HOSE ASSY, # 7.7" LONG 78 N/A RETURN HOSE, #." LONG 7808 N/A FITTING, # BEADED TUBE-ORB 7808 N/A FITTING, #8 BEADED TUBE-ORB N/A FITTING, STR-8MORB/-8MSL 788 N/A HEX PLUG FITTING, STR-8MORB 780 N/A SUCTION HOSE ASSY, FILTER-PUMP N/A SUCTION HOSE, TANK-FILTER N/A FITTING, T -8MJIC/8MJIC N/A FITTING, 0 FX0-S 0 78 N/A SUCTION HOSE, # " LONG 08 N/A TUBE, LP-TM LT LOOP 087 N/A TUBE, RP-BM LT LOOP 08 N/A TUBE, LP-BM RT LOOP 08 N/A TUBE, RP-TM RT LOOP 78 N/A FITTING, 90-0MORB/-8MSL 009 N/A HOSE GUARD NOTES:. Hydraulic system capacity is US quarts of 0W0 motor oil. Fill reservoir to within " of top of Item 8 (077 Strainer). See Hydraulic system on page 0-.. For mowers with serial numbers higher than HYDRAULIC SYSTEM CHARGING PROCEDURE. Set handles in the neutral position /0 -

18 Note:. Start engine at idle.. Let run for a minimum of 0 seconds.. Stroke handles to forward position.. If motors do not turn in seconds return handles to neutral and repeat step and (one time).. If motors do not turn after second attempt, shut off the engine and check for oil at the pump. 7. Increase throttle to half speed and work handles through forward and reverse position until the motor operates smoothly throughout the entire speed range. Seal Kit for hydraulic pump; 7898 (BDPL Overhaul Seal Kit) /0

19 This page intentionally left blank /0 -

20 Hydraulic System Installation Air Cooled Engines (Non HT) SUPER Z HOOD /0

21 Hydraulic System Installation Air Cooled Engines (Non HT) INDEX NO. SERVICE MFG. PART NO. QTY DESCRIPTION CS.0-0 X. HX G ZNYC FW.8 X. X.0/.080 HD ZNYC SEAL /8 X / X 7." LONG OIL COOLER N/A N/A N/A WEATHERSTRIP /8 X / X.88" LONG NT.0-0 HX NL ZNYC BREATHER CAP STRAINER CS.0-0 X.0 HX G ZNYC SUPER Z RESERVOIR NT.-8 HX G ZNYC FW. X.87 X.0/.080 HD ZNYC PUMP, HYDRO-GEAR BDP-L NT.00- HX G ZNYC FW. X.0 X.090 SAE HD ZN ZAF SERIES FILTER HEAD FILTER ELEMENT CS.00 - X.0 HX G WHITE MOTOR RC8 CCW HOSE CLAMP 78 N/A RETURN HOSE ASSY, # 7.7" LONG 78 N/A RETURN HOSE, #." LONG 7808 N/A FITTING, # BEADED TUBE-ORB 7808 N/A FITTING, #8 BEADED TUBE-ORB N/A FITTING, STR-8MORB/-8MSL 788 N/A HEX PLUG FITTING, STR-8MORB N/A SUCTION HOSE ASSY, FILTER-PUMP N/A SUCTION HOSE, TANK-FILTER N/A FITTING, T - 8MJIC/8MJIC N/A FITTING, 0 FX0-S 78 N/A SUCTION HOSE, # " LONG N/A TUBE, HYDRAULIC LINE N/A TUBE, HYDRAULIC LINE 788 N/A TUBE, HYDRAULIC LINE 78 N/A TUBE, HYDRAULIC LINE 78 N/A FITTING, 90-0MORB/-8MSL NOTES:. Hydraulic system capacity is US quarts of 0W0 motor oil. Fill reservoir to within "of top of Item 8 (077 Strainer). See Hydraulic system on page 0-.. For mowers with serial number prior to The single oil cooler (077) replaces the two coolers shown. See Hydraulic System Installation Air Cooled Engines (Non HT) on 080 0/0-7

22 Note: page - for current set up. HYDRAULIC SYSTEM CHARGING PROCEDURE. Set handles in the neutral position.. Start engine at idle.. Let run for a minimum of 0 seconds.. Stroke handles to forward position.. If motors do not turn in seconds return handles to neutral and repeat step and (one time).. If motors do not turn after second attempt, shut off the engine and check for oil at the pump. 7. Increase throttle to half speed and work handles through forward and reverse position until the motor operates smoothly throughout the entire speed range. Seal Kit for hydraulic pump; 7898 (BDPL Overhaul Seal Kit) /0

23 This page intentionally left blank /0-9

24 Hydraulic System Installation Kawasaki HP Engine KAWASAKI HP HOOD /0

25 Hydraulic System Installation Kawasaki HP Engine INDEX NO. SERVICE MFG. PART NO. QTY DESCRIPTION CS.0-0 X. HX G ZNYC FW.8 X. X.0/.080 HD ZNYC SEAL /8 X / X 7." LONG OIL COOLER N/A N/A N/A WEATHERSTRIP /8 X / X.88" LONG NT.0-0 HX NL ZNYC BREATHER CAP STRAINER SUPER Z RESERVOIR NT.-8 HX G ZNYC FW. X.87 X.0/.080 HD ZNYC CS.0-0 X.0 HX G ZNYC PUMP, HYDRO-GEAR BDP-L NT.00- HX G ZNYC FW. X.0 X.090 SAE HD ZN ZAF SERIES FILTER HEAD FILTER ELEMENT HOSE CLAMP CS.00-X.0 HX G WHITE MOTOR RC8 CCW 7990 N/A COOLER-RESERVOIR HOSE ASSY, " LONG 799 N/A COOLER-RESERVOIR HOSE ASSY, 9" LONG 7998 N/A PUMP COOLER HOSE, LONG 0 N/A CASE DRAIN HOSE 7808 N/A FITTING, # BEADED TUBE-ORB 7808 N/A FITTING, #8 BEADED TUBE-ORB N/A FITTING, STR-8MORB/-8MSL N/A HEX PLUG FITTING, STR-8MORB N/A SUCTION HOSE ASSY, FILTER-PUMP N/A SUCTION HOSE ASSY, FILTER-PUMP 7887 N/A FITTING, T -8MJIC/8MJIC 7898 N/A FITTING, 0 FX0-S 78 N/A SUCTION HOSE, # " LONG 08 N/A TUBE, HYDRAULIC LINE 087 N/A TUBE, HYDRAULIC LINE 08 N/A TUBE, HYDRAULIC LINE 7 08 N/A TUBE, HYDRAULIC LINE 8 78 N/A FITTING, 90-0MORB/-8MSL NOTES:. Hydraulic system capacity is US quarts of 0W0 motor oil. Fill reservoir to within " of top of Item 8 (077 Strainer). See Hydraulic system on page 0-.. For mowers with serial numbers higher than /0 -

26 Note:. The single oil cooler (077) replaces the two coolers shown. See Hydraulic System Installation Air Cooled Engines (Non HT) on page - for current set up. HYDRAULIC SYSTEM CHARGING PROCEDURE. Set handles in the neutral position.. Start engine at idle.. Let run for a minimum of 0 seconds.. Stroke handles to forward position.. If motors do not turn in seconds return handles to neutral and repeat step and (one time).. If motors do not turn after second attempt, shut off the engine and check for oil at the pump. 7. Increase throttle to half speed and work handles through forward and reverse position until the motor operates smoothly throughout the entire speed range. Seal Kit for hydraulic pump; 7898 (BDPL Overhaul Seal Kit) /0

27 This page intentionally left blank /0 -

28 Hydraulic System Installation Kawasaki HP Engine KAWASAKI HP HOOD /0

29 Hydraulic System Installation Kawasaki HP Engine INDEX NO. SERVICE MFG. PART NO. QTY DESCRIPTION CS.0-0 X. HX G ZNYC FW.8 X. X.0/.080 HD ZNYC SEAL /8 X / X 7." LONG OIL COOLER N/A N/A N/A WEATHERSTRIP /8 X / X.88" LONG NT.0-0 HX NL ZNYC BREATHER CAP STRAINER SUPER Z RESERVOIR NT.-8 HX G ZNYC FW. X.87 X.0/.080 HD ZNYC CS.0-0 X.0 HX G ZNYC PUMP, HYDRO-GEAR BDP-L NT.00- HX G ZNYC FW. X.0 X.090 SAE HD ZN ZAF SERIES FILTER HEAD FILTER ELEMENT HOSE CLAMP CS.00- X.00 HX G WHITE MOTOR CE-8 CCW 7990 N/A COOLER-RESERVOIR HOSE ASSY, " LONG 799 N/A COOLER-RESERVOIR HOSE ASSY, 9" LONG 7998 N/A PUMP COOLER HOSE, LONG 7808 N/A FITTING, # BEADED TUBE-ORB 7808 N/A FITTING, #8 BEADED TUBE-ORB N/A FITTING, STR-8MORB/-8MSL N/A HEX PLUG FITTING, STR-8MORB N/A SUCTION HOSE ASSY, FILTER-PUMP N/A SUCTION HOSE ASSY, FILTER-PUMP N/A FITTING, T -8MJIC/8MJIC 7898 N/A FITTING, 0 FX0-S 78 N/A SUCTION HOSE, # " LONG N/A TUBE, HYDRAULIC LINE N/A TUBE, HYDRAULIC LINE 788 N/A TUBE, HYDRAULIC LINE 78 N/A TUBE, HYDRAULIC LINE 7 78 N/A FITTING, 90-0MORB/-8MSL NOTES:. Hydraulic system capacity is US quarts of 0W0 motor oil. Fill reservoir to within " of top of Item 8 (077 Strainer). See Hydraulic system on page 0-.. For mowers with serial numbers prior to /0 -

30 Note:. The single oil cooler (077) replaces the two coolers shown. See Hydraulic System Installation Air Cooled Engines (Non HT) on page - for current set up. Seal Kit for hydraulic pump; 7898 (BDPL Overhaul Seal Kit) /0

31 This page intentionally left blank /0-7

32 Hydraulic System Installation Kawasaki HP Engine /0

33 Hydraulic System Installation Kawasaki HP Engine INDEX NO. SERVICE MFG. PART NO. QTY DESCRIPTION CS.0-0 X. HX G ZNYC FW.8 X. X.0/.080 HD ZNYC SEAL /8 X / X 7." LONG OIL COOLER NT.0-0 HX NL ZNYC BREATHER CAP STRAINER SUPER Z RESERVOIR NT.-8 HX G ZNYC FW. X.87 X.0/.080 HD ZNYC CS.0-0 X.0 HX G ZNYC PUMP, HYDRO-GEAR BDP-L NT.00- HX G ZNYC FW. X.0 X.090 SAE HD ZN ZAF SERIES FILTER HEAD FILTER ELEMENT HOSE CLAMP CS.00-X.0 HX G MOTOR, WHITE RC8 CCW 0 09 N/A HOSE, COOLER-LT RES 08 N/A HOSE, LEFT PUMP-COOLER 07 N/A HOSE, COOLER-RT RES 0 N/A HOSE, RIGHT PUMP-COOLER 7808 N/A FITTING, #8 BEADED TUBE-ORB N/A FITTING, STR-8MORB/-8MSL 788 N/A HEX PLUG FITTING, STR-8MORB N/A SUCTION HOSE ASSY, FILTER-PUMP N/A SUCTION HOSE ASSY, FILTER-PUMP N/A FITTING, T -8MJIC/8MJIC N/A FITTING, 0 FX0-S 78 N/A SUCTION HOSE, # " LONG 08 N/A TUBE, LP-TM LT LOOP 087 N/A TUBE, RP-BM LT LOOP 08 N/A TUBE, RP-TM RT LOOP 08 N/A TUBE, LP-BM RT LOOP 78 N/A FITTING, 90-0MORB/-8MSL N/A FITTING, # BEADED TUBE-ORB NOTES:. Hydraulic system capacity is US quarts of 0W0 motor oil. Fill reservoir to within "of top of Item 7 (077 Strainer). See Hydraulic system on page 0-. HYDRAULIC SYSTEM CHARGING PROCEDURE. Set handles in the neutral position.. Start engine at idle /0-9

34 . Let run for a minimum of 0 seconds.. Stroke handles to forward position.. If motors do not turn in seconds return handles to neutral and repeat step and (one time).. If motors do not turn after second attempt, shut off the engine and check for oil at the pump. 7. Increase throttle to half speed and work handles through forward and reverse position until the motor operates smoothly throughout the entire speed range /0

35 This page intentionally left blank /0 -

36 Hydraulic System Installation Kawasaki HP HT Engine /0

37 Hydraulic System Installation Kawasaki HP HT Engine INDEX NO. SERVICE MFG. PART NO. QTY DESCRIPTION CS.0-0 X. HX G ZNYC FW.8 X. X.0/.080 HD ZNYC SEAL /8 X / X 7." LONG OIL COOLER NT.0-0 HX NL ZNYC BREATHER CAP STRAINER SUPER Z RESERVOIR NT.-8 HX G ZNYC FW. X.87 X.0/.080 HD ZNYC CS.0-0 X.0 HX G ZNYC PUMP, HYDRO-GEAR BDP-L NT.00- HX G ZNYC FW. X.0 X.090 SAE HD ZN ZAF SERIES FILTER HEAD FILTER ELEMENT REMOTE AIR MOUNT BRACKET W/A CS.00-X.0 HX G MOTOR, WHITE RC CCW MOTOR, WHITE RC CW HOSE CLAMP 09 N/A HOSE, COOLER-LT RES 08 N/A HOSE, LEFT PUMP-COOLER 07 N/A HOSE, COOLER-RT RES 0 N/A HOSE, RIGHT PUMP-COOLER 7808 N/A FITTING, #8 BEADED TUBE-ORB N/A FITTING, STR-8MORB/-8MSL N/A HEX PLUG FITTING, STR-8MORB N/A SUCTION HOSE ASSY, FILTER-PUMP N/A SUCTION HOSE ASSY, FILTER-PUMP 7887 N/A FITTING, T -8MJIC/8MJIC 087 N/A FITTING, 0 FX0-S 0 N/A SUCTION HOSE, # " LONG 0 N/A TUBE, LP-BM LT LOOP 0 N/A TUBE, RP-TM LT LOOP 08 N/A TUBE, RP-TM RT LOOP 7 08 N/A TUBE, LP-BM RT LOOP 8 78 N/A FITTING, 90-0MORB/-8MSL N/A FITTING, # BEADED TUBE-ORB NOTES:. Hydraulic system capacity is US quarts of 0W0 motor oil. Fill reservoir to within "of top of Item 8 (077 Strainer). See Hydraulic system on page /0 -

38 HYDRAULIC SYSTEM CHARGING PROCEDURE. Set handles in the neutral position.. Start engine at idle.. Let run for a minimum of 0 seconds.. Stroke handles to forward position.. If motors do not turn in seconds return handles to neutral and repeat step and (one time).. If motors do not turn after second attempt, shut off the engine and check for oil at the pump. 7. Increase throttle to half speed and work handles through forward and reverse position until the motor operates smoothly throughout the entire speed range /0

39 This page intentionally left blank /0 -

40 Hydraulic System Installation Kohler 0HP HT SUPER Z HOOD /0

41 Hydraulic System Installation Kohler 0HP HT INDEX NO. SERVICE MFG. PART NO. QTY DESCRIPTION CS.0-0 X. HX G ZNYC FW.8 X. X.0/.080 HD ZNYC SEAL /8 X / X 7." LONG OIL COOLER NT.0-0 HX NL ZNYC BREATHER CAP STRAINER SUPER Z RESERVOIR NT. -8 HX G ZNYC FW. X.87 X.0/.080 HD ZNYC CS.0-0 X.0 HX G ZNYC PUMP, HYDRO-GEAR BDP-L NT.00- HX G ZNYC FW. X.0 X.090 SAE HD ZN ZAF SERIES FILTER HEAD FILTER ELEMENT HOSE CLAMP CS.00- X.0 HX G MOTOR, WHITE RC CW MOTOR, WHITE RC CCW 78 N/A RETURN HOSE ASSEMBLY 78 N/A HOSE, RETURN #." 7808 N/A FITTING, # BEADED TUBE-ORB 7808 N/A FITTING, #8 BEADED TUBE-ORB N/A FITTING, STR-8MORB/-8MSL 788 N/A HEX PLUG FITTING, STR-8MORB N/A SUCTION HOSE ASSY, FILTER-PUMP N/A SUCTION HOSE ASSY, FILTER-PUMP N/A FITTING, T -8MJIC/8MJIC N/A FITTING, 0 FX0-S 78 N/A SUCTION HOSE, # " LONG 0 N/A TUBE, HYDRAULIC LINE 0 N/A TUBE, HYDRAULIC LINE 08 N/A TUBE, HYDRAULIC LINE 08 N/A TUBE, HYDRAULIC LINE 78 N/A FITTING, 90-0MORB/-8MSL N/A HOSE GUARD NOTES:. Hydraulic system capacity is US quarts of 0W0 motor oil. Fill reservoir to within "of top of Item 8 (077 Strainer). See Hydraulic system on page /0-7

42 Note: HYDRAULIC SYSTEM CHARGING PROCEDURE. Set handles in the neutral position.. Start engine at idle.. Let run for a minimum of 0 seconds.. Stroke handles to forward position.. If motors do not turn in seconds return handles to neutral and repeat step and (one time).. If motors do not turn after second attempt, shut off the engine and check for oil at the pump. 7. Increase throttle to half speed and work handles through forward and reverse position until the motor operates smoothly throughout the entire speed range. Seal Kit for hydraulic pump; 7898 (BDPL Overhaul Seal Kit) /0

43 Section Battery Installation Deck Lift Assembly Steering Assembly Park Brake Assembly Steering Sub-Assembly Pump Belt and Pulleys Installation /0 -

44 Battery Installation MOWER FRAME /0

45 Battery Installation ITEM NO. SERVICE MFG. QTY DESCRIPTION NT.0-0 HX GR ZN RED BATTERY CABLE BOOT " NEGATIVE BATTERY CABLE POSITIVE BATTERY CABLE FW. X.87 X.0/.080 HD ZNYC NT.-8 HX NL ZN BATTERY CLAMP STRAP CS.0-0 X.70 HX G ZN LW.0 INT-EXT TOOTH ZN BATTERY NT.-8 HX G ZN CB.-8 X.00 FUL ZN NOTES:. 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.. Battery is not installed in export models.. Part of wireharness /0 -

46 Deck Lift Assembly MOWER FRAME /0

47 Deck Lift Assembly INDEX NO. SERVICE MFG. QTY DESCRIPTION STOP HANDLE DECK HEIGHT W/A /" PIN DECK LIFT INDICATOR NT.7- HX FLG ZN CLIP E,.00 X. X DECK LIFT SPRING ASSEMBLY STRAIGHT GREASE FITTING CS.7- X.70 HX G ZNYC DECK LIFT CHAIN ( LINKS) CS.-8 X.0 FLTHR GR ZNYC NT.-8 HX G ZNYC DECK LEVELER YOKE W/A CE.70 X. X.7 HEADLESS CS.7- X.70 FULTH G ZNYC NOTES:. Apply grease to zerks (see owners manual) /0 -

48 Steering Assembly See Steering Sub-Assembly on page /0

49 Steering Assembly ITEM NO. SERVICE MFG. QTY DESCRIPTION STEERING CONTROL PANEL NT.00- HX JAM ZN SS.00- X.7 SH ZN FW.0 X.8 X.00 SAE HD ZN CS.7- X.70 HX G ZN 0 0 NT.- HXZY NL FW. X.87 X.0/.080 HD ZN/YL PUMP ROD ADJUSTER ASSEMBLY CENTERING DAMPENER DAMPENER BALL STUD CS.0-0 X.00 HX G ZN FW.8 X. X.0/.080 HD ZN/YL LW. INT-EXT TOOTH Z NT.-8 HX G ZN SUPER Z PUMP ARM BRAKE ROD ASSEMBLY CS.7- X.000 HX G ZN ADJUSTABLE PIVOT NOTES: 080 0/0-7

50 Park Brake Assembly See Steering Sub-Assembly on page /0

51 Park Brake Assembly ITEM NO. SERVICE MFG. QTY DESCRIPTION CS 0- X.70 HXFLK ZN PUSH BUTTON SWITCH CS.7- X.7 HX G ZN FW.0 X.8 X.00 SAE HD ZN 0 0 NT.- HXZY NL FW. X.87 X.0/.080 HD ZN/YL BRAKE ROD ASSEMBLY L.S. BRAKE PIVOT ARM 0 0 R.S. BRAKE PIVOT ARM BUSHING NT.7- HX GRD ZN CS.7- X.7 HX G ZN 0 0 WHITE BRAKE LEVER EXTENSION NT.-8 HX G ZN BRAKE LINK TURNBUCKLE 0 0 CS.-8 X.000 HX G ZN LH WHITE BRAKE ASSY RH WHITE BRAKE ASSY FW. X.00 X. HRD ZNYC CS.-8 X.70 HX G8 ZNYC WHITE HUB ASSEMBLY 789 N/A WHITE HUB ASSEMBLY N/A NUT FOR WHITE MOTOR 788 N/A NUT FOR WHITE MOTOR 0 N/A KEY FOR WHITE MOTOR NT.7- HX LK NY NT #0- HX NL ZN NOTES:. Torque to 80-0 ft.-lbs. Included with wheel motor.. Torque to ft.-lbs.. 78 used on left wheel used on right wheel.. For mowers with serial numbers prior to use 789 and 788. For mowers with serial numbers higher than use 789) and /0-9

52 Steering Sub-Assembly ITEM NO. SERVICE MFG. QTY DESCRIPTION 780 N/A STEERING BAR GRIP STEERING BAR FW.0 X.8 X.00 SAE HD ZN 0 0 CS.7- X.000 HX G ZN CS.7- X.70 HX G ZN STEERING ARM MOUNT STEERLEVER SUPPORT LH STEERLEVER SUPPORT RH (NOT SHOWN) BUSHING STEERLEVER BUSHING SS.00- X.7 SH ZN NT.7- HX LK NY NOTES:. Includes Item (780 Steering Bar Grip) /0

53 This page intentionally left blank /0 -

54 Pump Belt and Pulleys Installation MOWER FRAME /0

55 Pump Belt and Pulleys Installation INDEX NO. SERVICE MFG. QTY DESCRIPTION 0 0 SUPER Z SINGLE ENGINE PULLEY 787 N/A SUPER Z SINGLE ENGINE PULLEY KEY / SQ X.0 LONG 0 0 CMS-00 WARNER CLUTCH FW.0 X.70 X.0 ZNYC (AIR COOLED ENGINES ONLY) FW.0X.X. HRD ZN ( HP KAWASAKI ONLY) CS.7-0 X.0 HX G ZNYC (AIR COOLED ENGINES ONLY) CS M0-.X HX ZY G8.8 ( HP KAWASAKI ONLY) SS. -8X.70 SQ-HD ZN PULLEY FOR BDP- 78 N/A PULLEY & FAN FOR BDP KEY FOR BDPL NT.00- HX G ZNYC FW. X.0 X.090 SAE HD ZN CS.00 - X. HX G ZNYC 7 7 CLUTCH ANCHOR ANGLE PUMP IDLER ARM STRAIGHT GREASE FITTING FW.70 X. X.08 ZN NT.70-0 HX NL ZN IDLER PULLEY FW. X.00 X. ZN CS. - X. HX G ZN IDLER SPRING 0 0 A SEC PUMP IDLER BELT.98" EL 78 N/A A - SEC PUMP IDLER BELT CLUTCH PIGTAIL HARNESS WITH DIODE 0 0 CS. -8 X.00 HX G ZNYC FW. X.87 X.0/.080 HD ZNYC NT. -8 HX G ZNYC FW. X.70X.0 ZY ( HP KAWASAKI ONLY) NOTES:. Torque bolt to -8 ft-lbs. Replace (do not reuse) cap screw if removed or loosened. Use only hand tools to install this fastener.. Torque to - ft-lbs.. Apply grease at zerk (see owners manual).. Do not torque Item (NT.70-0 HX NL ZN), Item (97 Pump Idler Arm) should pivot freely.. Used with Kawasaki HP engines only.. Use 787 on mowers with S/N prior to Used on mowers with serial numbers prior to Used on mowers with serial numbers and higher. 9. Electric clutch burnishing procedure: After installing a new clutch it is 080 0/0 -

56 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 seconds, and then off for seconds. Repeat this operation 0 times, it will require about minutes to complete /0

57 Section Kawasaki HP Engine Installation Kawasaki HP Engine Installation Kawasaki HP Engine Installation Honda HP Engine Installation Kohler 7 & 0 HP Engine Installation Kohler 8 HP EFI Engine Installation Fuel System Air Cooled W/Carburetor Fuel System Liquid Cooled (S/N Higher Than 0800) Fuel System Liquid Cooled (S/N Prior To 0800) Fuel System With EFI Instrument Panel Assembly Air Cooled W/Carb Instrument Panel Liquid Cooled Instrument Panel Assembly With EFI Electrical Schematic Common Air Cooled (7990) Elec. Schematic Kaw LC (7998) S/N Higher Than Elec. Schematic Kaw LC (7999) S/N Prior To Electrical Schematic Kohler EFI (799) /0 -

58 Kawasaki HP Engine Installation 7 0 TO ENGINE SENSOR, YELLOW RED/BLK 0 7 TO SPADE TERMINAL 8 9 TO BULLET TERMINALS NEGATIVE BATTERY CABLE A A 8 7 HOOD SECTION B-B VIEW A-A B B PURPLE POSITIVE BATTERY CABLE 8 RED MOWER FRAME /0

59 Kawasaki HP Engine Installation ITEM NO. SERVICE MFG. QTY DESCRIPTION KAWASAKI HP 00RPM ENGINE NT.-8 HX ZYNL FW. X.87 X.0/.080 HD ZN/YL LW. INT-EXT TOOTH ZN NT.0-0 HX GR. ZN FW.8 X. X.0/.080 HD ZN/YL BATTERY CABLE KAW ( & HP) WIRE HARNESS ADAPTER XR7 COMMON WIRE HARNESS NT #0- HX ZN RED BATTERY CABLE BOOT STARTER SOLENOID CS.0-0 X.00 HX G ZN STARTER RELAY GROUND WIRE CS.-8 X.7 HX G ZN DONALDSON AIR CLEANER CAP HOSE CLAMP AIR CLEANER AIR FILTER INDICATOR MOUNTING BAND NT.-8 HX G ZN SUPER Z HOOD SCOOP 0 0 CS.-8 X.00 HX G ZNYC CS.0-0 X.7 HX G ZNYC ELECTRIC COOLER FAN CN ZN TIN-C7-0 7 SUPER Z HOOD WIRING CLAMP REMOTE AIR FILTER HOSE M0 X. OIL DRAIN VALVE CS.-8 X.70 HX G ZNYC MUFFLER GUARD SUPER Z ENGINE GUARD CS.-8 X. HX G ZN FW. X.0 X.090 SAE HD ZN CS.00- X.00 HX G ZN KAW () MUFFLER GASKET MUFFLER MANIFOLD HEAT SHIELD LW. MED SPRING ZN NT M8 -. HX STAINLESS STEEL KAW () EXHAUST PIPE CLAMP CS M 8-. X HXFL ZN MUFFLER CLIP 0 0 ELBOW FITTING, STREET 080 0/0 -

60 NOTES:. Includes mounting hardware.. Part of Item 8 (799 Wire Harness, Adapter).. Engine oil capacity; See owners manual. ENGINE SPEEDS MODEL NO. ENDING IN: HIGH IDLE NO EXTENSION, A, B, EX 00±0 RPM. Supplied with engine.. Includes one () of 07 Hose Clamp.. When installing lower hose clamp on air cleaner hose, install as low as possible (against carburetor inlet). 7. Ground wires from main wire harness (7990) and starter solenoid (item 0087). 8. Wires from main wire harness (7990). 9. Air filter service parts: 78 MAIN AIR FILTER ELEMENT (S/N 009 AND AFTER) 7879 SAFETY AIR FILTER ELEMENT (S/N 009 AND AFTER) 78 VACUATOR VALVE /0

61 This page intentionally left blank /0 -

62 Kawasaki HP Engine Installation 7 8 A A KAWASAKI ENGINE SCREEN 9 0 PART OF ENGINE HOOD VIEW A-A B SECTION B-B 7 B POSITIVE BATTERY CABLE PUR 8 0 BLK NEGATIVE BATTERY CABLE /0

63 Kawasaki HP Engine Installation ITEM NO. SERVICE MFG. QTY DESCRIPTION KAWASAKI FD7V ENGINE KAWASAKI HP EXHAUST MANIFOLD KAW () MUFFLER GASKET LW. MED SPRING ZN NT M8-. HX STAINLESS STEEL KAWASAKI HP LC MUFFLER " MUFFLER CLAMP FW. X.0 X.090 SAE HD ZN CS.00- X.00 HX G ZN NT.00- HX G ZNYC CS.0-0 X.7 HX G ZNYC SUPER Z HOOD SCOOP FW.8 X. X.0/.080 HD ZN/YL ELECTRIC COOLER FAN KAWASAKI LC HP HOOD CN ZN TIN-C CS.-8 X.00 HX G ZNYC FW. X.87 X.0/.080 HD ZN/YL NT.0-0 HX GR. ZNYC FW.8 X.00 X.0 ZNYC 0 0 SCREEN SUPPORT CS.0-0 X. HX G MS #0- X.7 RD SL 0 0 NT #0- HX ZN OVER CENTER LATCH ZINC X.7 X WEATHERSTRIP X.7 X. WEATHERSTRIP M0 X. OIL DRAIN VALVE ENGINE AIR BAFFLE LW. INT-EXT TOOTH ZN CS M 8-. X 0 HX G SUPER Z ENGINE GUARD FW.0 X.0 X.0 SAE Z 077 N/A NT M8-.-0-HX ZNYC HP KAWASAKI WIRE HARNESS HP KAWASAKI WIRE HARNESS CS M8 X. X G0.9 HX CLIP NOTES:. Includes mounting hardware.. Part of Item (7998 Mower Wire Harness).. Engine oil capacity: See engine owner s manual.. Engine coolant capacity, See engine owner s manual.. Torque to 0 ft.-lbs /0-7

64 . Mowers with S/N prior to 000 use Mowers with S/N higher than 000 use Air filter service parts: 78 MAIN AIR FILTER ELEMENT 7879 SAFETY AIR FILTER ELEMENT 78 VACUATOR VALVE /0

65 This page intentionally left blank /0-9

66 Kawasaki HP Engine Installation { { PURPLE TO SPADE TERMINAL ON RECT YEL/BLK NEGATIVE BATTERY CABLE BLK RED/BLK TO SPADE TERMINAL ON STARTER BULLET CONNECTORS POSITIVE BATTERY CABLE HOOD 8 RIGHT SIDE /0

67 Kawasaki HP Engine Installation ITEM NO. SERVICE MFG. QTY DESCRIPTION 09 N/A KAWASAKI HP ENGINE CABLES HEAT SHIELD CS M8 X. X G0.9 HX MUFFLER " MUFFLER CLAMP MANIFOLD, 9/ KAW KAW MUFFLER GASKET N/A LW. MED SPRING ZN 9 78 N/A NT M8-. HX STAINLESS STEEL CS.7- X.00 HXFLK ZNYC FW.9 X.0 X.00 ZNYC NT.7- HX FLK ZNYC CS.0-0 X.7 HX G ZNYC FW.8 X. X.0/.080 HD ZN/YL HOOD SCOOP ELECTRIC COOLER FAN REMOTE AIR BRACKET WIRING CLAMP FW. X.87 X.0/.080 HD ZN/YL NT.-8 HX G ZN M0X. OIL DRAIN VALVE 0 0 CS.-8 X.00 HX G ZNYC CS.-8 X.70 HX G ZNYC EXHAUST HEAT SHIELD MMZ TALL HEAT SHIELD SUPER Z ENGINE GUARD CB.-8 X.70 FUL ZN FW. X.0 X.090 SAE HD ZN CS.00- X.00 HX G ZN CS.7- X.00 HX G ZNYC HEAT SHIELD, MMZ ROLLER 0 0 FITTING, 90 /8NPT BRASS AIR FILTER INDICATOR LW. INT-EXT TOOTH ZN XR7 COMMON WIRE HARNESS 0 0 WIRING HARNESS, KAWASAKI 9, CN ZN TIN-C CLIP FW.0X.8 X.00 SAE NOTES:. Includes mounting hardware.. Wires from Item (XR7 Common Wire Harness 7990).. Wires from Kawasaki 9HP, HP Wiring Harness (0).. Supplied with engine /0 -

68 . Engine oil capacity, Refer to engine owner s manual.. Torque to 0 ft.-lbs. If the fastener is loosened or removed, do not reuse. Replace with a new fastener. Use only hand tools to install this fastener. 7. Air filter service parts: ENGINE SPEEDS MODEL NO. ENDING IN: HIGH IDLE A, B, OR EX 00±0 RPM 78 MAIN AIR FILTER ELEMENT 7879 SAFETY AIR FILTER ELEMENT 0 MAIN AIR FILTER ELEMENT (PRIOR TO S/N 009) 0 SAFETY AIR FILTER ELEMENT (PRIOR TO S/N 009) /0

69 This page intentionally left blank /0 -

70 Honda HP Engine Installation HOOD VIEW A-A B 8 SECTION B-B B A A YEL 0 RED/BLK NEGATIVE BATTERY CABLE POSITIVE BATTERY CABLE ORG 9 BRN GRA PUR /0

71 Honda HP Engine Installation ITEM NO. SERVICE MFG. QTY DESCRIPTION HONDA HP ENGINE MUFFLER CS M 8-. X HXFL ZN " MUFFLER CLAMP 78 N/A NT M8-. HX STAINLESS STEEL 0700 N/A LW. MED SPRING ZN 7 78 N/A HONDA (0) MUFFLER GASKET MUFFLER MANIFOLD CS.0-0 X.00 HX G ZNYC FW.8 X. X.0/.080HD ZNYC 7877 N/A HONDA 0 AMP RECTIFIER LW.0 MED SPRING ZNYC NT.0-0 HX GR. ZNYC NT.-8 HX G ZN FW. X.87 X.0/.080 HD ZN/YL DONALDSON AIR CLEANER CAP HOSE CLAMP MOUNTING BAND HONDA OIL DRAIN VALVE " LOW PRESSURE HOSE,.00" LONG AIR CLEANER HOOD SCOOP CS.0-0 X.70 HX G ZNYC 0 0 CS.-8 X.00 HX G ZNYC ELECTRIC COOLER FAN CN ZN TIN-C7-0 7 SUPER Z HOOD WIRING CLAMP CS.-8X.70 HX G ZNYC NT.-8 HX ZYNL REMOTE AIR FILTER HOSE LW. INT-EXT TOOTH ZN CS.-8 X.7 HX G ZN SUPER Z ENGINE GUARD CS.00- X.00 HX G ZNYC FW. X.0 X.090 SAE HD ZN MMZ ROLLER HEAT SHIELD MUFFLER GUARD N/A NT M8-. X 0 HX ZNYC XR7 COMMON WIRE HARNESS HONDA HP WIRE HARNESS ADAPTER CLIP NOTES:. Includes mounting hardware.. Part of Item 0 (7990 XR7 Common Wire Harness) /0 -

72 . Part of Item (7990 Honda hp Wire Harness Adapter).. Engine oil capacity; See engine owner s manual.. Includes one () of 07 Hose Clamp.. Supplied with engine. 7. When installing lower hose clamp on air cleaner hose, install as low as possible (against carburetor inlet). 8. Air filter service parts: 78 MAIN AIR FILTER ELEMENT 78 VACUATOR VALVE /0

73 This page intentionally left blank /0-7

74 Kohler 7 & 0 HP Engine Installation NEGATIVE BATTERY CABLE RED/BLK BLK RED 7 7 POSITIVE BATTERY 8 CABLE PUR (P/O ENGINE) 0 A A HOOD VIEW A-A B 8 9 SECTION B-B B /0

75 Kohler 7 & 0 HP Engine Installation ITEM NO. SERVICE MFG. QTY DESCRIPTION KOHLER 7HP ENGINE CV KOHLER 0 HP ENGINE CV MUFFLER MUFFLER MANIFOLD " MUFFLER CLAMP CS.7- X.00 HXFLK ZNYC FW.9 X.0 X.00 ZNYC NT.7- HXFLK ZNYC DONALDSON AIR CLEANER CAP HOSE CLAMP AIR CLEANER MOUNTING BAND NT.-8 HX G ZN FW. X.87 X.0/.080 HD ZN/YL /8-8 OIL DRAIN VALVE " LOW PRESSURE HOSE HOOD SCOOP CS.0-0 X.70 HX G ZNYC FW.8 X. X.0/.080 HD ZNYC CS.-8 X.00 HX G ZNYC ELECTRIC COOLER FAN CN ZN TIN-C7-0 SUPER Z HOOD WIRING CLAMP CS.-8X.70 HX G ZNYC REMOTE AIR FILTER HOSE LW. INT-EXT TOOTH ZN CS.-8 X.7 HX G MUFFLER GUARD SUPER Z ENGINE GUARD FW. X.0 X.090 SAE HD ZN CS.00- X.00 HX G ZNYC MMZ ROLLER HEAT SHIELD COMMON AIR COOLED WIRE HARNESS CLIP AIR FILTER INDICATOR NT.-8 HX ZYNL ELBOW FITTING, STREET NOTES:. Includes mounting hardware.. Part of Item (7990 Mower Wire Harness).. Engine oil capacity; See engine owner s manual /0-9

76 ENGINE SPEEDS MODEL NO. ENDING IN: HP LOW IDLE HIGH IDLE NO EXTENSION, A, B, OR EX 7 N/A 00±0 RPM A, B, OR EX 0 800±00 RPM 00±0 RPM. Includes one () of 07 Hose Clamp.. Supplied with engine.. Supplied with the 7 HP Engine (788); not required on the 0 HP Engine (7999). 7. Air filter service parts: 78 MAIN AIR FILTER ELEMENT 78 VACUATOR VALVE /0

77 This page intentionally left blank /0 -

78 Kohler 8 HP EFI Engine Installation HOOD VIEW A-A B 7 SECTION B-B B A A 7 7 POSITIVE BATTERY CABLE 8 9 NEGATIVE BATTERY CABLE RED/BLK /0

79 Kohler 8 HP EFI Engine Installation ITEM NO. SERVICE MFG. QTY DESCRIPTION KOHLER CV7 EFI ENGINE MUFFLER 79 N/A KOHLER EFI OXYGEN SENSOR MUFFLER MANIFOLD " MUFFLER CLAMP CS.7- X.00 HXFLK ZNYC FW.9 X.0 X.00 ZNYC NT.7- HXFLK ZNYC FUSE/RELAY MOUNT PLATE CLIP CFV CS 0-X.00 HXFLK ZNYC DONALDSON AIR CLEANER CAP HOSE CLAMP AIR CLEANER MOUNTING BAND NT.-8 HX G ZN FW. X.87 X.0/.080 HD ZN/YL /8-8 OIL DRAIN VALVE " LOW PRESSURE HOSE HOOD SCOOP CS.0-0 X.70 HX G ZNYC FW.8 X. X.0/.080 HD ZNYC CS.-8 X.00 HX G ZNYC CS 0- X.00 HX G ZNYC FW.9 X.00 X.08 ZNYC NT #0- HX NL ZN N/A KOHLER EFI ECU ELECTRIC COOLER FAN CN ZN TIN-C7-0 0 SUPER Z HOOD WIRING CLAMP CS.-8 X.70 HX G REMOTE AIR FILTER HOSE LW. INT-EXT TOOTH ZN CS.-8 X.7 HX G MUFFLER GUARD SUPER Z ENGINE GUARD FW. X.0 X.090 SAE HD ZN CS.00- X.00 HX G ZNYC MMZ ROLLER HEAT SHIELD SUPER Z KOHLER EFI WIRE HARNESS CLIP AIR FILTER INDICATOR NT.-8 HX ZYNL 0 0 ELBOW FITTING, STREET 080 0/0 -

80 NOTES:. Includes mounting hardware.. Part of Item (799 Mower Wire Harness).. Engine oil capacity; See engine owner s manual. ENGINE SPEEDS MODEL NO. ENDING IN: HIGH IDLE A, B, OR EX 00±0 RPM. Includes one () of 07 Hose Clamp.. Supplied with engine.. Air filter service parts: 78 MAIN AIR FILTER ELEMENT 78 VACUATOR VALVE /0

81 This page intentionally left blank /0 -

82 Fuel System Air Cooled W/Carburetor /0

83 Fuel System Air Cooled W/Carburetor ITEM NO. SERVICE MFG. QTY DESCRIPTION FUEL TANK CAP LEFT SIDE FUEL TANK RIGHT SIDE FUEL TANK 07 N/A REAR SEAT SUPPORT FW.0 X.8 X.00 SAE HD ZN FW.0 X.00 X. HRD ZN CS.7- X.70 HX G ZN CS.7- X.000 HX G ZN HOSE CLAMP " FUEL LINE. TOTAL FUEL LINE. TOTAL FUEL LINE. TOTAL (KAWASAKI) FUEL LINE TOTAL (HONDA) FUEL LINE 8 TOTAL (KOHLER) CLIP CS.00-X. HX G Z FW. X.0 X.090 SAE HD ZN WAY FUEL VALVE FUEL SHUT-OFF BRACKET BLACK CABLE TIE (NOT SHOWN) NOTES:. Torque to 0 ft.-lbs.. Service parts for fuel tanks (not shown): DESCRIPTION 09 SUCTION HOSE ASSY 789 FUEL GROMMET 7998 / X / ELBOW FITTING 080 0/0-7

84 Fuel System Liquid Cooled (S/N Higher Than 0800) /0

85 Fuel System Liquid Cooled (S/N Higher Than 0800) ITEM NO. SERVICE MFG. QTY DESCRIPTION " FUEL TANK CAP LEFT SIDE Z FUEL TANK RIGHT SIDE Z FUEL TANK REAR SEAT SUPPORT CS.7- X.70 HX G ZN FW.0 X.00 X. HRD Z CLIP IN-LINE FUEL FILTER "DIA RUBBER COATED CLAMP WAY NYLON FUEL VALVE 0 0 CS.7- X.00 HX G ZNYC FUEL SHUT-OFF BRACKET CS.00- X. HX G Z FW. X.0 X.090 SAE HD ZN FUEL LINE.00" LONG FUEL LINE.7" LONG FUEL LINE.8 LONG FUEL LINE 9.00 LONG HOSE CLAMP " BLACK CABLE TIE (NOT SHOWN) NOTES:. Torque to 0 ft.-lbs.. Service parts for fuel tanks (not shown): DESCRIPTION 09 SUCTION HOSE ASSY 789 FUEL GROMMET 7998 / X / ELBOW FITTING 080 0/0-9

86 Fuel System Liquid Cooled (S/N Prior To 0800) /0

87 Fuel System Liquid Cooled (S/N Prior To 0800) ITEM NO. SERVICE MFG. QTY DESCRIPTION " FUEL TANK CAP LEFT SIDE Z FUEL TANK RIGHT SIDE Z FUEL TANK 8 N/A REAR SEAT SUPPORT CS.7- X.70 HX G ZN FW.0 X.00 X. HRD Z CLIP IN-LINE FUEL FILTER " DIA RUBBER COATED CLAMP WAY NYLON FUEL VALVE 0 0 CS.7- X.00 HX G ZNYC FUEL SHUT-OFF BRACKET CS.00- X. HX G Z FW. X.0 X.090 SAE HD ZN FUEL LINE.00" LONG FUEL LINE.7" LONG FUEL LINE.8 LONG FUEL LINE 9.00 LONG HOSE CLAMP " BLACK CABLE TIE (NOT SHOWN) NOTES:. Torque to 0 ft.-lbs.. Service parts for fuel tanks (not shown): DESCRIPTION 09 SUCTION HOSE ASSY 789 FUEL GROMMET 7998 / X / ELBOW FITTING 080 0/0 -

88 Fuel System With EFI MOWER FRAME WITH ENGINE /0

89 Fuel System With EFI ITEM NO. SERVICE MFG. QTY DESCRIPTION FUEL TANK CAP LEFT SIDE SUPER Z FUEL TANK RIGHT SIDE SUPER Z FUEL TANK REAR SEAT SUPPORT FW.0 X.8 X.00 SAE HD ZN CS.7- X.70 HX G ZN N/A KOHLER EFI FUEL FILTER / CRIMP FUEL LINE CLAMP CLAMP 0 0 N/A CS.-8 X.00 HX G ZNYC FW. X.87 X.0/.080HD ZNYC FW.0 X.00 X. HRD ZNYC NT.-8 HX G ZN CLIP HOSE CLAMP WAY DOUBLE FUEL VALVE N/A KOHLER EFI FUEL REGULATOR EFI FUEL MOUNT NT.0-0 HX GR. ZNYC FW.8 X. X.0/.080 HD ZNYC CS.0-0 X.7 HX G ZNYC CS.-8X.70 HX G CS.00- X. HX G Z FW. X.0 X.090 SAE HD ZN FUEL LINE FUEL LINE MULTI FUEL INJECTION FUEL LINE MULTI FUEL INJECTION FUEL LINE MULTI FUEL INJECTION FUEL LINE MULTI FUEL INJECTION FUEL LINE FUEL LINE N/A KOHLER EFI FUEL PUMP BLACK CABLE TIE (NOT SHOWN) NOTES:. Torque to 0 ft.-lbs.. This hardware is also used to mount (Super Z Hood). See Kohler 8 HP EFI Engine Installation on page -.. For mowers with serial numbers prior to order Service parts for fuel tanks (not shown): DESCRIPTION 09 SUCTION HOSE ASSY 0 RETURN HOSE ASSY 789 FUEL GROMMET 7907 FITTING, / HOSE BARB 080 0/0 -

90 Instrument Panel Assembly Air Cooled W/Carb. RELAYS RELAY ASSEMBLY WIRE HARNESS RIGHT SIDE FUEL TANK FUSE SIZE AND LOCATION 0a a a BLK HOUR METER CONNECTION ORG /0

91 Instrument Panel Assembly Air Cooled W/Carb ITEM NO. SERVICE MFG. QTY DESCRIPTION PTO SWITCH KEY SET KEY SWITCH Z CHOKE CABLE (KAWASAKI) CHOKE CABLE (HONDA/KOHLER 7 CARB.) CHOKE CABLE (KOHLER 0 CARB.) RED INDICATOR LIGHT TIE STRAP MS #0- X. HX ZN FW.9 X.00 X.08 ZN NT #0- HX NL ZN HOUR METER THROTTLE CABLE (ALL, EXCEPT FOR 0 HP KOHLER AND HP KAWASAKI) THROTTLE CABLE (0 HP KOHLER, ONLY) THROTTLE CABLE ( HP KAWASAKI, ONLY) CS.0-0 X.00 HX G ZN FW.8 X. X.0 /.080 HD ZN/YL 0 0 INSTRUMENT PANEL RELAY 79 N/A DELAY MODULE (NOT SHOWN) RELAY BRACKET RIVET.88 DIA BLK HD CB 0- X.00 ZYNC. Part of wire harness. NOTES: 080 0/0 -

92 Instrument Panel Liquid Cooled 7 RELAY ASSEMBLY RELAYS WIRE HARNESS 9 BLK HOUR METER CONNECTION ORG RIGHT SIDE FUEL TANK FUSE SIZE AND LOCATION 0A A A /0

93 Instrument Panel Liquid Cooled ITEM NO. SERVICE MFG. QTY DESCRIPTION CHOKE CABLE PTO SWITCH KEY SET KEY SWITCH RED INDICATOR LIGHT MS #0- X. HX ZN FW.9 X.00 X.08 ZN NT #0- HX NL ZN ULTRA LOUD WARBLE ALARM HOUR METER THROTTLE CABLE CS.0-0 X.00 HX G ZN FW.8 X. X.0 /.080 HD ZN/YL 0 0 INSTRUMENT PANEL 07 N/A RELAY 79 N/A DELAY MODULE (NOT SHOWN) RELAY BRACKET CB 0- X.00 ZYNC RIVET.88 DIA BLK HD TIE STRAP (ONE SHOWN). Part of 79 (Wire Harness). NOTES: 080 0/0-7

94 Instrument Panel Assembly With EFI RELAY ASSEMBLY 8 RELAYS BLK WIRE HARNESS RIGHT SIDE FUEL TANK ORG HOUR METER CONNECTION 0 FUSE SIZE AND LOCATION 0a a a /0

95 Instrument Panel Assembly With EFI ITEM NO. SERVICE MFG. QTY DESCRIPTION PTO SWITCH KEY SET KEY SWITCH RED INDICATOR LIGHT CB 0- X.00 ZYNC FW.9 X.00 X.08 ZN HOUR METER NT #0- HX NL ZN THROTTLE CABLE CS.0-0 X.00 HX G ZN FW.8 X. X.0 /.080 HD ZN/YL 0 0 INSTRUMENT PANEL 07 N/A RELAY 79 N/A DELAY MODULE (NOT SHOWN) RELAY BRACKET RIVET.88 DIA BLK HD MS #0- X. HX ZN TIE STRAP (NOT SHOWN). Part of 799 (Wire Harness). NOTES: 080 0/0-9

96 Electrical Schematic Common Air Cooled (7990) /0

97 Elec. Schematic Kaw LC (7998) S/N Higher Than /0 -

98 Elec. Schematic Kaw LC (7999) S/N Prior To /0

99 Electrical Schematic Kohler EFI (799) 080 0/0 -

100 /0

101 Section Front Wheel Assembly Front Wheel Breakdown Optional Semi-Pneumatic Tire/Wheel Drive Wheel Assembly Anti-Rollover Wheel Assembly /0 -

102 Front Wheel Assembly MOWER FRAME /0

103 Front Wheel Assembly INDEX NO. SERVICE MFG. QTY DESCRIPTION CS.00- X. HX G ZN 7 7 FW.0 X. X.87 SPL ZN FW. X. X. HD ZY 7 7 BEARING DISC BEARING W/O COLLAR SPACER,.07 X. X FW.00 X.00 X. ZN FORK CS.70-0 X 9.0 HX ZN FW.70 X. X.08 ZN NT.70-0 HX NL ZN WHEEL & TIRE ASSY NOTES:. Apply grease to zerks (see owners manual).. Torque to 00 ft.-lbs.. Assemble with extended inner race toward item (870 Spacer,.07 x. x.79) /0 -

104 Front Wheel Breakdown 7778 ITEM NO. SERVICE MFG. QTY DESCRIPTION 0977 N/A WHEEL BEARING 777 N/A X.0 TIRE 778 N/A X. WHEEL 7877 N/A BEARING SPACER 09 N/A TIRE VALVE 0 N/A GREASE FITTING DEG /. Inflate tire to 8- psi. NOTES: /0

105 Optional Semi-Pneumatic Tire/Wheel 7897 ITEM NO. SERVICE MFG. QTY DESCRIPTION 0977 N/A WHEEL BEARING 7897 N/A TIRE/WHEEL ASSEMBLY 0 N/A GREASE FITTING DEG / 7877 N/A BEARING SPACER NOTES: 080 0/0 -

106 Drive Wheel Assembly INDEX NO. SERVICE MFG. QTY DESCRIPTION WHEEL & TIRE ASSY FOR " SD, 7" SD, 0" RD & 7" RD (QTY PER MOWER) 78 N/A TIRE, X X 780 N/A WHEEL ASSY X N/A TIRE VALVE WHEEL NUT (QTY PER WHEEL) WHEEL LUG STUD / WHEEL & TIRE ASSY FOR 0" & " SD (QTY PER MOWER) 78 N/A TIRE, X X 78 N/A WHEEL ASSEMBLY X N/A TIRE VALVE WHEEL NUT (QTY PER WHEEL) WHEEL LUG STUD /-0. Torque to -7 ft. lbs.. Inflate tire to 8- psi. NOTES: /0

107 Anti-Rollover Wheel Assembly MOWER FRAME INDEX NO. SERVICE MFG. QTY DESCRIPTION CS.00- X.00 HX G ZN ANTI-SCALP WHEEL FW. X.0 X.090 SAE HD ZN NT.0- HX LK NY. Do not torque, wheel must turn freely. NOTES: 080 0/0-7

108 /0

109 Section 7 7" Side Discharge XR7 Deck Assembly " Side Discharge Deck Pulley Assembly (XR7) " Side Discharge Deck Pulley Assembly (XR7) " Side Discharge Deck Assembly (XR7) " Side Discharge Deck Pulley Assembly (XR7) " Side Discharge Deck Assembly (XR7) " Side Discharge Deck Pulley Assembly (XR7) Side Discharge Deck "A" Adaptors Side Discharge Deck "B" Adaptors " Rear Discharge Deck Assy S/N Higher Than " Rear Discharge Deck Assy S/N " Rear Discharge Deck Assy S/N Prior To " Rear Disch Deck Pulley Assy S/N Higher Than " Rear Disch. Deck Pulley Assy S/N Prior To " Rear Discharge Deck Assy S/N & Higher " Rear Discharge Deck Assy S/N " Rear Discharge Deck Assy S/N Prior To " Rear Disch. Deck Pulley Assy S/N & Higher " Rear Disch. Deck Pulley Assy S/N Spindle Assembly Spindle Assembly /0 7-

110 7" Side Discharge XR7 Deck Assembly /0

111 7" Side Discharge XR7 Deck Assembly ITEM NO. SERVICE MFG. QTY DESCRIPTION " DECK WA CRATED RUBBER CHUTE ASSEMBLY CS.7-9 X.0 HX G ZN FW.0 X.8.00 SAE HD ZN NT.7 - HXZY NL DISCHARGE CHUTE MOUNT BRACKET NT.0- HX LK NY CS.7- X.7 HX G 9 N/A 8088 /-8 THREAD RIVET NUT PUSHER STRAIGHT GREASE FITTING REAR ANTI-SCALP BRACKET CB.7- X.00 STD CD N/A 8089 /8 - THREAD RIVET NUT ANTI SCALP WHEEL ASSY N/A CS.00 - X. HX G ZN N/A FW. X.0 X.090 SAE HD ZN N/A ANTI-SCALP WHEEL N/A NT.00- HX JAM ZN NOTES:. Do not torque, Item (7989 Discharge Chute) must pivot freely.. Includes items 9.. Service part deck includes decals (see 7", " & 0" Side Discharge Deck Decals(XR7) on page 9- for listing of decals) /0 7-

112 7" Side Discharge Deck Pulley Assembly (XR7) " DECK ASSY BELT GUIDE INDEXING /0

113 7" Side Discharge Deck Pulley Assembly (XR7) ITEM NO. SERVICE MFG. QTY DESCRIPTION B-SECTION BELT CS. - 8 X.0 FLT SH ZNYC 0 0 UHMW IDLER SLIDE CS. - X.7 HX G ZNYC 7 7 DECK BELT IDLER GUIDE FW. X.00 X. ZN " IDLER PULLEY CHAIN DECK LIFT SPRING ( LINKS) IDLER SPRING DECK IDLER RS PULLEY COVER 7" XR LS PULLEY COVER 7" XR NT. - HX G ZNYC " IDLER PULLEY FW.0 X. X.8 ZNYCG / - 8 X /" MALE KNOB CS.00 - X.00 HX G ZN CW. X. X.0 ZN DRIVE PULLEY DB CS.00- X. HX G ZNYC FW. X.0 X.090 SAE HD ZN FW. X.87 X.0/.080 HD ZN NT. -8 HXZY NL 7 7 KEY / SQ X.00 LONG SPINDLE HOUSING ASSEMBLY 79X N/A SPINDLE HOUSING ASSEMBLY BLADE, F.0" -H-F-CW CW..0 X.87 PNT FW. X.0 X.0 ZNYC CS.- X. HXGZY 099 N/A CS. - X.00 HX G ZNYC CS.- X.00 FULL HX G ZN NOTES:. Torque to 8 ft. lbs.. Torque to 7-7 ft. lbs.. See 7", ", & " Side Discharge Belt Routing and Tensioning on page 8- for belt tensioning.. Used on mowers with serial numbers prior to See Spindle Assembly 79 on page 7- for breakdown.. Used on mowers with serial numbers higher than Item (0) replaces idler slide components 007, 0089 and 78 found on mowers with serial numbers prior to /0 7-

114 " Side Discharge Deck Assembly /0

115 " Side Discharge XR7 Deck Assembly ITEM NO. SERVICE MFG. QTY DESCRIPTION 8 08 " DECK W/A CRATED RUBBER CHUTE ASSEMBLY CS.7- X.0 HX G ZN FW.0 X.8.00 SAE HD ZN NT.7- HXZY NL DISCHARGE CHUTE MOUNT BRACKET ANTI SCALP WHEEL ASSY NT.0- HX LK NY CB.7- X.00 STD CD /-8 THREAD RIVET NUT STRAIGHT GREASE FITTING 0 0 PUSHER /8- THREAD RIVET NUT N/A CS.00- X. HX G ZN 779 N/A FW. X.0 X.090 SAE HD ZN 0997 N/A ANTI-SCALP WHEEL N/A NT.00- HX JAM ZN NOTES:. Do not torque, Item (7989 Discharge Chute) must pivot freely.. Includes items 7.. Service part deck includes decals (see 7", " & 0" Side Discharge Deck Decals(XR7) on page 9- for listing of decals) and item (Discharge Chute) /0 7-7

116 " Side Discharge Deck Pulley Assembly (XR7) " DECK ASSY BELT GUIDE INDEXING /0

117 " Side Discharge Deck Pulley Assembly (XR7) ITEM NO. SERVICE MFG. QTY DESCRIPTION B-SECTION BELT CS.-8 X.0 FLT SH ZNYC 0 0 UHMW IDLER SLIDE CS.- X.7 HX G ZNYC 7 7 DECK BELT IDLER GUIDE FW. X.00X. ZN " IDLER PULLEY SIDE MOUNT CHAIN ( LINKS) IDLER SPRING DECK IDLER RS " XR7 PULLEY COVER LS " XR7 PULLEY COVER NT. - HX G ZNYC " IDLER PULLEY, FW.0X.X.8 ZNYC G /-8 X /" MALE KNOB CS.00- X.00 HX G ZN CW.X.X.0 ZN B-SEC. EOD PULLEY CS.00- X. HX G ZNYC FW. X.0 X.090 SAE HD ZN FW. X.87 X.0/.080 HD ZN NT.-8 HXZY NL 7 7 KEY / SQ X.00 LONG SPINDLE HOUSING ASSEMBLY 79X N/A SPINDLE HOUSING ASSEMBLY BLADE, F.0"-H-F-CW FW. X.0X.0 ZNYC CW..0 X.87 PNT CS.- X. HXGZY 099 N/A CS. - X.00 HX G ZNYC CS.- X.00 FULL HX G ZN NOTES:. Torque to 8 ft. lbs.. Torque to 7-7 ft. lbs.. See 7", ", & " Side Discharge Belt Routing and Tensioning on page 8- for belt tensioning.. Used on mowers with serial numbers prior to See Spindle Assembly 79 on page 7- for breakdown.. Used on mowers with serial numbers higher than Item (0) replaces idler slide components 007, 0089 and 78 found on mowers with serial numbers prior to /0 7-9

118 0" Side Discharge Deck Assembly (XR7) /0

119 0" Side Discharge Deck Assembly (XR7) ITEM NO. SERVICE MFG. QTY. DESCRIPTION " DECK W/A CRATED RUBBER CHUTE ASSEMBLY CS.7- X. HX G FW.0 X.8 X.00 SAE HD ZN NT.7- HX LK NY DISCHARGE CHUTE MOUNT BRACKET NT.0- HX LK NY /-8 THREAD RIVET NUT REAR ANTI-SCALP BRACKET CS.7- X.7 HX G ZNYC 0 0 PUSHER STRAIGHT GREASE FITTING /8- THREAD RIVET NUT CB.7- X.00 STD CD ANTI SCALP WHEEL ASSY N/A CS.00- X. HX G ZN N/A FW. X.0 X.090 SAE HD ZN N/A ANTI-SCALP WHEEL N/A NT.00- HX JAM ZN NOTES:. Do not torque, Item (7989 Discharge Chute) must pivot freely.. Includes items 9.. Service part deck includes decals (see 7", " & 0" Side Discharge Deck Decals(XR7) on page 9- for listing of decals) and item (Discharge Chute) /0 7-

120 0" Side Discharge Deck Pulley Assembly (XR7) " DECK ASSY BELT GUIDE INDEXING /0

121 0" Side Discharge Deck Pulley Assembly (XR7) ITEM NO. SERVICE MFG. QTY DESCRIPTION B-SECTION BELT CS.-8 X.0 FLT SH ZNYC 0 0 UHMW IDLER SLIDE CS.- X.7 HX G ZNYC 7 7 DECK BELT IDLER GUIDE FW. X.00 X. ZN " IDLER PULLEY SIDE MOUNT CHAIN ( LINKS) IDLER SPRING DECK IDLER RS 0" XR7 PULLEY COVER LS 0" XR7 PULLEY COVER NT.- HX G ZNYC " IDLER PULLEY, FW.0 X. X.8 ZNYCG /-8 X /"MALE KNOB CS.00- X.00 HX G ZN CW. X. X.0 ZN DECK DRIVE PULLEY CS.00- X. HX G ZNYC FW. X.0 X.090 SAE HD ZN FW. X.87 X.0/.080 HD ZN NT.-8 HXZY NL 7 7 KEY / SQ X.00 LONG SPINDLE HOUSING ASSEMBLY 79X N/A SPINDLE HOUSING ASSEMBLY BLADE, F0.0" H-F-CW CW..0 X.87 PNT FW. X.0X.0 ZNYC CS.- X. HXGZY 099 N/A CS. - X.00 HX G ZNYC CS.- X.00 FULL HX G ZN NOTES:. Torque to 8 ft. lbs.. Torque to -7 ft. lbs.. See 0" Side Discharge Belt Routing and Tensioning on page 8- for belt tensioning.. Used on mowers with serial numbers prior to See Spindle Assembly 79 on page 7- for breakdown.. Used on mowers with serial numbers higher than Item (0) replaces idler slide components 007, 0089 and 78 found on mowers with serial numbers prior to /0 7-

122 " Side Discharge Deck Assembly (XR7) /0

123 " Side Discharge Deck Assembly (XR7) ITEM NO. SERVICE MFG. QTY. DESCRIPTION " DECK W/A CRATED " DISCHARGE CHUTE CS.7- X. HX G ZN FW.0 X.8 X.00 SAE HD ZN NT.7- HX LK NY CB.7-X.00 STD CD DISCHARGE CHUTE MOUNT BRACKET 8 N/A 8088 /-8 THREAD RIVET NUT NT.0- HX LK NY STRAIGHT GREASE FITTING 0 0 PUSHER CS.7-X.7 HX G REAR ANTI-SCALP BRACKET N/A 8089 /8- THREAD RIVET NUT ANTI-SCALP WHEEL ASSEMBLY N/A CS.00- X. HX G ZN N/A FW. X.0 X.090 SAE HD ZN N/A ANTI-SCALP WHEEL N/A NT.00- HX JAM ZN NOTES:. Do not torque, Item (7989 Discharge Chute) must pivot freely.. Includes items 9.. Service part deck includes decals (see " Side Discharge Deck Decals (XR7) on page 9- for listing of decals) and item (Discharge Chute) /0 7-

124 " Side Discharge Deck Pulley Assembly (XR7) " DECK ASSY BELT GUIDE POSITIONING /0

125 " Side Discharge Deck Pulley Assembly (XR7) ITEM NO. SERVICE MFG. QTY. DESCRIPTION B-SECTION BELT NT.- HX G ZNYC CS.- X.0 HX G ZN FW. X.00 X. ZN " IDLER PULLEY FW.0 X. X.8 ZNYCG CS.-8X.0FLT SH ZY IDLER SLIDE UHMW RS DECK BELT IDLER TOP GUIDE " IDLER PULLEY DECK IDLER SIDE MOUNT CHAIN LINKS IDLER SPRING RS " PULLEY COVER LS " PULLEY COVER CS.00- X.00 HX G ZN CW. X. X.0 ZN DECK DRIVE PULLEY CS.00- X. HX G ZY FW. X.0X.090 SAE 7 7 KEY / SQ X.00 LONG SPINDLE HOUSING ASSEMBLY 79X N/A SPINDLE HOUSING ASSEMBLY BLADE, F8.0"-H-F-CW CW. X.0 X.87 PNT FW. X.87 X.0/.080H NT.-8 HXZY NL CS.- X.00 FULL HX G ZN FW. X.0 X.0 ZNY CS.- X. HXGZY 099 N/A CS. - X.00 HX G ZNYC /-8 X /"MALE KNOB NOTES:. Torque to 8 ft. lbs.. Torque to -7 ft. lbs.. See 7", ", & " Side Discharge Belt Routing and Tensioning on page 8- for belt tensioning.. Used on mowers with serial numbers prior to See Spindle Assembly 79 on page 7- for breakdown.. Used on mowers with serial numbers higher than Item (0) replaces idler slide components 007, 0089 and 78 found on mowers with serial numbers prior to /0 7-7

126 Side Discharge Deck "A" Adaptors Deck Assembly /0

127 Side Discharge Deck "A" Adaptors ITEM NO. SERVICE MFG. QTY. DESCRIPTION AIR FLOW FLOOR (7" DECKS) AIR FLOW FLOOR (" DECKS) AIR FLOW FLOOR (0" DECKS) AIR FLOW FLOOR (" DECKS) CB.7-X.00 STD CD FW.0X.8 X.00 SAE NT.7- HXZY NL NOTES: 080 0/0 7-9

128 Side Discharge Deck "B" Adaptors Deck Assembly 7 Assembled Detail /0

129 Side Discharge Deck "B" Adaptors ITEM NO. SERVICE MFG. QTY. DESCRIPTION AIR FLOW BAFFLE, "B" RIGHT SIDE (7" DECKS) AIR FLOW BAFFLE, "B" RIGHT SIDE (" DECKS) AIR FLOW BAFFLE, "B" RIGHT SIDE (0" DECKS) AIR FLOW BAFFLE, "B" RIGHT SIDE (" DECKS) AIR FLOW BAFFLE, "B" LEFT SIDE (7" DECKS) AIR FLOW BAFFLE, "B" LEFT SIDE (" DECKS) AIR FLOW BAFFLE, "B" LEFT SIDE (0" DECKS) AIR FLOW BAFFLE, "B" LEFT SIDE (" DECKS) AIR LIFT DEFLECTOR (7" DECKS) AIR LIFT DEFLECTOR (" DECKS) AIR LIFT DEFLECTOR (0" DECKS) AIR LIFT DEFLECTOR (" DECKS) CB.7-X.00 STD CD FW.0 X.8 X.00 SAE HD ZN NT.7- HXZY NL CS.7-X.000 HXFLK NOTES:. Service parts for 080, 08, 080, and 08 include rivet nuts /0 7-

130 7" Rear Discharge Deck Assy S/N Higher Than DEFLECTOR DETAIL /0

131 7" Rear Discharge Deck Assy S/N Higher Than ITEM NO. SERVICE MFG. QTY. DESCRIPTION " REAR DISCHARGE DECK DISCHARGE SHIELD GUARD MOUNTING ANGLE PUSHER CHUTE BRACKET CHUTE BRACKET NT.-8 HX ZY NL FW. X.87 X.0/.080 HD ZN FW.78 X.7 X.0 ZN YC STRAIGHT GREASE FITTING FW.0 X.8 X.00 SAE HD ZN 0 0 CS.7- X.00 HX G ZN CLAMP ANGLE RS RUBBER SIDE FLAP CLAMP ANGLE LS 0 0 CB.-8 X.70 FUL ZN CB.-8 X.000 FUL Z NT.7- HX LK NY ANGLE, DISCHARGE CHUTE RD REAR FLAP DECK STIFFENER ANGLE CN.-8X CB.7- X.0 STD G /-8 THREAD RIVET NUT " REAR DISCHARGE FRONT ANGLE NT.0- HX ZY NL ANTI SCALP WHEEL ASSEMBLY N/A CS.00- X. HX G ZN N/A 8 FW. X.0 X.090 SAE HD ZN N/A ANTI-SCALP WHEEL 099 N/A NT.00- HX JAM ZN NOTES:. Includes items 8.. Service part deck includes decals, see 7" Rear Discharge Deck Decals on page /0 7-

132 7" Rear Discharge Deck Assy S/N /0

133 7" Rear Discharge Deck Assy S/N ITEM NO. SERVICE MFG. QTY. DESCRIPTION " REAR DISCHARGE DECK DISCHARGE SHEILD GUARD MOUNTING ANGLE FW. X.87 X.0/.080 HD ZN NT.7- HX LK NY FW.0 X.8 X.00 SAE HD ZN DECK STIFFENER ANGLE CB.7- X.0 STD G N/A /-8 THREAD RIVET NUT STRAIGHT GREASE FITTING PUSHER 0 0 CS.7- X.00 HX G ZN " REAR DISCHARGE FRONT ANGLE N/A CS.00- X. HX G ZN 779 N/A 8 FW. X.0 X.090 SAE HD ZN 099 N/A NT.00- HX JAM ZN N/A ANTI-SCALP WHEEL NT.0- HX ZY NL CLAMP ANGLE LS CLAMP ANGLE RS RUBBER SIDE FLAP ANGLE, DISCHARGE CHUTE RD REAR FLAP CHUTE BRACKET RS CHUTE BRACKET LS FW.78 X.7 X.0 ZN YC CB.-8 X.70 FUL ZN CB.-8 X.000 FUL Z NT.-8 HX ZY NL ANTI SCALP WHEEL ASSEMBLY NOTES:. Includes Items 7.. Service part deck includes decals, see 7" Rear Discharge Deck Decals on page /0 7-

134 7" Rear Discharge Deck Assy S/N Prior To /0

135 7" Rear Discharge Deck Assy S/N Prior To ITEM NO. SERVICE MFG. QTY. DESCRIPTION " REAR DISCHARGE DECK RD DECK GUARD FW. X.87 X.0/.080 HD ZN NT.7- HX LK NY FW.0 X.8 X.00 SAE HD ZN DECK STIFFENER ANGLE CB.7- X.00 STD CD /-8 THREAD RIVET NUT STRAIGHT GREASE FITTING PUSHER 0 0 CS.7- X.00 HX G ZN " REAR DISCHARGE FRONT ANGLE N/A CS.00- X. HX G ZN 779 N/A 8 FW. X.0 X.090 SAE HD ZN 099 N/A NT.00- HX JAM ZN 0997 N/A ANTI-SCALP WHEEL NT.0- HXZY NL RD DEFLECTOR CLAMP LS ANGLE RD DEFLECTOR CLAMP RS ANGLE RD SIDE FLAP ANGLE, DISCHARGE CHUTE RD REAR FLAP RD DECK GUARD BRACKET FW.78 X.7 X.0 ZNYC 0 0 CB.-8 X.70 FUL ZN FW. X.00 X. HRD ZN NT.-8 HXZY NL ANTI SCALP WHEEL ASSEMBLY NOTES:. Includes Items.. Service part deck includes decals, see 7" Rear Discharge Deck Decals on page /0 7-7

136 7" Rear Disch Deck Pulley Assy S/N Higher Than /0

137 7" Rear Disch Deck Pulley Assy S/N Higher Than ITEM NO. SERVICE MFG. QTY. DESCRIPTION " REAR DISCHARGE DECK BELT PULLEY COVER RH PULLEY COVER LH CS.-X. HX G Z FW. X.00 X. ZN " HB IDLER PULLEY RD DECK IDLER SPACER NT.00- HX G8 ZY NL FW. X.0 X.090 SAE HD ZN PLASTIC BUSHING.70X IDLER PIVOT BUSHING IDLER ARM W/A IDLER SPRING SIDE MOUNT CHAIN ( LINKS) FW.00X.0X.07 ZNY IDLER GUIDE UHMW CS.-8 X.0FLT SH ZY NT.- HX G ZNYC CS.00- X.00 HX G ZN CW. X. X.0 ZN DRIVE PULLEY DB /-8 X /" MALE KNOB CW. X.0 X.87 PNT CS.- X.00 FULL HX G ZN REAR DISCHARGE DECK SPINDLE ASSEMBLY 7980X N/A REAR DISCHARGE DECK SPINDLE ASSEMBLY BLADE, F.8-L-F-CCW KEY / SQ X.00 LONG CS.- X. LH HY 797 N/A CS.- X.00 LH HX G FW. X.87 X.0/.080 HD ZN NT.-8 HXZY NL SPINDLE HOUSING ASSEMBLY 79X N/A SPINDLE HOUSING ASSEMBLY BLADE, F.8-L-F-CW CS.- X. HXGZY 099 N/A CS.- X.00 HX G ZNYC NOTES:. Torque to 8 ft. lbs.. Torque to -7 ft. lbs.. See 7" & 0" Rear Discharge Belt Routing and Tensioning on page 8- for belt tensioning.. Used on mowers with serial numbers prior to See Spindle Assembly 79 on page 7- for breakdown.. Used on mowers with serial numbers prior to See Spindle Assembly 7980 on page 7- for breakdown.. Used on mowers with serial numbers higher than /0 7-9

138 7" Rear Disch. Deck Pulley Assy S/N Prior To /0

139 7" Rear Disch. Deck Pulley Assy S/N Prior To ITEM NO. SERVICE MFG. QTY. DESCRIPTION " REAR DISCHARGE DECK BELT 0 0 RIGHT 7" REAR DISCHARGE PULLEY COVER 0 0 LEFT 7" REAR DISCHARGE PULLEY COVER NT.- HX G ZNYC FW. X.00 X. ZN CS.-X.00 HX G " HB IDLER PULLEY RD IDLER SPRING SIDE MOUNT CHAIN ( LINKS) CS.-8 X.0FLT SH ZY 0 0 UHMW IDLER SLIDE REAR DISCHARGE DECK IDLER /-8 X /" MALE KNOB CS.00- X.00 HX G ZN CW. X. X.0 ZN DRIVE PULLEY DB FW. X.0 X.090 SAE HD ZN 8 79X 79 SPINDLE HOUSING ASSEMBLY X 7980 REAR DISHCARGE DECK SPINDLE ASSEMBLY KEY / SQ X.00 LONG BLADE, F.8-L-F-CW BLADE, F.8-L-F-CCW CW. X.0 X.87 PNT CS.- X.00 HX G ZNYC FW. X.87 X.0/.080 HD ZN NT.-8 HXZY NL CS.- X.00 FULL HX G ZN CS.- X.00 LH HX G NOTES:. Torque to 8 ft. lbs.. Torque to -7 ft. lbs.. See 7" & 0" Rear Disch. Belt Routing and Tensioning on page 8-7 for belt tensioning.. See Spindle Assembly 79 on page 7- for breakdown.. See Spindle Assembly 7980 on page 7- for breakdown.. Item (0) replaces idler slide components 007, 0089 and 78 found on mowers with serial numbers prior to /0 7-

140 0" Rear Discharge Deck Assy S/N & Higher DEFLECTOR DETAIL /0

141 0" Rear Discharge Deck Assy S/N & Higher ITEM NO. SERVICE MFG. QTY. DESCRIPTION " REAR DISCHARGE DECK DISCHARGE SHIELD GUARD MTG ANGLE PUSHER CHUTE BRACKET LS CHUTE BRACKET RS NT.-8 HXZY NL FW. X.87 X.0/.080 HD ZN FW.78 X.7 X.0 ZNYC STRAIGHT GREASE FITTING FW.0 X.8 X.00 SAE HD ZN 0 0 CS.7- X.00 HX G ZN CLAMP ANGLE RS SIDE FLAP RUBBER CLAMP ANGLE LS 0 0 CB.-8 X.70 FUL ZN CB.-8 X.000 FUL Z NT.7- HX LK NY ANGLE, DISCHARGE CHUTE RD REAR FLAP 7 7 DECK STIFFENER ANGLE CN.-8X CB.7- X.0 STD G /-8 HX TH RIVET NUT 9 9 0" REAR DISCHARGE FRONT ANGLE NT.0- HXZY NL ANTI SCALP WHEEL ASSEMBLY N/A CS.00- X. HX G ZN N/A 8 FW. X.0 X.090 SAE HD ZN N/A ANTI-SCALP WHEEL 099 N/A NT.00- HX JAM ZN NOTES:. Includes items 8.. Service part deck includes decals, see 7" Rear Discharge Deck Decals on page /0 7-

142 0" Rear Discharge Deck Assy S/N DEFLECTOR DETAIL /0

143 0" Rear Discharge Deck Assy S/N ITEM NO. SERVICE MFG. QTY. DESCRIPTION " REAR DISCHARGE DECK DISCHARGE SHIELD FW. X.87 X.0/.080 HD ZN NT.7- HX LK NY FW.0 X.8 X.00 SAE HD ZN CB.7- X.0 STD G /-8 THREAD RIVET NUT STRAIGHT GREASE FITTING PUSHER CS.7- X.00 HX G ZN 9 9 0" REAR DISCHARGE FRONT ANGLE N/A CS.00- X. HX G ZN 779 N/A 8 FW. X.0 X.090 SAE HD ZN 099 N/A NT.00- HX JAM ZN NT.0- HXZY NL 0997 N/A ANTI-SCALP WHEEL CLAMP ANGLE LS CLAMP ANGLE RS SIDE FLAP RUBBER ANGLE, DISCHARGE CHUTE RD REAR FLAP 7 7 DECK STIFFENER ANGLE CHUTE BRACKET RS CHUTE BRACKET LS FW.78 X.7 X.0 ZNYC 0 0 CB.-8 X.70 FUL ZN NT.-8 HXZY NL BAFFLE INNER 0" RD CB.-8 X.000 FUL Z GUARD MTG ANGLE ANTI SCALP WHEEL ASSEMBLY NOTES:. Factory assembled in top hole for shipping purposes.. Includes Items through and.. Service part deck includes idler components from 0" Rear Disch. Deck Pulley Assy S/N & Higher on page 7-8 and decals, see 7" Rear Discharge Deck Decals on page /0 7-

144 0" Rear Discharge Deck Assy S/N Prior To /0

145 0" Rear Discharge Deck Assy S/N Prior To ITEM NO. SERVICE MFG. QTY. DESCRIPTION " REAR DISCHARGE DECK RD DECK GUARD CS.-8 X.70 HX G FW. X.87 X.0/.080 HD ZN NT.7- HX LK NY FW.0 X.8 X.00 SAE HD ZN DECK STIFFENER ANGLE CB.7- X.00 STD CD 9 N/A 8088 /-8 THREAD RIVET NUT STRAIGHT GREASE FITTING PUSHER 0 0 CS.7- X.00 HX G ZN 9 9 0" REAR DISCHARGE FRONT ANGLE N/A CS.00- X. HX G ZN 779 N/A 8 FW. X.0 X.090 SAE HD ZN 099 N/A NT.00- HX JAM ZN NT.0- HXZY NL N/A ANTI-SCALP WHEEL RD DEFLECTOR CLAMP LS ANGLE RD DEFLECTOR CLAMP RS ANGLE RD SIDE FLAP ANGLE, DISCHARGE CHUTE RD REAR FLAP RD DECK GUARD BRACKET FW.78 X.7 X.0 ZNYC 0 0 CB.-8 X.70 FUL ZN FW. X.00 X. HRD ZN NT.-8 HXZY NL ANTI SCALP WHEEL ASSEMBLY NOTES:. Factory assembled in top hole for shipping purposes.. Includes Items through and 8.. Service part deck includes idler components from 0" Rear Disch. Deck Pulley Assy S/N & Higher on page 7-8 and decals, see 7" Rear Discharge Deck Decals on page /0 7-7

146 0" Rear Disch. Deck Pulley Assy S/N & Higher /0

147 0" Rear Disch. Deck Pulley Assy S/N & Higher ITEM NO. SERVICE MFG. QTY. DESCRIPTION " REAR DISCHARGE DECK BELT 0 0 PULLEY COVER, RH,0" 0 0 PULLEY COVER, LH,0" CS.-X.00 HX G Z FW. X.00 X. ZN " HB IDLER PULLEY RD NT.00- HX G8 ZY NL FW. X.0 X.090 SAE HD ZN BUSHING, PLAS.70X(FS) BUSHING, IDLER PIVOT DECK IDLER SPACER IDLER ARM W/A IDLER SLIDE UHMW CS.-8X.0FLT SH ZY FW.00X.0X.07 ZNY IDLER SPRING DECK LIFT CHAIN ( LINKS) NT.- HX G ZNYC CS.00- X.00 HX G ZN FW.0 X.7 X.8 ZN B-SECTION PULLEY /-8 X /" MALE KNOB CW. X.0 X.87 PNT CS.-X.00 FULL HX G ZN REAR DISCHARGE DECK SPINDLE ASSEMBLY 7980X N/A REAR DISCHARGE DECK SPINDLE ASSEMBLY DECK SPINDLE ASSY 79X N/A DECK SPINDLE ASSY KEY / SQ X.00 LONG BLADE, F0.0"-L-F-CW BLADE, F0.0"-L-F-CCW CS.- X. LH HY 797 N/A CS.- X.00 LH HX G CS.- X. HXGZY 099 N/A CS.- X.00 HX G ZNYC FW.X.87X.0/.080H NT.-8 HXZY NL NOTES:. Torque to 8 ft. lbs.. Torque to -7 ft. lbs.. See 7" & 0" Rear Discharge Belt Routing and Tensioning on page 8- for belt tensioning.. Used on mowers with serial numbers prior to See Spindle Assembly 79 on page 7- for breakdown.. Used on mowers with serial numbers prior to See Spindle Assembly 7980 on page 7- for breakdown.. Used on mowers with serial numbers higher than /0 7-9

148 0" Rear Disch. Deck Pulley Assy S/N /0

149 0" Rear Disch. Deck Pulley Assy S/N ITEM NO. SERVICE MFG. QTY. DESCRIPTION " REAR DISCHARGE DECK BELT 9 9 RIGHT 0" REAR DISCHARGE PULLEY COVER 9 9 LEFT 0" REAR DISCHARGE PULLEY COVER NT.- HX G ZNYC FW. X.00 X. ZN CS.- X.70 HX G " HB IDLER PULLEY RD IDLER SPRING SIDE MOUNT CHAIN ( LINKS) CS.-8 X.0 FLT SH ZNYC 0 0 UHMW IDLER SLIDE REAR DISCHARGE DECK IDLER /-8 X /" MALE KNOB CS.00- X.00 HX G ZN FW.0 X.7 X.8 ZN B-SECTION PULLEY FW. X.0 X.090 SAE HD ZN 8 79X 79 SPINDLE HOUSING ASSEMBLY X 7980 REAR DISHCARGE DECK SPINDLE ASSEMBLY KEY / SQ X.00 LONG BLADE, F0.0"-L-F-CW BLADE, F0.0"-L-F-CCW CW. X.0 X.87 PNT CS.- X.00 HX G ZNYC FW. X.87 X.0/.080 HD ZN NT.-8 HXZY NL CS.-X.00 FULL HX G ZN CS.- X.00 LH HX G NOTES:. Torque to 8 ft. lbs.. Torque to -7 ft. lbs.. See 7" & 0" Rear Disch. Belt Routing and Tensioning on page 8-7 for belt tensioning.. See Spindle Assembly 79 on page 7- for breakdown.. See Spindle Assembly 7980 on page 7- for breakdown.. Item (0) replaces idler slide components 007, 0089 and 78 found on mowers with serial numbers prior to /0 7-

150 Spindle Assembly 79 ITEM NO. SERVICE MFG. QTY. DESCRIPTION 077 N/A BEARING W/O COLLAR 70 N/A BLADE SPINDLE BUSHING 08 N/A CAST SPINDLE HOUSING 000 N/A GREASE FITTING 0089 N/A BEARING DUST COVER 797 N/A SADDLELESS SPINDLE SHAFT NOTES:. Install upper bearing with extended inner race up.. Install lower bearing with extended inner race down /0

151 Spindle Assembly 7980 ITEM NO. SERVICE MFG. QTY. DESCRIPTION 077 N/A BEARING W/O COLLAR 70 N/A BLADE SPINDLE BUSHING 08 N/A CAST SPINDLE HOUSING 000 N/A GREASE FITTING 0089 N/A BEARING DUST COVER 7998 N/A SPINDLE SHAFT NOTES:. Install upper bearing with extended inner race up.. Install lower bearing with extended inner race down /0 7-

152 /0

153 Section 8 Deck Installation ", ", & " Side Discharge Belt Routing and Tensioning " Side Discharge Belt Routing and Tensioning " & 0" Rear Discharge Belt Routing and Tensioning " & 0" Rear Disch. Belt Routing and Tensioning Seat Installation S/N Higher Than Seat Installation S/N Prior To ROPS Installation /0 8-

154 Deck Installation MOWER ASSEMBLY DECK ASSEMBLY /0

155 Deck Installation ITEM NO. SERVICE MFG. QTY DESCRIPTION CS.7 - X.70 HX G ZN NT.70-0 HX NL ZN FW.70 X. X.08 ZN CS.70-0 X.000 HX G ZN NT.7 - HX FLG ZN NOTES:. Install front deck hanger chains in lower holes only. REAR DISCHARGE DECK ASSEMBLY DETAIL USE BOTTOM HOLE DECK ASSEMBLY 080 0/0 8-

156 7", ", & " Side Discharge Belt Routing and Tensioning 9." 0." DECK ASSEMBLY NOTES:. Spring length after tensioning belt. Measure spring from outside of hook to outside of hook with deck set at leveling height.. Route belt as shown /0

157 0" Side Discharge Belt Routing and Tensioning 9." 0." DECK ASSEMBLY NOTES:. Spring length after tensioning belt. Measure spring from outside of hook to outside of hook with deck set at leveling height.. Route belt as shown /0 8-

158 7" & 0" Rear Discharge Belt Routing and Tensioning 9." 0." DECK ASSEMBLY NOTES:. Spring length after tensioning belt. Measure spring from outside of hook to outside of hook with deck set at leveling height.. Route belt as shown.. For mowers with serial numbers higher than /0

159 7" & 0" Rear Disch. Belt Routing and Tensioning DECK ASSEMBLY NOTES:. For mowers with serial numbers prior to Spring length after tensioning belt. Measure spring from outside of hook to outside of hook with deck set at leveling height.. Route belt as shown /0 8-7

160 Seat Installation S/N Higher Than LATCH W/A DETAIL HP KAW ONLY SEAT PAN LIQUID COOLED KAW ONLY 0 9 SEAT PAN /0

161 Seat Installation S/N Higher Than INDEX NO. SERVICES MFG. QTY DESCRIPTION MICHIGAN SUSPENSION SEAT SEAT PAN BLACK CABLE TIE NT.7- HX LK NY FW.0 X.8 X.00 SAE HD ZN FIBER WASHER SEAT PAN STOP CS.7- X.000 HX G ZN CS.7- X.0 HX G ZN FW. X.87 X.0/.080 HD ZN/Y FW. X.87 X.0/.080 HD ZN/Y (LC KAW ONLY) NT.-8 HX G ZN NT.-8 HX G ZN (LC KAW ONLY) BUMPER GM.0 X.00 X.7 X. GROMMET FW.0 X.000 X.08 ZNY CS.7-0 X.0 G ZNY RUBBER BUMPER " WIDE SCOTCH POLYURETHANE." LONG SEAT BELT SEAT LATCH STOP ROD ROPS LATCH TORSION SPRING LATCH W/A 0 0 SEAT STOP HP (LC KAW ONLY) CS.-8 X.70 HX G (LC KAW ONLY) FW. X.00 X. HRD ZN (LC KAW ONLY) SEAT STOP HP (KAW ONLY) NOTES:. Must pivot freely.. Service parts available for Michigan Suspension seat; DESCRIPTION 79 SEAT SWITCH 7907 SLIDE KIT 79 KNOB KIT 79 ONE ARMREST (SQUARE STYLE W/O BRACKET) ONE ARMREST (ROUND STYLY W/O BRACKET) 797 ARMREST STOP ASSY 798 BACK CUSHION KIT 7999 SEAT CUSHION KIT 7977 SEAT BACK 080 0/0 8-9

162 Seat Installation S/N Prior To SEAT PAN /0

163 Seat Installation S/N Prior To INDEX NO. SERVICES MFG. QTY DESCRIPTION MICHIGAN SUSPENSION SEAT SEAT PAN BLACK CABLE TIE NT.7- HX LK NY FW.0 X.8 X.00 SAE HD ZN FIBER WASHER SEAT PAN STOP CS.7- X.000 HX G ZN CS.7- X.0 HX G ZN FW. X.87 X.0/.080 HD ZN/Y FW. X.87 X.0/.080 HD ZN/Y (LC KAW ONLY) NT.-8 HX G ZN NT.-8 HX G ZN (LC KAW ONLY) BUMPER GM.0 X.00 X.7 X. GROMMET LATCH SPRING PLUNGER 0 0 SEAT LATCH BRACKET RUBBER BUMPER " WIDE SCOTCH POLYURETHANE." LONG SEAT STOP HP (LC KAW ONLY) CS.-8 X.70 HX G (LC KAW ONLY) FW. X.00 X. HRD ZN (LC KAW ONLY) NOTES:. Must pivot freely.. Service parts available for Michigan Suspension seat; DESCRIPTION 79 SEAT SWITCH 7907 SLIDE KIT 79 KNOB KIT 79 ONE ARMREST (SQUARE STYLE W/O BRACKET) ONE ARMREST (ROUND STYLY W/O BRACKET) 797 ARMREST STOP ASSY 798 BACK CUSHION KIT 7999 SEAT CUSHION KIT 7977 SEAT BACK 080 0/0 8-

164 ROPS Installation ENGINE GUARD /0

165 ROPS Installation ITEM NO. SERVICE MFG. QTY DESCRIPTION 00 N/A ROPS 07 N/A LYNCH PIN W/ LANYARD 070 N/A KNOB 08 N/A CS.00 - X.00 HX G 07 N/A ROPS STOP 07 N/A NT.00 - X UNT LK G ZN N/A CS.00 - X.0 HX G N/A FW. X.0 X.090 SAE 9 07 N/A SPACER WASHER 0 00 N/A ROPS WARNING DECAL NOTES: 080 0/0 8-

166 /0

167 Section 9 Mower Decals ", " & 0" Side Discharge Deck Decals(XR7) " Side Discharge Deck Decals (XR7) " Rear Discharge Deck Decals " Rear Discharge Deck Decals /0 9-

168 Mower Decals TOP OF SEAT PAN 9 0 BOTTOM OF SEAT PAN /0

169 Mower Decals 8 INDEX NO. SERVICE MFG. QTY. DESCRIPTION DECK HEIGHT INDICATOR DECAL HOT & HYDRAULIC OIL DECAL INSTRUMENT PANEL DECAL (SEPARATE CHOKE) INSTRUMENT PANEL DECAL (LC) EFI Z DASH PANEL DECAL HYD PRESSURE DECAL FUEL INDICATOR DECAL FUEL INDICATOR-EFI DECAL Z OPERATION DECAL ENGINE COMPARTMENT DECAL Z ARMREST WARNING DECAL Z SERVICE DECAL BATTERY DECAL STABILIZER DECAL MADE IN USA DECAL N/A 0879 TURF PROD SERIAL NO PLATE FIRST ZERO TURN DECAL HUSTLER NAME PLATE SUPER Z ID DECAL PUMP BELT WARNING DECAL HIGH TORQUE DECAL NOTES:. Used on High Torque (HT) models only /0 9-

170 7", " & 0" Side Discharge Deck Decals(XR7) INDEX NO. SERVICE MFG. QTY. DESCRIPTION " SIDE DISCHARGE DECK ID DECAL " SIDE DISCHARGE DECK ID DECAL " SIDE DISCHARGE DECK ID DECAL MOWER DECK QUICK REFERENCE DECAL DEFLECTOR SHIELD DECAL "MADE IN U.S.A." DECAL BELT & PULLEY DECAL WHIRLING BLADES DECAL BELT ROUTING DECAL (0" DECK ONLY) BELT ROUTING DECAL (7", ", & " DECKS) DECK XR7 ID DECAL X 9.00 STEP TREAD FUSION DECAL /0

171 " Side Discharge Deck Decals (XR7) INDEX NO. SERVICE MFG. QTY. DESCRIPTION " SIDE DISCHARGE DECK ID DECAL MOWER DECK QUICK REFERENCE DECAL DEFLECTOR SHIELD DECAL "MADE IN U.S.A." DECAL BELT & PULLEY DECAL WHIRLING BLADES DECAL BELT ROUTING DECAL DECK XR7 ID DECAL X 9.00 STEP TREAD FUSION DECAL 080 0/0 9-

172 7" Rear Discharge Deck Decals 8 7 INDEX NO. SERVICE MFG. QTY. DESCRIPTION " DECK ID DECAL MOWER DECK QUICK REFERENCE DECAL WHIRLING BLADES DECAL BELT & PULLEY DECAL "MADE IN U.S.A." DECAL REAR DISCHARGE DECK ROUTING DECAL STEP TREAD.00 X FUSION DECAL /0

173 0" Rear Discharge Deck Decals 8 7 INDEX NO. SERVICE MFG. QTY. DESCRIPTION " DECK ID DECAL MOWER DECK QUICK REFERENCE DECAL WHIRLING BLADES DECAL BELT & PULLEY DECAL "MADE IN U.S.A." DECAL REAR DISCHARGE DECK ROUTING DECAL X 9.00 STEP TREAD FUSION DECAL 080 0/0 9-7

174 /0

175 Section 0 Assembly Pictures and Aids General information for all models: Super Zs with Honda engines: Super Zs with Kawasaki air cooled engines: Super Zs with HP engines Super Zs with Kawasaki HP liquid cooled engines Super Zs with Kohler w/ carburetor engines (7 HP): Super Zs with Kohler w/ carburetor engines (0 HP): Super Zs with Kohler EFI engines (8 HP): Maintenance & Adjustment Safety Safe Maintenance & Adjustment Practices Maintenance Introduction Safety filter Recommended service procedure This page intentionally left blank Adjustment /0

176 Assembly Pictures and Aids General information for all models: PTO clutch wire routing "FIG. ". Extend braided portion of pigtail through frame opening about /" as shown in "FIG. ". TIE STRAP /" CLUTCH PIGTAIL WIRE FIG. FIG /0

177 PTO clutch switch installation (Instrument Panel) "FIG. " & "FIG. ". PTO SWITCH TIE STRAP FIG. FIG. Super Zs with Honda engines: Throttle/Choke cable routing "FIG. ". CHOKE CABLE ON TOP TIE STRAP HYDRAULIC RESERVOIR FIG. THROTTLE CABLE ROUTED THROUGH TUBE /0

178 Wire harness and fuel line routing "FIG. " Oil sensor wire routing "FIG. 7". POS. & NEG. BATTERY CABLES FUEL LINES THROTTLE & CHOKE CABLES FIG. FIG. 7 OIL SENSOR WIRE Fuel line routing "FIG. 8" & "FIG. 9". NEG. BATTERY CABLE TIE STRAP WIRE HARNESS FUEL LINE FUEL LINE POS. BATTERY CABLE TIE STRAP FIG /0

179 HYDRAULIC COOLER LINES LEFT FUEL LINE TO FUEL VALVE TIE STRAP ENGINE FIG. 9 Hydraulic oil heat exchanger hose ties; left side "FIG. 0" & right side "FIG. " TIE STRAP HYDRAULIC COOLER LINES TIE STRAP HYDRAULIC COOLER LINES FIG. 0 FIG /0

180 Honda carburetor drain/vent hose routing "FIG. " TO CLUTCH VENT/DRAIN HOSES FIG /0

181 Super Zs with Kawasaki air cooled engines: DOES NOT INCLUDE MACHINES WITH 0 HP ENGINES. Throttle/Choke cable routing "FIG. ". THROTTLE CABLE ROUTED THROUGH TUBE TIE STRAP WIRE HARNESS HYDRAULIC RESERVOIR POSITIVE BATTERY NEGATIVE CABLE BATTERY CABLE FIG. Choke cable routing, front and rear tie straps "FIG. " & "FIG. ". POS. & NEG. BATTERY CABLES WIRE HARNESS TIE STRAP TIE STRAP CHOKE CABLE OIL SENSOR WIRE CHOKE CABLE FIG. FIG /0

182 Fuel line routing "FIG. " & "FIG. 7". TIE STRAP FUEL LINE FIG. FUEL LINE FUEL LINE RIGHT FUEL LINE LEFT FUEL LINE RIGHT FUEL LINE TO ENGINE FIG /0

183 Hydraulic oil heat exchanger hose ties; left side "FIG. 8" & right side "FIG. 9" TIE STRAP HYDRAULIC COOLER LINES TIE STRAP ENGINE LIFT LUG FUEL LINE HYDRAULIC LINE FIG. 8 FIG. 9 Super Zs with HP engines. Wireharness and battery cable routing "FIG. 0". POSITIVE BATTERY CABLE WIRE HARNESS TIE STRAP NEGATIVE BATTERY CABLE FIG /0

184 Choke and throttle cable routing, front and rear tie straps "FIG. " & "FIG. ". TIE STRAP POS. & NEG. BATTERY CABLES THROTTLE CABLE WIRE HARNESS TIE STRAP TIE STRAP CHOKE CABLE CHOKE CABLE FIG. TIE STRAP OIL SENSOR WIRE THROTTLE CABLE FIG. Choke and throttle cable connections to engine "FIG. ". CHOKE CABLE THROTTLE CABLE FIG /0

185 Hydraulic oil heat exchanger hose ties "FIG. " TIE STRAP Fuel line routing "FIG. " &"FIG. ". FIG. FUEL LINE TIE STRAP FUEL LINE FUEL LINE FIG /0

186 LEFT FUEL LINE RIGHT FUEL LINE RIGHT FUEL LINE TO ENGINE FIG. Super Zs with Kawasaki HP liquid cooled engines. Throttle and choke cable connections "FIG. 7". CHOKE CABLE THROTTLE CABLE FIG. 7 TIE STRAP /0

187 Hydraulic cooler line routing "FIG. 8". TIE STRAP TIE STRAP FIG. 8 Wireharness and cable routing "FIG. 9" & "FIG. 0". WIRE HARNESS TIE STRAP POSITIVE BATTERY CABLE NEGATIVE BATTERY CABLE FIG. 9 FIG. 0 CABLES BATTERY THRU WIRE TIE ONLY /0

188 Super Zs with Kohler w/ carburetor engines (7 HP): Throttle and choke cable routing "FIG. " & "FIG. ". TIE STRAP TIE STRAP THROTTLE CABLE THROTTLE CABLE CHOKE CABLE HYDRAULIC HOSE ROUTE CHOKE CABLE THROUGH RESERVOIR TUBE FIG. FIG. Wire harness and battery cable routing "FIG. ". POSITIVE BATTERY CABLE NEGATIVE BATTERY CABLE WIRE HARNESS TIE STRAP FIG /0

189 Fuel line routing "FIG. ". FUEL VALVE LEFT RIGHT FUEL FUEL LINE LINE RIGHT FUEL LINE TO ENGINE TIE STRAP LEFT FUEL LINE FUEL FILTER TIE STRAP TO VALVE FIG /0

190 Hydraulic oil heat exchanger hose ties, right and left side (Kohler carburetor) "FIG. " and "FIG. ". TIE STRAP (TIE TO FAN GUARD TIE STRAP (TIE TO ACCUMULATOR FIG. FIG. Super Zs with Kohler w/ carburetor engines (0 HP): Wireharness and cable routing "FIG. 7". CHOKE CABLE TIE STRAP HYDRAULIC HOSE TIE STRAP WIRE HARNESS NEGATIVE BATTERY CABLE FIG /0

191 Choke and throttle cable connections to engine "FIG. 8". See "FIG. 9" for routing choke cable through hydraulic lines. CHOKE CABLE THROTTLE CABLE FIG. 8 Hydraulic oil heat exchanger hose ties, right and left side (Kohler 0 carburetor) "FIG. 9" and "FIG. 0". CHOKE CABLE TIE STRAP TIE STRAP (TIE TO FAN GUARD TIE STRAP (TIE TO ACCUMULATOR FIG. 9 FIG /0

192 Fuel line routing "FIG. ". RIGHT FUEL LINE POSITIVE & NEGATIVE BATTERY CABLES TO ENGINE LEFT FUEL LINE TIE STRAP THROTTLE CABLE FUEL VALVE LEFT FUEL LINE TIE STRAP RIGHT FUEL LINE THROTTLE CABLE TIE STRAP FUEL LINE FIG /0

193 Super Zs with Kohler EFI engines (8 HP): Front and rear throttle cable routing "FIG. " and "FIG. " TIE STRAP TIE STRAP THROTTLE CABLE FUEL LINE THROTTLE CABLE FUEL FILTER FIG. FIG. Right Side Fuel line routing "FIG. ". RS RETURN LINE LS SUPPLY LINE LS RETURN LINE RETURN LINE FUEL REGULATOR RS SUPPLY LINE TIE STRAP FUEL PUMP OUTLET FUEL PUMP TO FUEL FILTER FUEL PUMP INLET TIE STRAP FIG /0

194 Fuel pump wire harness connection"fig. " BLACK WIRE GRN/ORG WIRE FIG. Left side fuel line routing "FIG. " RETURN LINE SUPPLY LINE FIG /0

195 Fuel line routing beneath seat support, "FIG. 7" and "FIG. 8" (as seen from rear). TIE STRAP TIE STRAP FUEL LINE FROM LS TANK FUEL LINE FUEL LINE FIG. 7 FIG. 8 Wire harness, throttle cable, and fuel line routing around battery "FIG. 9" NEG. BATTERY CABLE POS. BATTERY CABLE INCLUDE IN TIE STRAP: POS. BAT. CABLE NEG. BAT. CABLE WIREHARNESS THROTTLE CABLE NO FUEL LINE TIE STRAP TIE STRAP WIRE HARNESS FIG /0

196 Kohler 8 HP EFI Engine harness fuse and relay mounting "FIG. 0" ENGINE DIAGNOSTIC PORT ENGINE HARNESS FUSES ENGINE HARNESS RELAY FIG. 0 Kohler engine harness fuse tie "FIG. " TIE STRAP ENGINE HARNESS FUSE FIG /0

197 Hydraulic oil heat exchanger hose ties, upper right side "FIG. " & "FIG. ". TIE STRAP HYDRAULIC LINE ENGINE FAN GUARD TIE STRAP TIE TO ACCUMULATOR FIG. FIG. Hydraulic oil heat exchanger hose ties, right side "FIG. " TIE STRAP FIG /0

198 Maintenance & Adjustment Safety This safety alert symbol is used to call attention to a message intended to provide a reasonable degree of PERSONAL SAFETY for operators and other persons during the normal operation and servicing of this equipment. DANGER denotes immediate hazards which WILL result in severe personal injury or death. WARNING denotes a hazard or unsafe practice which COULD result in severe personal injury or death. This manual uses two other words to highlight information. IMPORTANT calls attention to special mechanical information and NOTE: emphasizes general information worthy of special attention. All operators should read this manual, or be instructed about safe operating and maintenance procedures. This is the owner s responsibility. Improper use or maintenance by the operator, mechanic, or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means DANGER or WARNING personal safety instructions. Failure to comply with the instructions may result in personal injury or death. Incorrect usage 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, operate, adjust, or service this machine. The Quick Reference Decals, located in front of and to the right of the seat, are designed to give the operator/mechanic brief information needed in the daily operation and service of the machine. These decals are not intended to be used in place of this manual but instead is to be used as an extension of this manual. These decals should not be removed or obliterated. Replace these decals if they become unreadable. It is the owner s responsibility to make certain that the operator/mechanic reads and understands this manual and all decals before operating this machine. It is also the owner s responsibility to make certain that the operator/mechanic is a qualified and physically able individual, properly trained in the operation of this equipment. Local regulations may restrict the age of the operator/mechanic. The owner should also ensure that the operator/mechanic knows that they are responsible for their own safety as well as the safety of other persons within the vicinity. Remember, the operator/mechanic is responsible for accidents or hazards occurring to other people or their property /0

199 Safe Maintenance & Adjustment Practices This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death. Unless specifically required, DO NOT have engine running when servicing or making adjustments to mower. Place control levers in the park brake position, disengage deck clutch, remove ignition switch key and disconnect the negative battery cable. Repairs or maintenance requiring engine power should be performed by trained personnel only. To prevent carbon monoxide poisoning, be sure proper ventilation is available when engine must be operated in an enclosed area. Follow daily and weekly checklists, making sure hoses are tightly secured and bolts are tightened. Keep your machine clean and remove any deposits of trash and clippings, which can cause engine fires and hydraulic overheating as well as excessive belt wear. Clean up oil or fuel spillage. Allow machine to cool before storing. Clean flammable material from machine. Prevent fires by keeping engine compartment, battery, hydraulic lines, fuel line, fuel tank and operator s station clean of accumulated trash, grass clippings, and other debris. Always clean up spilled fuel and oil. Always wear adequate ear protection, such as earplugs, when operating this equipment as prolonged exposure to uncomfortable or loud noises can cause impairment or loss of hearing. Do not wear radios or music headphones while operating the machinery. Safe operation requires your full attention. Never put hands or feet under any part of the machine while it is running. 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. Never use your hand! Exercise caution when loading or unloading the machine onto a trailer or truck. Always wear safety goggles or safety glasses with side shields when operating the mower. Never leave machine unattended with ignition key in switch, especially with children present. Be alert and turn the machine off if children enter the area. Always wear adequate eye protection when servicing the battery, hydraulic system, cooling system or when grinding mower blades and removing accumulated debris. Use extra caution when handling gasoline and other fuels. They are flammable and vapors are explosive. Never refuel mower while engine is running; never refuel near an open flame or near devices which can create a spark. Refuel outdoors preferably, or in well ventilated areas. Never attempt to start engine when there is a strong odor of gasoline fumes present. Locate and correct cause. Never run the engine in an enclosed area unless exhaust is vented to the outside. Exhaust gases contain carbon monoxide which is odorless and deadly poison. Never attempt to make any adjustments or repairs to the mower drive system, mower deck or any attachment while the mower engine is running or deck clutch is engaged. Repairs or maintenance requiring engine power should be performed by trained personnel only. Never work under the machine or attachment unless it is safely supported with jack stands. Make certain machine is secure when it is raised and placed on the jack stands. The jack stands should not allow the machine to move when the engine is running and the drive wheels are rotating. Use only certified jack stands. Use only appropriate jack stands, with a minimum weight rating of 000 pounds to block the unit up. Use in pairs only. Follow the instructions supplied with the vehicle stands. Before working on or under the deck, make certain engine cannot be accidentally started. Shut engine /0

200 off and remove ignition switch key for maximum safety. Repairs or maintenance requiring engine power should be performed by trained personnel only. Use a stick or similar instrument to clean under the mower making sure that no part of the body, especially arms and hands are under mower. Exercise caution when working under the deck as the mower blades are extremely sharp. Wearing gloves or wrapping the blade(s) is advisable when working around or with the blades. Do not touch hot parts of machine. Keep nuts and bolts tight, especially the blade attachment bolts. Keep equipment in good condition. Never tamper with safety devices. Check their proper 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 replace with manufacturer s recommended parts, when necessary. Use only genuine Hustler replacement parts to ensure that original standards are maintained Using a ramp Use extreme caution when loading and unloading a unit with a ramp. Use only a single, full width ramp; do not use individual ramps for each side of the unit. Having a full width ramp provides a surface for the mower frame to contact if the unit starts to tip backwards. It also reduces the risk of a wheel going off and the machine tipping over. Do not exceed a degree angle between the ramp and the ground or between the ramp and the trailer or truck. When on a ramp avoid sudden acceleration /0

201 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 nonreadable. The following illustrations show the various safety 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. Part Number 770 Read Owner s Manual and Quick Reference Decal before attempting to operate this machine. Avoid skin contact with battery acid. Always wear eye protection when checking the battery, acid can cause serious injury to skin and eyes. If contact occurs, flush area with clean water and call physician immediately. Acid will also damage clothing. Do not allow open flame near the 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 last. Do not overfill battery. Electrolyte may overflow and damage paint, wiring or structure. When cleaning the battery, use soap and water. Be careful not to get soap and water into the battery. Use soda mixed in water to clean corrosion off the terminals. Part Number 770 Part Number 778 Do not smoke while refueling. Do not fill tank with engine running, or while the engine is hot. Allow engine to cool before storing machine inside a building. Store away from open flame or spark if there is fuel in tank. Clean up any gasoline spills. Do not refuel while in enclosed trailer or other enclosed areas. Never operate the mower deck with side deflector removed or in raised position, except when the grass catcher attachment is being used. Whirling blades! Keep hands and feet away. Beware of thrown objects /0

202 Part Number 77 Do not remove or modify stabilizer wheels or rear engine guard or injury can result. Part Number 77 Keep shields or covers in place while machine is in operation. Keep hands away from rotating pulleys and belts. Part Number Part Number Keep engine and pump compart-ment(s) clean (especially in exhaust area) to prevent fire and provide maximum engine and hydraulic cooling. Hydraulic fluid escaping under pressure can penetrate skin. Hydraulic fluid may also cause infection in a minor cut or opening in the skin; if exposed to hydraulic fluid, see a doctor at once. Before applying pressure to hydraulic system, make sure all connections are tight and all hoses and lines are in good condition. Relieve all pressure in the system before disconnecting or working 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. Part Number Part Number 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 replacement intervals and refer to above paragraph for emergency procedures. Hot surface! /0

203 Maintenance Maintenance Locator Chart a 7 9 c 0 a b 7 b a. Engine Oil Fill & Dipstick (Kawasaki & Honda) b. Engine Oil Fill & Dipstick (Kohler) a. Fuel Filter (Honda & Kawasaki air cooled) b. Fuel Filter (Kohler EFI) c. Fuel Filter (Kawasaki liquid cool & Kohler carb.). Engine Air Cleaner. Engine Oil Drain Plug. Battery. Fuel Tanks 7. Hydraulic Oil Reservoir 8. Hydraulic Oil Filter 9. Gauge Wheel Bearing Zerks () 0. Engine Oil Filter. Deck Height Pivot Zerks (). Park Brake Switch (). Drive Tire. Pump Idler Zerk (). Pump Belt. Hydraulic Oil Heat Exchanger 7. Engine Coolant Fill (Kawasaki liquid cool) 8 9 Viewed from bottom of mower FIG /0

204 Maintenance Locator Chart "/"/7" XR7 deck 0" XR7 deck 0"/7" RD deck. Deck Pusher Arm Zerks (). Deck Belt. Spindle Housing Zerk (). Blades FIG /0

205 SERVICE AT INTERVALS INDICATED Verify safety start interlock system Check coolant level Visually inspect unit for loose hardware and/or damaged parts Visually inspect tires Check oil level, engine () Clean air intake screen () Clean oil heat exchanger () Check radiator screen () Check fuel level Blades - sharpen & securely fastened Discharge chute - securely in place & in lowest position Clean engine and pump compartment Replace air cleaner paper element () Grease deck idler Grease deck pusher arms Grease pump idler Grease deck height pivots Grease gauge wheel bearings Change engine oil and filter () () Clean cylinder and head fins(a) Check battery connections Check tire pressure with a gauge Check hydraulic oil level Clean engine exterior (a) Clean & regap spark plugs (a) Check pump and deck belt tension and condition () Check fuel and hydraulic lines (7) Check fuel valve and grommet (7) Tighten lug nuts on wheels () Change fuel filter Clean or replace hydraulic fill cap Change hydraulic oil and filter () Grease deck spindle housings Replace spark plugs Drain & replace engine coolant Clean radiator core (8) WEEKLY OR 0 HOURS X X X X X X X X X X X MONTHLY OR 00 HOURS Daily Daily Daily Daily Daily or every hours Daily or every hours Daily or every hours Daily or every hours Daily Daily Daily Daily As needed X X X X X ANNUALLY OR 00 HOURS X X X X X X X NOTES:. Initial oil change is after hours of operation. Thereafter, change oil after every 0 hours operation. Change more often under dusty or dirty conditions and during hot weather periods.. Torque initially and after first hours of operation.. Perform initial hydraulic filter change after 0 hours (one week) of operation.. Change engine oil filter per the engine manufacturer s recommendations. Refer to Engine Owner s Manual for recommendations and other maintenance items.. Service more often under dusty or dirty conditions. Use caution when servicing to prevent dust contamination in the engine. Do not clean filter element. Replace with a new one.. Pump drive belt only - Inspect every 00 hours and replace if worn or cracking is noticed. Otherwise, replace every 00 hours or years whichever comes first. 7. Check fuel line hoses, fuel valve and grommets for any cracks or leaks /0

206 8. Clean more often under dirty or dusty conditions and during hot weather. REFERENCES: a-- Refer to Engine Owner s Manual NOTE: After completing maintenance cycle (00 hours), repeat cycle. INTRODUCTION Regular maintenance is the best prevention for costly downtime or expensive, premature repair. The following pages contain suggested maintenance information and schedules which the operator should follow on a routine basis. Remain alert for unusual noises, they could be signaling a problem. Visually inspect the machine for any abnormal wear or damage. A good time to detect potential problems is while performing scheduled maintenance service. Correcting the problem as quickly as possible is the best insurance. Clear away heavy build-up of grease, oil and dirt, especially in the engine and hydraulic reservoir areas; minute dust particles are abrasive to close-tolerance engine and hydraulic assemblies. Daily inspect mower for grass clippings and wire and string tangles. The underside of the mower deck will collect a build-up of grass clippings and dirt, especially when grass is wet or has high moisture content. This build-up will harden, restricting blade and air 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 stands or blocks, and scrape the build-up from underneath. 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. 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 are given below: Ft-lbs. Nm Wheel (lug) nuts Wheel motor nut Blade spindle bolt top Blade spindle bolt bottom It is recommended that these be checked after the first hours of operation initially, every 0 hours, and following removal for repair or replacement. For all other torques refer to the various mower parts manuals for standard torque charts. NOTE: For engine torque values, see engine owner s manual /0

207 Tires It is important for level mowing that the tires have the same amount of air pressure. The recommended pressures are: Drive wheels psi (-9 KPa) Gauge wheels psi (-9 KPa) Solid fill tires are not recommended for Hustler turf equipment. On any machine, with solid filled tires, the warranty claim will be denied. 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. Welding can weaken or deform a wheel. When inflating tires, stand to one side and not in front of or over the tire assembly. Check tires for low pressure, blemishes, damaged rims or missing lug bolts and nuts. To recognize when your machine needs 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. 7". HOUR METER Lubrication FIG. 7. Grease the front gauge wheel bearings per the Maintenance Schedule. Use SAE multi-purpose grease.. Grease the four deck lift pivots, located to the side of the operator s footrest per the Maintenance Schedule. Use SAE multi-purpose grease.. Grease the deck idler per the Maintenance Schedule. Use SAE multi-purpose grease.. Grease the pump idler per the Maintenance Schedule. Use SAE multi-purpose grease.. Grease the two deck pusher arm pivots per the Maintenance Schedule. Use SAE multi-purpose grease.. Grease the blade spindle assemblies per the Maintenance Schedule. The spindle assemblies require lubrication annually. Each spindle shaft is equipped with a grease zerk located under the deck. Use no more than one or two ounces of SAE multi-purpose grease, ( to pumps on an average grease gun). Do not force lubricant into grease zerks. Bearings are sealed and do not require much lubricant /0

208 Electrical system The electrical system is a -volt, negative ground. Recommended battery size is a garden mower BCI group UR with or better cranking AMP rating. A maintenance-free battery is recommended. Otherwise, follow battery manufacturer s maintenance, safety, storing and charging specifications. The battery is located under the seat platform "FIG. 8". BATTERY FIG. 8 WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. WARNING: Avoid skin and clothing contact with battery acid. Always wear eye protection when checking the battery, acid can cause serious injury to skin and eyes. If contact occurs, flush area with clean water and call physician immediately. 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 and may cause an explosion if exposed to flame. Always remove the negative ground first and replace it last. Do not overfill battery. Electrolyte may overflow and damage paint, wiring or structure. When cleaning the battery, use soap and water. Be careful not to get soap and water into the battery. Clean the battery terminals with a solution of four parts water and one part baking soda when they become corroded. WARNING: Shorts caused by battery terminals or metal tools touching metal mower components can cause sparks. Sparks can cause a battery gas explosion which will result in personal injury. Prevent the battery terminals from touching any metal mower parts when removing or installing the battery. Do not allow metal tools to short between the battery terminals and metal mower parts /0

209 WARNING: Incorrect battery cable routing could cause damage to the mower and battery cables. This can cause sparks which can cause a battery gas explosion which will result in personal injury. Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. Always connect the positive (red) battery cable before connecting the negative (black) cable. Common circuit failures are usually caused by shorting, corroded or dirty terminals; loose connections, defective wire insulation or broken wires. Switches, solenoids and ignition components may also fail, causing a shorted or open circuit. Before attempting any failure diagnosis of the electrical system, use a test light or voltmeter to check the battery voltage. If the battery voltage is satisfactory, check the cleanliness and tightness of the terminals and ground connections. A general understanding of electrical servicing and use of basic test equipment is necessary for troubleshooting and repair. Major overhaul or repair of the starting motor or charging system should be performed by trained technicians only. 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. 9") will prevent the seat from going all the way over. However, if more access is desired under the seat platform, the seat platform catch can be raised allowing the seat to pivot more. Make certain to place the control arms in the park brake position and pivot the arm rests upward before placing the seat platform in the full forward position to prevent arm rest damage. SEAT PLATFORM CHECK SEAT PLATFORM CONTROL LEVER FIG. 9 Hydraulic system IMPORTANT: Never use hydraulic or automatic transmission fluid in this system; use only motor oil as specified. Remember, dirt is the primary enemy of any hydraulic system. WARNING: Hydraulic oil escaping under pressure can penetrate skin. Hydraulic oil may cause infection in a minor cut or opening in the skin. If exposed to hydraulic fluid, see a doctor at once. Before applying pressure to hydraulic system, make sure all connections are tight and all hoses and lines are in good condition. To find a leak under pressure, use a piece of cardboard or wood never use your hands. Relieve all pressure in the system before disconnecting or working on hydraulic lines. To relieve pressure, lower all attachments and shut off engine. The.0 U.S. gallon (.79 liter) hydraulic reservoir is located in front of the engine and under the operator s platform "FIG. 0". Check oil level in hydraulic system after every 0 hours of operation or weekly, whichever occurs first /0

210 Check more often if system appears to be leaking or otherwise malfunctioning. Fluid level should be from top of reservoir. Use only SAE 0W0 SG, SF/CC, CD service motor oil. Change hydraulic system filter element ("FIG. 0") after first 0 hours of mower operation, then replace filter and oil in reservoir every 00 hours thereafter. The system filter is located directly in front of the hydraulic reservoir. A standard oil filter wrench is used to change filter, threads are right handed. Use a Hustler approved filter element only. HYDRAULIC RESERVOIR COOLING FAN HEAT EXCHANGER HYDRAULIC FILTER ENGINE FIG. 0 FIG. IMPORTANT: Prefill the filter element with clean oil, before installing, to prevent drawing air into the system pump.. Fill the filter element with clean system oil. Smear a light coating of oil on upper surface of rubber seal.. Install the filter element on base. Tighten the oil filter by hand until the filter seal makes contact with the filter head, then tighten an additional / - turn with an oil filter wrench. DO NOT OVERTIGHTEN.. Start mower engine and let run at approximately / throttle for a few minutes to work any trapped air out of the system before engaging the steering control lever.. Stop the engine and check the filter and connections for leaks.. Check the hydraulic reservoir for specified oil level. Add clean oil as necessary. Clean or replace hydraulic reservoir cap annually. Cap may be cleaned by dipping in or flushing with cleaning solvent. Follow manufacturer s instructions and warnings for application of solvent type selected. A hydraulic oil heat exchanger is installed on the Super Z. This heat exchanger is designed to keep hydraulic system oil temperature lower in hot operating conditions or heavy continuous operating conditions. This hydraulic heat exchanger is located above the engine. Air is drawn across the cooling fins by an electric fan located above the heat exchanger "FIG. ". Never force anything into the heat exhanger fins which may bend or distort them. For cleaning, use compressed air or pressurized water only /0

211 Fuel system DANGER: Observe usual fuel handling precautions: Do not smoke while refueling. Do not fill tank with engine running or while engine is hot. Clean up any gasoline spills. Allow engine to cool before storing machine inside a building. Keep fuel away from open flame or spark and store machine away from open flame or spark if there is fuel in the tank. Use extra caution when handling gasoline and other fuels. They are flammable and vapors are explosive. A fire or explosion from gasoline can burn you and others and can damage property. Refuel outdoors preferably, or in well ventilated areas. Never attempt to start engine when there is a strong odor of gasoline fumes present. Locate and correct cause. Store gasoline in an approved container and keep it out of the reach of children. Never buy more than a 0 day supply of gasoline. Always place gasoline containers on the ground away from your vehicle 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 static charge. When practical, remove equipment from the truck or trailer and refuel the equipment with its wheels on the ground. If this is not 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. Keep gas away from eyes and skin. WARNING: Fuel System Under Pressure! The EFI fuel system operates under high pressure, and the fuel filter and fuel line used must be approved system components only. Use of substitute parts can result in system failure, gasoline leakage and possible explosion. FUEL FILTER FUEL TANK Kawasaki Engine Shown FIG. FIG /0

212 The fuel tanks are located in the mower s fenders. ("FIG. ") Total capacity for the fuel tanks is U.S. gallon (.8 liter) Use regular unleaded gasoline with an octane rating of 87 or higher. The fuel filter ("FIG. ") is installed in the fuel line between fuel tanks and engine fuel pump. Replace filter annually or after every 00 hours of operation, whichever occurs first. When replacing the fuel filter, check the fuel line hoses and fuel shut-off valve grommet for any cracks or leaks. Replace as needed. Super Z mowers are equipped with a fuel shutoff valve located on the right fuel tank mount ("FIG. "). Rotate the valve to the middle position (shown) to prevent fuel flow to the fuel pump. The forward position allows fuel to flow from the right fuel tank to the fuel pump. The rear position allows fuel to flow from the left fuel tank to the fuel pump. Close this valve to prevent fuel flow to the engine when servicing the fuel system or when transporting the unit on a trailer or truck. NOTE: Models 9800, 9808 & 980 are equipped with a fuel shutoff valve located on the right fuel tank mount ("FIG. "). Rotate the valve to the forward position to prevent fuel flow to the fuel pump. The middle position (shown) allows fuel to flow from the right fuel tank to the fuel pump. The rear position allows fuel to flow from the left fuel tank to the fuel pump. RIGHT TANK POSITION CLOSED POSITION LEFT TANK POSITION FUEL SHUT-OFF VALVE CLOSED POSITION SHOWN FUEL SHUT-OFF VALVE RIGHT TANK SHOWN LEFT TANK POSITION Engine oil and filter FIG. FIG. Check engine oil daily and after every hours of operation. Crankcase dipstick and oil filler tube are located at the rear of the machine ("FIG. "). Mower must be sitting level when checking oil. Refer to engine manual and maintenance schedule for oil recommendation and capacities. Change the engine oil and filter after the first hours of operation, per the engine manufacturer s recommendations after that. If mower is being operated in extremely dirty conditions, then it is recommended oil be changed more frequently /0

213 The oil drain and oil filter are located at the rear of the engine "FIG. ". ENGINE OIL FILLER TUBE ENGINE OIL DRAIN PLUG ENGINE OIL FILTER Kawasaki Engine Shown FIG. Engine air filter Perform engine air filter maintenance per the scheduled maintenance chart. See SERVICE AT INTERVALS INDICATED on page 0-. A specially designed dry filter is standard equipment on the Hustler Z and Super Z mowers and supplies clean combustion air to the engine "FIG. 7". PRE-CLEANER ENGINE OIL FILTER Kawasaki Engine Shown FIG. 7 SAFETY FILTER The Super Z liquid cool mower is equipped with a safety filter. The filter element slides over the safety filter. Use Hustler part number 7879 only when replacing the safety filter. NOTE: The safety filter does not require servicing unless it becomes contaminated with dirt or moisture. RECOMMENDED SERVICE PROCEDURE Many engine failures can be attributed to improper air cleaner servicing. Ingested dust and dirt will cause /0

214 cylinder, piston and bearing damage in a few hours. Dusted engines will result from:. Overservicing the air filter element.. Improper installation.. Damaged filter, seals or canister.. Incorrect air filter element size.. Use of poorly designed aftermarket air filter elements. Air cleaner servicing is an inexpensive maintenance check that can prevent costly non-warrantable premature engine damage. Overservicing Overservicing occurs when an air filter element is removed for cleaning or replacement before it is necessary. 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 normal service life of an engine to cause a dusted engine. 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. The Donaldson warranty for air filters expires upon cleaning or servicing in any manner because the condition of the filter after servicing is completely out of their control. Therefore, on a dust ingested engine failure, there will be no warranty consideration if the air filter element has been cleaned or serviced in any manner. A partially dirty air filter element works better than a new element. Therefore, a dirty filter element is not bad for the engine unless it is excessively restricting the air flow and engine performance is affected. The reason is simple. The media in the filter must be porous to allow air to pass through it. When dirty air passes through the filter, the dirt plugs some of the holes in the media and actually acts as part of the filter media. When the next round of dirt enters, the first dirt helps filter out even smaller particles making the filter more efficient at stopping dirt from entering the engine. This is referred to as barrier filtration. Of course, at some point the filter media becomes too clogged to allow air to pass. The mowing conditions will determine the frequency of air filter element changing. Improper installation of an air filter element Dust must not leak past the seals on each end of the air filter element. The filter must be aligned within the canister and properly seated for an effective seal so that no dirt can enter the engine. Damaged filter, seals or canister Never bang or bump the filter element against the tire or any solid object, as dust and dirt particles will be forced through the media causing continual passing of dirt into the engine. Visually inspect the outside of the air cleaner canister periodically for external damage and replace if necessary. Incorrect air cleaner element Use only the correct Donaldson air filter element, Hustler part number 78, which is designed to fit the canister properly. Hustler air filter elements have the correct media composition, filter area, micron size and dimensions. Always use genuine Hustler filters. Many aftermarket filters have been found to be incompatible with Hustler s canisters and engines. The air filter must remain intact to block passage of dirt and foreign particles from entering 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 must be sufficient size and construction to withstand stresses, caused by rapid cycling of /0

215 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. The filter specified is a Donaldson filter, Hustler part number 78. Owners should be reminded that failure to use original equipment replacement parts is an alteration and will not be considered for warranty in the event of engine damage. Recommended service procedure. Release clamps and remove element. Clean the canister with a damp cloth.. Before installing a new element, inspect it by placing a bright light inside and rotate the 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.. Reinstall the dust cup. Make sure it seals all the way around the air cleaner body, then tighten the clamps.. Check all fittings and clamps periodically for tightness and inspect hoses for holes or cracks.. Periodically check the intake hose for signs of ingested dust. Locate and repair the source of ingested dirt.. Never operate a machine without an air filter installed. Air restriction indicator Any unit with a Kohler or Kawasaki engine will have an air restriction indicator installed in the air cleaner "FIG. 8". Replace the element whenever the restriction indicator shows reaches the change filter red line. Check the indicator daily and replace element as needed or annually whichever occurs first. Reset the indicator by pushing in on the yellow button after each element change "FIG. 8" A restriction indicator takes the guesswork out of air cleaner servicing and allows you to safely benefit from the filter s optimum performance. RESET BUTTON INDICATOR FIG. 8 Cooling system Applies to models 979, 9799, 9797 & 979 only Engine cooling is accomplished with circulated water and Ethylene Glycol mixture. The radiator is equipped with a pressure cap and overflow reservoir. System capacity is approximately.9 U.S. quart (.7 liter). Follow the information found in the engine owner s manual for the recommended coolant solution. Visually inspect the system daily prior to operating mower. Be sure the engine is level. Check the coolant level only when the system is cold. Check the coolant level only at the overflow reservoir "FIG. 9". The cooling system is a closed type. Never open the radiator cap. Doing so may induce air into the cooling /0

216 system and may cause overheating. The coolant level should be between the H and L marks. If the amount of coolant is insufficient, remove the cap from the reservoir and add coolant to the L mark. Install the cap. DANGER: Never remove radiator cap or overflow reservoir cap when engine is hot. Pressurized hot steam and water may be released, causing serious burns or possible blindness. The system should be drained, flushed and refilled with fresh solution after every 00 hours of operation. To drain the radiator remove the overflow reservoir cap and remove the coolant drain plug. When draining the system use a flexible funnel to keep the coolant off the muffler "FIG. 70". If frequent refilling is necessary or if coolant appears rusty, thoroughly check the system. Refer to the engine manual for information on checking and cleaning system. The engine cooling fan draws air through the engine cooling radiator. This is protected by a screen shroud. Keep the screen clean at all times and make sure trash is not allowed to accumulate on the radiator, nor allow the fins and cores to become plugged. The radiator screen can be removed by disengaging the latch at the rear of screen and pulling the screen towards the rear of mower. IMPORTANT: Take special care not to bend the screen mount. Never force anything into the radiator fins which may bend or distort them. For cleaning, use compressed air or pressurized water only. OVERFLOW RESERVOIR COOLANT DRAIN PLUG RADIATOR SCREEN General engine maintenance Detailed instructions and recommendations for break-in and regular maintenance are specified in the Engine Owner s manual. Please refer to this manual for engine servicing, lubricating oil levels with quality and viscosity recommendations, bolt torques, etc. The engine warranty is backed by the manufacturer. Special attention should be paid to applicable data which will not be duplicated here. IMPORTANT: Refer to the Kohler EFI engine owner s manual for specific cleaning instructions. Belt replacement FIG. 9 FIG. 70 "FIG. 7", "FIG. 7", "FIG. 7" & "FIG. 7" 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, tears, separation, weather checking and cracking, or burns caused by slipping. Slight raveling of belt covering does not indicate failure, trim ravelings with a sharp knife /0

217 VIEWED FROM BOTTOM OF UNIT. Pump belt. Engine pulley. Pump idler pulley. Pump idler arm. Pump pulley. Electric deck clutch 7. Pump idler spring, 7 FIG. 7 FIG. 7 Deck Belt Drive Layout. Spindle drive belt. Deck blade spindle pulley. Spindle belt tension idler. Spindle belt tension idler spring (9.0" at operation). Deck belt idler. Idler arm "/"/7" XR7 DECK Deck Belt Drive Layout. Spindle drive belt. Deck blade spindle pulley. Spindle belt tension idler. Spindle belt tension idler spring (9.0" at operation). Deck belt idler. Idler arm 0" XR7 DECK Deck Belt Drive Layout. Spindle drive belt. Deck blade spindle pulley. Spindle belt tension idler. Spindle belt tension idler spring (9.0" at operation). Deck belt idler. Idler arm FIG. 7 FIG. 7 0" & 7" RD DECK 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. Replace the pulley when this is the case, otherwise belt will lose power and slip excessively. Never pry a belt to get it on a pulley as this will cut or damage the fibers of the belt covering. Keep oil and grease away from belts, and never use belt dressings. Any of these will destroy the belt composition in a very short time /0

218 Mower blade maintenance Check the mower blades daily, they are the key to power efficiency and well groomed turf. Keep them sharp, a dull blade will tear rather than cut the grass, leaving a brown ragged top on the grass within a few hours. A dull blade also requires more 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 cause serious injury. DANGER: INever work with blades while engine is running or deck clutch switch is engaged (on). Always place deck clutch switch in the disengaged position, place control levers in the park brake position and turn engine off and disconnect negative battery cable. Block up mower when you must work under it. Wear gloves when handling blades. Always check for blade damage if mower strikes rock, branch or other foreign object during mowing! WARNING: IAlways wear adequate eye protection when grinding mower blades. Mower blade removal Use a /" wrench to remove the /8" cap screw holding the blade to the spindle shaft from underneath. Sharpen the blades on a grinder following pattern as shown "FIG. 77". Touch-up sharpening can be done with a file. Check the blades for balance following grinding. A commercial balancing tool is available through most hardware supply stores, or balancing can be done by placing the blade on an inverted line punch or /" bolt. Blade should not lean or tilt. Spin the blade slowly, blade should not wobble. If blade is out of balance, true it up before reinstalling. Lay the blade on a flat surface and check for distortion "FIG. 7" and "FIG. 7". Replace any distorted blade. Do not re-use spindle bolts which have stripped, worn or undercut threads. Torque bolts to 8 footpounds 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 to correctly torque the bolt may result in the loss of the blade which can cause serious injury. WARNING: Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves and use extra caution when servicing them /0

219 Warped Blade (Replace) Cutting plane Straight Blade (Replace) Comparison of Warped and Straight Blades 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 FIG. 7 Cutting Plane Cutting edge Twisted Blade Edge (replace) FIG. 77 Original edge Straight Blade Edge End view of blades, comparing twisted and straightened blades FIG /0

220 This page intentionally left blank /0

221 Adjustment Introduction Your Super 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. Correcting the problem as quickly as possible is the best insurance. Clear away heavy build-up of grease, oil and dirt, especially in the area of reservoir and oil and engine combustion air; minute dust particle are abrasive to close-tolerance engine and hydraulic assemblies. 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. Steering linkage The neutral adjustment for the control levers in the neutral position is discussed in this section. The mower steering has been factory adjusted to eliminate creeping when the control levers are in the neutral position "FIG. 78". However, should the mower begin to creep, the control lever linkage can be adjusted as follows: CONTROL LEVER IN THE NEUTRAL POSITION PARK BRAKE SLOT CONTROL LEVER FIG. 78 Control Lever Neutral Adjustment Before considering any adjustment, check the tire air pressure and make certain hydraulic system oil is at operating temperature. Unequal tire pressure will cause the mower to drift to one side. Refer to tire pressure information in the Maintenance section of this manual. Fine adjustment to the unit s steering is made with the adjustable pump linkage rods located between the control lever and pump arms "FIG. 79". Neutral is properly adjusted when the control levers are in the neutral position and the drive wheels are not turning /0

222 JAM NUT JAM NUT CONTROL PANEL PUMP LINKAGE ROD PUMP ARM STOP CONTROL LEVER If the mower creeps in the neutral position the control linkage may be adjusted as follows:. Raise and block the mower 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. Make certain machine is secure when it is raised and placed on the jack stands. The jack stands should not allow the machine to move when the engine is running and the drive wheels are rotating. Use only certified jack stands. Use only appropriate jack stands, with a minimum weight rating of 000 pounds to block the unit up. Use in pairs only. Follow the instructions supplied with the vehicle stands.. Position the control lever in the neutral position. Disengage the deck clutch.. Start the engine and observe which way the wheels are rotating.. If wheel(s) are rotating forward, loosen the jam nuts on the pump linkage rods and rotate the rod to lengthen the steering control linkage until the wheel(s) come to a stop "FIG. 79". Repeat for the opposite side if necessary. NOTE: The left linkage controls the left hydraulic pump and the right linkage controls the right hydraulic pump.. If wheel(s) are rotating in reverse then loosen the jam nuts on the pump linkage rods and rotate the rod to shorten the steering control linkage until the wheel(s) come to a stop "FIG. 79". Repeat for the opposite side if necessary. NOTE: The left linkage controls the left hydraulic pump and the right linkage controls the right hydraulic pump.. When both wheels remain in neutral, tighten the jam nuts to lock the turnbuckle in place. 7. Test again by moving the control levers forward and backward before returning them to the neutral position. If the tires are in neutral, the unit is now ready for operation. 8. After adjusting for neutral it may be necessary to re-adjust the control lever stop "FIG. 80". Control lever stops FIG. 79 FIG. 80 The control lever stops "FIG. 80" are designed to do two things: First, and most important, they must keep the pumps from bottoming out internally. Secondly, the stops may be adjusted to help drive straight when the control levers are pushed forward against the stops. To keep the pumps from bottoming out internally use the following procedure:. To make the first adjustment the mower engine must NOT be running.. 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. If you sense that the /0

223 pump arms are stopping the forward motion of the control arms, loosen the jam nut on the adjustable stop of the corresponding side and turn the stop (set screw) inward to stop the control levers slightly before the pump bottoms out. Lock in place when the adjustment is correct by re-tightening the jam nut.. Do this for each side. To adjust the stops for driving straight when control levers are against the stops during operation:. Determine which drive tire is rotating too fast when both control levers are against the stops. Then stop the mower 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. Tighten the lock nut on the stop and test again. Repeat this procedure until unit drives straight. NOTE: Since this is a hydrostatic drive, variables such as temperature of oil, efficiency of pumps and motors, tire pressure etc. may effect the consistency of the ability to rely on the stops to drive straight without the operator making minor steering adjustments with the control arms. Steering dampener The steering dampener, "FIG. 8", is spring loaded to return the control levers to the neutral position from the reverse position. This gives the operator a sense of neutral during operation. To set the steering dampeners in the correct operating position follow these steps:. Place the control lever in the neutral position.. Loosen the steering dampener s front ball stud.. Pull the dampener spring housing pass the point that the internal spring is engaged.. Release the dampener spring housing and allow the internal spring to bring the housing back to the neutral position.. Tighten the nut on the steering dampener s front ball stud. SPRING HOUSING CAP SCREWS UPPER CONTROL LEVER FRONT BALL STUD LOWER CONTROL LEVER Control lever adjustment FIG. 8 FIG. 8 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. 8", 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 /0

224 Park brake adjustment Occasionally check the park brakes and adjustment using the following method:. Position the control levers in the neutral position. Disengage the deck clutch. WARNING: Never work under the machine or attachment unless it is safely supported with jack stands. Make certain machine is secure when it is raised and placed on the jack stands. The jack stands should not allow the machine to move when the engine is running and the drive wheels are rotating. Use only certified jack stands. Use only appropriate jack stands, with a minimum weight rating of 000 pounds to block the unit up. Use in pairs only. Follow the instructions supplied with the vehicle stands. NOTE: The front brake link is not adjustable. "FIG. 8". Raise and block the mower up so the drive wheels are off of the floor.. Open the hydraulic pump s bypass valve "FIG. 8", on the side that is being adjusted, by turning bypass valves counter clockwise one-half to one revolution. The valve stems on each hydraulic pump are located near the top and are identified as a hex stud. FRONT BRAKE LINK (RIGHT SIDE) BYPASS VALVE FIG. 8 FIG. 8. Rotate the tire. The tire should rotate. Remember hydraulic oil resistance will prevent the tire from rotating freely even with the bypass valves open. There should be no resistance from the brakes at this point.. Move the control lever to where it is just inside (/8 ) the park brake slot "FIG. 8". 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. However, if no brake resistance is noticed, the brake needs adjusted as follows: 7. Loosen the brake linkage jam nuts "FIG. 8". PARK BRAKE SLOT CONTROL LEVER JAM NUTS /8" OUTSIDE EDGE BREAK LINKAGE TURNBUCKLE FIG. 8 FIG /0

225 8. Rotate the tire and at the same time rotate the turnbuckle to shorten the length of the brake linkage to increase the brake pressure. When you feel the brake begin to engage, stop adjusting the turnbuckle. Re-tighten the jam nuts on the turnbuckle. 9. Place the control lever in the park brake slot "FIG. 8". The tire should not rotate when the control lever is in the park brake position. 0. Place the control lever in the neutral position. The tire should rotate freely.. Close the hydraulic pump s bypass valve.. Repeat steps thru for the other side.. Remove 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. 87". There is no tension adjustment of this belt. NOTE: Replace the belt every 00 hours or every two () years whichever comes first. 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. SPRING PUMP BELT DRIVE TENSION IDLER Deck drive belt adjustment FIG. 87 The spindle belt tension remains constant by means of a tension idler and spring "FIG. 89". The spring tension should be such that the belt does not slip under normal operating load conditions, assuming the belt is not excessively worn or damaged. As belt stretches and wears in, adjustment may become necessary. To increase belt tension, move the spring chain one (or more) link(s) at the anchor bracket "FIG. 89". Installed spring length should be 9.0" ±." (.8 cm ±.7 cm) originally with adjustments of.0" (.mm) per chain link "FIG. 88". IMPORTANT: Do not over tension the spring to compensate for a badly worn belt or pulley /0

226 TENSION IDLER SPRING EXTENSION 9.0" SPRING NORMAL SPRING LENGTH.0" FIG. 88.0" CHAIN FRONT BLOCKS ANCHOR BRACKET " Engine RPM setting The Super Z is designed so that the engine will run at 00 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. Before considering any mower deck leveling adjustments, check that the tire air pressure is within the specified range. Deck level adjustments FIG. 89 FIG. 90 Leveling the deck must be done in the following manner and order:. Check tire pressures to make certain they are properly inflated before starting to level deck. The recommended pressures are as follows: Drive wheels tire pressure psi Gauge wheels tire pressure psi WARNING: Stop engine. Make sure deck clutch switch is in the down (OFF) position. Place control levers in the brake position before leaving machine.. Park the unit on a flat surface.. Raise deck and place. block under the back of the deck and a block under the front of the deck "FIG. 90". This will set the cutting height at -/ ". NOTE: Back of deck will automatically be set approximately ¼" higher.. Set cutting height at -/" in the height indicator by placing the height adjusting stop /0

227 in the -/" hole, and turning the height stop so that the pin side is against the stop handle "FIG. 9". Clamp the height adjusting stop against the stop handle "FIG. 9". This will assure that the height will not move during the setting process. Otherwise, spring pressure from the deck lift springs will tend to pull the stop away from the handle. STOP HANDLE HEIGHT ADJUSTING STOP FIG. 9. Loosen all nuts on the deck lift threaded rods, and the hardware on the adjuster (on the right front), until all the deck lift chains are loose, and the deck is sitting tightly on all four blocks "FIG. 9", "FIG. 9", "FIG. 9". DECK LIFT THREADED ROD NUT DECK LIFT THREADED ROD NUT NUT CHAINS CHAINS NUT FIG. 9 FIG. 9 ADJUSTER /" BOLT JAM NUT HARDWARE FIG Loosen the two nuts on the front of height indicator so that the foot pedal is free "FIG. 9" /0

228 8. Start the leveling process on the left front of the mower. 9. Set the amount of threads protruding on the deck lift rod from the lift block at approximately " "FIG. 9". 0. Jam both nuts against the block.. 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 " block.. While keeping the chain tight, tighten the nuts against the deck lift block on the height indicator rod "FIG. 9".. Go to the right front of the mower.. Loosen the /" jam nut on the adjuster lift chain "FIG. 9", and back the adjuster bolt out to allow the adjuster to move up and down freely.. Be sure that adjuster is free to move up and down.. Tighten the adjuster bolt until the chain just becomes tight, making sure that the deck stays tight against the " block. 7. Tighten the adjuster bolt jam nut to prevent the adjuster bolt from moving "FIG. 9" 8. Tighten the hardware holding the chain and adjuster onto the deck lift arm. 9. Go to the right rear of the mower. 0. 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. 9".. Tighten the appropriate nut until the chain just becomes tight, making sure that the deck stays tight against the " block.. Tighten the other nut on the opposite side of the block, and jam them tightly together against the block.. Go to the left rear of the mower.. 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. 9".. Tighten the appropriate nut until the chain just becomes tight.. Tighten the other nut on the opposite side of the block, and jam them tightly together against the block. 7. Compress the deck lift assist springs so that there is of space between the front nut and on the spring and the rear nut on the deck lift block "FIG. 9". Typical both sides. 8. When completed, all chains will be tight, and deck cutting height will be set to the deck height indicator. FOOT PEDAL LIFT BLOCK " " DECK LIFT ROD NUTS FIG. 9 FIG /0