Hustler Z4 Parts Manual

Transcription

1 Hustler Z4 Parts Manual Hustler Turf Equipment P.O. Box 7000 Hesston, Kansas Rev. 10/10

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 500 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.

3 Table of Contents Section 1 General Information Section Frame Footrest Engine Guard Section Hydraulic System Pump Drive Pump Drive Belt Routing Steering Steering Sub Assembly Brake Section 4 Wheel and Tire Assembly Wheel and Tire Breakdown Front Wheel Breakdown Section 5 /5 HP KAW Engine Install HP KAW Engine Install Fuel System Fuel System Routing Detail Section 6 Battery Install Instrument Panel Electrical Schematic (60088) Section 7 48" Deck Decals " Deck Decals " Deck Decals " Deck Pulley Assembly " Deck Pulley Assembly " Deck Pulley Assembly " Deck Assembly " Deck Belt Routing " Deck Assembly " Deck Belt Routing " Deck Assembly " Deck Belt Routing Deck Lift Deck Installation Deck Adjustments _1010 c-1

4 Section 8 Seat ROPS Index i-1 c _1010

5 Section 1 General Information This Manual covers Hustler Z4 models 991, 9949, 9956, 99406, & 994. Frequently Ordered Parts PART NO. DESCRIPTON Hydraulic Filter Element Pump Drive Belt A Sec 59.90" EL In Line Fuel Filter Main Air Filter Element Air Filter Safety Element Kawasaki Oil Filter Deck Belt B-Sec " EL (60" Side Disch. Deck) Deck Belt B-Sec " EL (54" Side Disch. Deck) Deck Belt B-Sec " EL (48" Side Disch. Deck) F0.50"-H-F-CW Blade (60" Side Disch. Deck) F18.50"-H-F-CW Blade (54" Side Disch. Deck) F16.50"-H-F-CW Blade (48" Side Disch. Deck) Service Literature PART NO. DESCRIPTION 60 Owner s Manual 7784 /5 HP Kaw Engine Owner s Manual HP Kaw Engine Owner s Manual Options Available From Your Dealer PART NO. DESCRIPTION 997 Z4 BAG CATCHER 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 _

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. Hardware Description Codes & Abbreviations The following codes are used throughout this parts manual. Refer to this list when ordering parts. ABBREVIATION CB CE CP CS CW FDRW FW HX LW MB MS NT SC SH SB SS OD ID DESCRIPTION Carriage Bolt Clevis Pin Cotter Pin Cap Screw Cup Washer Fender Washer Flat Washer Hex Head Lock Washer Machine Bushing Machine Screw Nut Self Tapping Cap Screw Socket Head Shoulder Bolt Set Screw Outside Diameter Inside Diameter 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 M M M M M M M M M M NOTE: Loctite 59 to be used on all pipe threads. Lubricate all grease zerks _1010

7 Section Frame Footrest Engine Guard _1010-1

8 Frame _1010

9 Frame INDEX NO. PART NO. QTY. DESCRIPTION " FRAME WELDMENT " FRAME WELDMENT " FRAME WELDMENT /8-16 THREAD RIVET NUT /-1 THREAD RIVET NUT DECK HEIGHT DECAL SAFE OPERATION DECAL 6 N/A 1 SERIAL NO PLATE TURF PRODUCT HOT DECAL NOTES: 1. In the event the serial number tag becomes damaged or illegible, please contact your Hustler dealer to order a replacement.. Width of 48" frame measured from center to center of caster.. Width of 54" frame measured from center to center of caster. 4. Width of 60" frame measured from center to center of caster. 5. Item 1 (Frame Weldment) includes Items _1010 -

10 Footrest _1010

11 Footrest INDEX NO. PART NO. QTY. DESCRIPTION UPPER STEP TREAD FLOOR PAN LOWER STEP TREAD NT HXZY NL FW.406X.81 X.060 SAE BUMPER.500X 1.00X CB.75-16X 1.00 STD CD NOTES: 1. Do not tighten ( places), Item ( Floor Pan) must be able to pivot on these bolts.. Item includes Items 1 and (Step Treads) _1010-5

12 Engine Guard _1010

13 Engine Guard INDEX NO. PART NO. QTY. DESCRIPTION ENGINE GUARD (USED ON 48" & 54" TRACTORS) ENGINE GUARD (USED ON 60" TRACTORS) MUFFLER GUARD HEAT SHIELD ANTI-SCALP WHEEL FW.4X.687X.051/.080H NT.1-18 HX G5 ZNYC CS.1-18X.65 HX G CS.500-1X1.00 HX G5 Z FW.51X 1.06X.090 SAE CS.500-1X4.500 HX G NT HX G8 ZY NL 1. Do not torque, wheel must turn freely. NOTES: 11167_1010-7

14 _1010

15 Section Hydraulic System Pump Drive Pump Drive Belt Routing Steering Steering Sub Assembly Brake _1010-1

16 _1010 Hydraulic System

17 Hydraulic System INDEX NO. PART NO. QTY. DESCRIPTION HYDRAULIC OIL RESERVOIR STRAINER BREATHER CAP NT.1-18 HX G5 ZNYC FW.4X.687X.051/.080H RIGHT SIDE PUMP, HYD 1CC W/ FAN LEFT SIDE PUMP, HYD 1CC W/ FAN NT HX G5 ZNYC FW.45X.81X.060 ZNYC MOTOR, TF040 PARKER 6009 MOTOR, HGM-15E CS.500-1X.500 HX G FW.51X 1.06X.090 SAE CS.47-14X1.75 HX G CS.50-0X.500 HX G FW.81X.65X.051/.080H FILTER HEAD ZINGA BF SE FILTER ELEMENT FITTING, STR-6MORB-6MJIC HOSE ASSY RES-FILTER Z FITTING, 6 BEADED TUBE FITTING, -1MORB/-6FORB FITTING, STR-8MORB/HEX 6009 HOSE ASSY CASE DRAIN Z HOSE ASSY FILT-RPUMP Z FITTING,STR-6MORB/-6MJIC FITTING, 90-6MORB/-6MJI FITTING, 90-8MORB/-8MSL FITTING, 90-10MORB/-8MS TUBE, RP-BM RT LOOP TUBE, LP-TM RT LOOP TUBE, RP-BM LT LOOP TUBE, LP-TM LT LOOP FITTING, STR-8MORB/-8MS HOSE ASSY FILT-LPUMP Z C6X-S JIC SWIVEL ELBOW FITTING T,-6 O-RING/-6J PUMP FAN SHROUD PUMP FAN KIT PUMP SHROUD BRACKET NOTES: 1. Hydraulic system capacity is 5 US quarts of 0W50 motor oil. Fill reservoir to within 1" of top of Item (0771 Strainer).. These items are available as service parts for the pumps (Items 6 & 7).. Use 608 for mowers with serial numbers and higher. Use 6009 for mowers with serial numbers prior to _1010 -

18 HYDRAULIC SYSTEM CHARGING PROCEDURE 1. Set handles in the neutral position.. Start engine at idle.. Let run for a minimum of 0 seconds. 4. Stroke handles to forward position. 5. If motors do not turn in 15 seconds return handles to neutral and repeat steps and 4 (one time). 6. If motors do not run 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. NOTE: Seal Kit for hydraulic pumps: _1010

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20 Pump Drive _1010

21 Pump Drive INDEX NO. PART NO. QTY. DESCRIPTION CS.1-18X1.000 HX G FW.4X.687X.051/.080H NT.1-18 HX G5 ZNYC SS.1-18X.750 SQ-HD PULLEY KEY 5MM X0MM RADIUS EN BUMPER, RUBBER ENGINE PULLEY SC SINGL KEY 1/4 SQ X 1.50 LG(FS) FW 1.156X1.750X.50 ZY CLUTCH, WARNER CMS CLUTCH PIGTAIL HARNESS FW.460X 1.750X.50 ZN CS.47-0X.50 HX G5 Z GREASE FITTING STRAIGHT PUMP IDLER ARM W/A FW.760X 1.65X.08 ZNYC NT HXZY NL IDLER PULLEY NHI 5.00" FW.65X1.00X.14 ZNYC CS.65-11X1.5 HX G5 Z IDLER SPRING BELT A SEC 59.90" EL NOTES: 1. Torque to ft-lbs.. If fastener is loosened or removed, do not reuse. Replace with new fastener. Use only hand tools to install this fastener.. Torque to 1 15 ft-lbs.. Apply grease at zerk. 4. Do not torque Item 18 ( NT HZXY NL), Item 16 ( Pump Idler Arm) should pivot freely. 5. Item 10 (797654) is used on 9956 and 994 (Kawasaki 7 HP engines only) _1010-7

22 Pump Drive Belt Routing 6. Route belt as shown. NOTES: HYDRAULIC PUMP BELT ADJUSTMENT The pump drive belt tension remains constant by means of a tension idler and spring. There is no tension adjustment of this belt. NOTE: Replace the belt every 400 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 _1010

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24 _1010 Steering STEERING SUB-ASSEMBLY STEERING SUB-ASSEMBLY MOWER FRAME

25 Steering 1 1 INDEX NO. PART NO. QTY. DESCRIPTION STEERING CONTROL COVER W/A NT.1-4 HXZY NL FW.4X.687X.051/.080H STEER PIVOT TUBE SCOTCH POLYURETH " X 6" (SOLD BY THE FOOT) LOCK COLLAR PUMP ROD ADJUSTER ASSY STEERING DAMPER BALL STUD DAMPER PUMP ARM FW.81X.65X.051/.080H CS.50-0X.00 HX G5 Z NT.50-0 HXZY NL NT.1-18 HX G5 ZNYC LW.1 INT-EXT TOOTH Z BUSHING, UHMW FW.406X.81 X.060 SAE CS.75-16X.750 HX G SS.500-1X.000 SH ZNY NT HX JAM ZNYC FIRST ZERO TURN DECAL Z4 ID DECAL 'MADE IN U.S.A.' DECAL NOTES: 1. Pin to be clean and free of rust. Apply thin coat of grease prior to installing (Bushing) from Steering Sub-Assembly.. Item 1 (Steering Control Cover) includes Item 5, 0, 1 and (decals) _

26 STEERING CONTROL ADJUSTMENT 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 (see FIG. ). Neutral is properly adjusted when the control levers are in the neutral position and the drive wheels are not turning. 1. 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 FIG. 1. Disengage the deck clutch. CONTROL LEVER IN THE NEUTRAL POSITION PARK BRAKE SLOT CONTROL LEVER FIG. 1. Start the engine and observe which way the wheels are rotating. 4. 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.. Repeat for the opposite side if necessary. JAM NUT PUMP LINKAGE ROD PUMP ARM FIG. 5. If wheel(s) are rotating in reverse then loosen the jam nuts on the pump linkage rods _1010

27 and rotate the rod to shorten the steering control linkage until the wheel(s) come to a stop. (see FIG. ) Repeat for the opposite side if necessary. 6. 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 and/or damper. (see FIG. or FIG. 4) CONTROL LEVER STOPS The control lever stops (see "FIG. ") 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: 1. 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 pump arms are stopping the forward motion of the control arms, loosen the jam nut on the adjustable stop of the corresponding side, 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.. JAM NUT CONTROL PANEL STOP FIG. CONTROL LEVER To adjust the stops for driving straight when control levers are against the stops during operation: 1. Determine which drive tire is rotating too fast when both control levers are against the stops in the control panel (see FIG. ). 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 _1010-1

28 STEERING DAMPER STEERING DAMPER SPRING HOUSING FRONT BALL STUD FIG. 4 The steering dampers (see FIG. 4) are 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: 1. Place the control lever in the neutral position.. Loosen the steering damper s front ball stud.. Pull the damper spring housing past the point that the internal spring is engaged. 4. Release the damper spring housing and allow the internal spring to bring the housing back to the neutral position. 5. Tighten the nut on the steering damper s front ball stud. NOTE: The damper must not bottom out when the pump lever is fully stroked in either direction. CONTROL LEVER ADJUSTMENT 1. The control levers can be adjusted for operator comfort. By loosening the cap screws that attach the upper control lever to the lower lever the upper control lever can be pivoted to fit the operator s personal preference (see FIG. 5). The control levers should be adjusted so that they align vertically with each other when in the neutral position... ALIGN HANDLES ±.15 CAP SCREWS FIG. 5 FIG _1010

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30 Steering Sub Assembly _1010

31 Steering Sub Assembly INDEX NO. PART NO. QTY. DESCRIPTION STEERING BAR GRIP STEERING BAR W/A CS.75-16X1.000 HX G FW.406X.81 X.060 SAE STEERING ARM MOUNT W/A STEERLEVER BUSHING CS.75-16X1.750 HX G LEFT SIDE STEERING LEVER SUPPORT RIGHT SIDE STEERING LEVER SUPPORT (NOT SHOWN) UHMW BUSHING NT HXZY NL SS.500-1X SH ZNY NOTES: 1. Left side steering sub assembly is shown; the right side is similar.. Item (Steering Bar) includes Item 1 (Steering Bar Grip) _

32 Brake STEERING SUB-ASSEMBLY TRACTOR FRAME _1010

33 Brake INDEX NO. PART NO. QTY. DESCRIPTION BRAKE ROD ASSEMBLY FW.4X.687X.051/.080H NT.1-4 HXZY NL CS 10-4X.750 HXFLK ZN PUSH BUTTON SWITCH NT HXZY NL FW.406X.81 X.060 SAE NUT PLATE W/.40 CENTERS CS.75-16X4.750 HX G LEFT BRAKE PIVOT ARM RIGHT BRAKE PIVOT ARM (NOT SHOWN) IGUS BUSHING NT HX GRD 5 ZNY SB.500X.65 SH BRAKE ROD ASSEMBLY NT.1-18 HX G5 ZNYC LEFT BRAKE ASSY RIGHT BRAKE ASSY (NOT SHOWN) WHEEL HUB CS.1-18X.875 HX G BRAKE ARM Z4 NOTES: 1. Part of wire harness.. Included with wheel motor.. Torque to ft-lbs. 4. Torque to 17 ft-lbs. 5. Do not torque this fastener, should be snug but allow Item 10/11 (094/095 Brake Pivot Arm) to pivot freely _

34 PARK BRAKE ADJUSTMENT BRAKE LINK FIG. 7 Occasionally check the park brakes and adjustment using the following method: 1. 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. (see FIG. 7). Raise and block the tractor up so the drive wheels are off of the floor.. Open the hydraulic pump s bypass valve, on the side that is being adjusted, by turning bypass valves (see FIG. 8) 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. BYPASS VALVE FIG 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 _1010

35 5. Move the control lever to where it is just inside (1/8") the park brake slot see FIG. 9. CONTROL LEVER PARK BRAKE SLOT OUTSIDE EDGE 1/8" FIG. 9 NOTE: When the control lever is against the outside edge of the slot, the brakes should NOT be engaged. 6. 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. (see FIG. 10) JAM NUTS FIG 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 (see FIG. 9). The tire should not rotate when the control lever is in the park brake position. 10. Place the control lever in the neutral position. The tire should rotate freely. 11. Close the hydraulic pump s bypass valve. 1. Repeat steps through 11 for the other side. 1. Remove the jack stands and lower the unit. It is now ready to operate _1010-1

36 _1010

37 Section 4 Wheel and Tire Assembly Wheel and Tire Breakdown Front Wheel Breakdown _

38 Wheel and Tire Assembly _1010

39 Wheel and Tire Assembly INDEX NO. PART NO. QTY. DESCRIPTION TIRE/WHEEL ASSY X9.50 (ONLY USED WITH 48" & 54" DECKS) TIRE/WHEEL ASSY 4 X 1 (ONLY USED WITH 60" DECKS) WHEEL NUT CS.500-1X1.5 HX G5 Z FW.510X.15X.187 SPL FW.51X 1.75X.15 ZNY BEARING SPACER FASTRAK FW 1.00X 1.500X.14 ZN FORK W/A MINI Z FW.760X 1.65X.08 ZNYC CS X8.00 HX GR NT HXZY NL TIRE/WHEEL ASSY 1X500 NOTES: 1. Inflate tires to 8 1 psi.. Torque to ft.-lbs.. Assemble with extended inner race down. 4. Apply grease to zerks _

40 Wheel and Tire Breakdown 1 INDEX NO. PART NO. QTY. DESCRIPTION TIRE X (ONLY USED WITH 48" & 54" DECKS) TIRE 4X1-1 (ONLY USED WITH 60" DECKS) WHEEL ASSY 1 X 7.00 (ONLY USED WITH 48" & 54" DECKS) WHEEL ASSY 1 X 8.50 (ONLY USED WITH 60" DECKS) TIRE VALVE NOTES: 1. Quantities for Items 1 are per tire assembly _1010

41 Front Wheel Breakdown INDEX NO. PART NO. QTY. DESCRIPTION WHEEL BEARING TIRE 1X5 SUPER GUIDE WHEEL GREASE FITTING 45 DEG TIRE VALVE TR-41 GOODY 1. Inflate tire to 8-1 psi. NOTES: 11167_

42 _1010

43 Section 5 /5 HP KAW Engine Install HP KAW Engine Install Fuel System Fuel System Routing Detail _

44 /5 HP KAW Engine Install } 5 AUXILIARY CONNECTION 1 OIL SENSOR YEL/BLK TO BULLET TERMINALS ENGINE GROUND RED/BLK TO BLADE TERMINAL SOLENOID GROUND _1010

45 /5 HP KAW Engine Install INDEX NO. PART NO. QTY. DESCRIPTION 1 N/A 1 KAW HP ENGINE W/ HD AIR USED ON 991 N/A 1 KAW 5HP ENGINE W/ H/D AIR USED ON CS M 8-1.5X0 10.9HXFLZ FW.4X.687X.051/.080H MUFFLER /5 KAW MMZ EXHAUST CLAMP KAW HEAT SHIELD MUFFLER GASKET MANIFOLD /5 KAW MMZ LW.1 MED SPRING ZNYC NT M8-1.5 HX STAINLESS OIL DRAIN VALVE M0X NT.1-18 HXZY NL CS.1-18X1.750 HX G NEGATIVE BATTERY CABLE 6" LW.1 INT-EXT TOOTH Z NT.50-0 HX GR.5 ZNYC FW.81X.65X.051/.080H CLIP " FUEL LINE RED BATTERY CABLE BOOT STARTER SOLENOID HW KIT RED POSITIVE BATTERY CABLE NT #10- HX ZN MALE TAB -.50 PUSH ON POSITIVE BATTERY CABLE LW.50 INT-EXT TOOTH Z CS.50-0X.750 HX G CAP HUSTLER Z FAN CON WIRE TIE, SMALL/SHORT NOTES: 1. Includes mounting hardware.. Part of wire harness (60088).. Contains a 5A fuse; part of wire harness (60088). 4. Engine oil capacity: See engine owner s manual. 5. Engine RPM to be set at 600± Supplied with engine. AIR FILTER SERVICE PARTS MAIN AIR FILTER ELEMENT AIR FILTER SAFETY ELEMENT 11167_

46 7 HP KAW Engine Install 1 AUXILIARY CONNECTION } OIL SENSOR YEL/BLK PURPLE RED/BLK TO BLADE TERMINAL GROUND 4 TO BULLET TERMINALS GROUND _1010

47 7 HP KAW Engine Install INDEX NO. PART NO. QTY. DESCRIPTION 1 N/A 1 KAW 7 HP ENGINE HEAT SHIELD CS M8X1.5 X16 G10.9 HX /1 KAW MANIFOLD EXHAUST CLAMP KAW MUFFLER GASKET LW.1 MED SPRING ZNYC NT M8-1.5 HX STAINLESS MUFFLER CS.75-16X1.000 HXFLK FW.91X 1.50X.060 ZNY NT HXFLK ZNYC CLIP " FUEL LINE OIL DRAIN VALVE M0X FW.406X.81 X.060 SAE CS.75-16X1.00 HXG5 P LW.1 INT-EXT TOOTH Z NEGATIVE BATTERY CABLE 6" RED POSITIVE BATTERY CABLE LW.1 MED SPRING ZNYC NT M8-1.5 HX STAINLESS NT.50-0 HX GR.5 ZNYC FW.81X.65X.051/.080H LW.50 INT-EXT TOOTH Z CS.50-0X.750 HX G CAP HUSTLER Z FAN CON WIRE TIE, SMALL/SHORT NOTES: 1. Includes mounting hardware.. Part of wire harness (60088).. Contains a 5A fuse; part of wire harness (60088). 4. Engine oil capacity: See engine owner s manual. 5. Engine RPM to be set at 600± Supplied with engine. 7. Torque to 0 ft-lbs. If fastener is loosened or removed, do not re-use. Replace with new fastener. Use only hand tools to install this fastener. AIR FILTER SERVICE PARTS MAIN AIR FILTER ELEMENT AIR FILTER SAFETY ELEMENT 11167_

48 Fuel System _1010

49 Fuel System INDEX NO. PART NO. QTY. DESCRIPTION RIGHT SIDE FUEL TANK LEFT SIDE FUEL TANK FUEL CAP,.5" CLIP FUEL LINE 1.5" (SOLD BY THE FOOT) FUEL LINE.5" (SOLD BY THE FOOT) FUEL VALVE -WAY FW.406X 1.00X.1 HRD Z CS.75-16X.750 HX G WIRE TIE SMALL/SHORT 1. Torque to 0 ft. lbs. NOTES: FUEL TANK SERVICE PARTS FUEL SHUTOFF VALVE GROMMET SUCTION HOSE ASSY 6.5" 11167_

50 Fuel System Routing Detail NOTES:. Route the left side fuel line under the seat support and secure with wire ties in () places _1010

51 Section 6 Battery Install Instrument Panel Electrical Schematic (60088) _

52 Battery Install MOWER FRAME 1 NEGATIVE BATTERY CABLE 7 1 POSITIVE BATTERY CABLE _1010

53 Battery Install INDEX NO. PART NO. QTY. DESCRIPTION BATTERY VU1LH CS.1-18X.00 HX G5 Z 7685 FW.4X.687X.051/.080H BATTERY CLAMP STRAP CS.50-0X.750 HX G LW.50 INT-EXT TOOTH Z RED BATTERY CABLE BOOT NT.50-0 HX GR.5 ZNYC CN.1-18X.00 MAX THK WIRE TIE, SMALL/LONG NOTES: 1. When performing service on mower, disconnect negative battery cable and do not reconnect to battery until engine is ready to be started. See Owners Manual.. Battery is not installed in export models _

54 Instrument Panel A 10A FUSE SIZE AND LOCATION RIGHT SIDE FUEL TANK _1010

55 Instrument Panel INDEX NO. PART NO. QTY. DESCRIPTION INSTRUMENT PANEL Z CHOKE CABLE HOUR METER CB 10-4 X.500 ZYNC KEY ASSEMBLY IGN SWITCH INDAK H PTO SWITCH RED INDICATOR LIGHT Z SPARK IGNITION CONTROLLER NT #10-4 HX NL ZN CS 10-4X.750 HXFLK ZN WIRE TIE SMALL/LONG THROTTLE CABLE LG HNDL 60" FW.19X.500X.048 ZNYC WIRE HARNESS, KAWASAKI CS.50-0X.500 HX G FW.81X.65X.051/.080H INSTRUMENT PANEL DECAL Z4 NOTES: 1. Relay and fuses are part of Item 15 (Wire Harness).. Instrument panel includes Item 18 (60) _

56 Electrical Schematic (60088) _1010

57 Section 7 48" Deck Decals " Deck Decals " Deck Decals " Deck Pulley Assembly " Deck Pulley Assembly " Deck Pulley Assembly " Deck Assembly " Deck Belt Routing " Deck Assembly " Deck Belt Routing " Deck Assembly " Deck Belt Routing Deck Lift Deck Installation Deck Adjustments _

58 48" Deck Decals INDEX NO. PART NO. QTY. DESCRIPTION " DECK WELDMENT CN.1-18 X.00 MAX THK DISCHARGE CHUTE DECAL DECK DANGERS DECAL DECK BELT RTG DECAL STEP TREAD 'MADE IN U.S.A.' DECAL THROWN OBJECTS DECAL NOTES: 1. Item 1 (550) includes Items 8 as a service deck _1010

59 54" Deck Decals INDEX NO. PART NO. QTY. DESCRIPTION " DECK WELDMENT CN.1-18X.00 MAX THK DISCHARGE CHUTE DECAL DECK DANGERS DECAL DECK BELT ROUTING DECAL STEP TREAD 'MADE IN U.S.A.' DECAL THROWN OBJECTS DECAL NOTES: 1. Item 1 (550) includes Items 8 as a service deck _

60 60" Deck Decals INDEX NO. PART NO. QTY. DESCRIPTION " DECK WELDMENT CN.1-18X.00 MAX THK DISCHARGE CHUTE DECAL DECK DANGERS DECAL DECK BELT RTG DECAL STEP TREAD 'MADE IN U.S.A.' DECAL THROWN OBJECTS DECAL NOTES: 1. Item 1 (5504) includes Items 8 as a service deck _1010

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62 48" Deck Pulley Assembly _1010

63 48" Deck Pulley Assembly INDEX NO. PART NO. QTY. DESCRIPTION CS.65-11X1.750 HX G FW.656X.00X.078 ZNYC FW.650X1.15X.18 ZNYCG IDLER PULLEY NHI 5.00" FW.65X1.00X.14 ZNYC DECK IDLER SPACER IDLER W/A IDLER SPRING CHAIN DECK LIFT SPRING CS.1-18X1.50FLT SH ZY UHMW IDLER SLIDE NT HX G5 ZNYC CS.65-11X1.5 HX G5 Z CW.61.50X.187 PNT PULLEY 5.00"OD 80B NT HX GRD 5 ZNY FW.406X.81 X.060 SAE FW.4X.687X.051/.080H NT.1-18 HX G5 ZNYC CS.1-18X.750 HX G RIGHT PULLER & PIN ASSY LEFT PULLER & PIN ASSY CS.500-1X4.50 HX G FW.51X 1.06X.090 SAE ANTI-SCALP WHEEL NT HX JAM ZNYC NT HX G8 ZY NL NT.1-18 HXZY NL CS.65-11X.00 FULL HX CS.75-16X1.75 HX G BLADE SPINDLE ASSEMBLY ANTI SCALP WHEEL ASSY NOTES: 1. Item (Anti-scalp Wheels) include Items 6.. Torque to 118 ft.-lbs _

64 48" Deck Pulley Assembly INDEX NO. PART NO. QTY. DESCRIPTION HANGER EXT REAR RIGHT SIDE HANGER EXT REAR LEFT SIDE FW.4X.687X.051/.080H NT.1-18 HX G5 ZNYC FW.468X 1.00X.090 HT T NT HX G5 ZNYC CS.1-18X1.000 HX G CS.47-14X1.000 HX G HANGER EXT FRONT NOTES: _1010

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66 54" Deck Pulley Assembly _1010

67 54" Deck Pulley Assembly INDEX NO. PART NO. QTY. DESCRIPTION CS.65-11X1.750 HX G FW.656X.00X.078 ZNYC FW.650X1.15X.18 ZNYCG IDLER PULLEY NHI 5.00" FW.65X1.00X.14 ZNYC DECK IDLER SPACER IDLER W/A IDLER SPRING CHAIN DECK LIFT SPRING CS.1-18X1.50FLT SH ZY UHMW IDLER SLIDE NT HX G5 ZNYC CS.65-11X1.5 HX G5 Z CW.61.50X.187 PNT DECK DRIVE PULLEY NT HX GRD 5 ZNY FW.406X.81 X.060 SAE FW.4X.687X.051/.080H NT.1-18 HX G5 ZNYC CS.1-18X.750 HX G RIGHT PULLER & PIN ASSY LEFT PULLER & PIN ASSY CS.500-1X4.50 HX G FW.51X 1.06X.090 SAE ANTI-SCALP WHEEL NT HX JAM ZNYC NT HX G8 ZY NL NT.1-18 HXZY NL CS.65-11X.00 FULL HX CS.75-16X1.75 HX G BLADE SPINDLE ASSEMBLY ANTI SCALP WHEEL ASSY NOTES: (Anti-scalp Wheels) include Items 6.. Torque to 118 ft.-lbs _

68 54" Deck Pulley Assembly INDEX NO. PART NO. QTY. DESCRIPTION HANGER EXT REAR RIGHT SIDE HANGER EXT REAR LEFT SIDE FW.4X.687X.051/.080H NT.1-18 HX G5 ZNYC FW.468X 1.00X.090 HT T NT HX G5 ZNYC CS.1-18X1.000 HX G CS.47-14X1.000 HX G HANGER EXT FRONT NOTES: _1010

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70 60" Deck Pulley Assembly _1010

71 60" Deck Pulley Assembly INDEX NO. PART NO. QTY. DESCRIPTION CS.65-11X1.750 HX G FW.656X.00X.078 ZNYC FW.650X1.15X.18 ZNYCG IDLER PULLEY NHI 5.00" FW.65X1.00X.14 ZNYC DECK IDLER SPACER IDLER W/A IDLER SPRING CHAIN DECK LIFT SPRING CS.1-18X1.50FLT SH ZY UHMW IDLER SLIDE NT HX G5 ZNYC CS.65-11X1.5 HX G5 Z CW.61.50X.187 PNT DECK DRIVE PULLEY NT HX GRD 5 ZNY FW.406X.81 X.060 SAE FW.4X.687X.051/.080H NT.1-18 HX G5 ZNYC CS.1-18X.750 HX G PULLER AND PIN ASSEMBLY PULLER AND PIN ASSEMBLY DECK PIN & ROD ASSY NT HX G8 ZY NL NT.1-18 HXZY NL CS.65-11X.00 FULL HX CS.75-16X1.75 HX G BLADE SPINDLE ASSEMBLY ANTI SCALP WHEEL ASSY CS.500-1X4.50 HX G FW.51X 1.06X.090 SAE ANTI-SCALP WHEEL NT HX JAM ZNYC NOTES: 1. Torque to 118 ft.-lbs (Anti-scalp Wheels) include Items 9-.. For mowers with serial numbers prior to _

72 60" Deck Pulley Assembly INDEX NO. PART NO. QTY. DESCRIPTION HANGER EXT REAR RIGHT SIDE HANGER EXT REAR LEFT SIDE FW.4X.687X.051/.080H NT.1-18 HX G5 ZNYC FW.468X 1.00X.090 HT T NT HX G5 ZNYC CS.1-18X1.000 HX G CS.47-14X1.000 HX G HANGER EXT FRONT CS.500-1X4.50 HX G FW.51X 1.06X.090 SAE ANTI-SCALP WHEEL NT HX JAM ZNYC NOTES: _1010

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74 48" Deck Assembly _1010

75 48" Deck Assembly INDEX NO. PART NO. QTY. DESCRIPTION DISCHARGE CHUTE BELT B " EL RIGHT SIDE PULLEY COVER 48" FUSION DECAL LEFT SIDE PULLEY COVER 48" " DECK ID DECAL NT HXZY NL FW.406X.81 X.060 SAE CHUTE BRACKET CHUTE PIN TORSION SPRING /16-18 X /4" MALE KNOB CB.75-16X 1.00 STD CD F16.50"-H-F-CW BLADE CW.61.50X.187 PNT CS.65-11X1.5 HX G5 Z NOTES: 1. Torque to 118 ft-lbs.. Item (Right Side Pulley Cover) includes Item 4 (Fusion Decal).. Item 5 (Left Side Pulley Cover) includes Item 6 (ID Decal) _

76 48" Deck Belt Routing 8.5" 9.5" 4 NOTES: 4. Spring length after tensioning new belt. Measured from outside of hook to outside of hook. 5. Route belt as shown _1010

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78 54" Deck Assembly _1010

79 54" Deck Assembly INDEX NO. PART NO. QTY. DESCRIPTION DISCHARGE CHUTE BELT B " EL RIGHT SIDE PULLEY COVER 54" FUSION DECAL LEFT SIDE PULLEY COVER 54" " DECK ID DECAL NT HXZY NL FW.406X.81 X.060 SAE CHUTE BRACKET CHUTE PIN TORSION SPRING /16-18 X /4" MALE KNOB CB.75-16X 1.00 STD CD F18.50"-H-F-CW BLADE CW.61.50X.187 PNT CS.65-11X1.5 HX G5 Z NOTES: 1. Torque to 118 ft-lbs.. Item (Right Side Pulley Cover) includes Item 4 (Fusion Decal).. Item 5 (Left Side Pulley Cover) includes Item 6 (ID Decal) _

80 54" Deck Belt Routing 8.5" 9.5" 4 NOTES: 4. Spring length after tensioning new belt. Measured from outside of hook to outside of hook. 5. Route belt as shown _1010

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82 60" Deck Assembly _1010

83 60" Deck Assembly INDEX NO. PART NO. QTY. DESCRIPTION DISCHARGE CHUTE BELT, B " EL RIGHT SIDE PULLEY COVER 60" FUSION DECAL LEFT SIDE PULLEY COVER 60" " DECK ID DECAL NT HXZY NL FW.406X.81 X.060 SAE CHUTE BRACKET CHUTE PIN TORSION SPRING /16-18 X /4" MALE KNOB CB.75-16X 1.00 STD CD F0.50"-H-F-CW BLADE CW.61.50X.187 PNT CS.65-11X1.5 HX G5 Z NOTES: 1. Torque to 118 ft-lbs.. Item (Right Side Pulley Cover) includes Item 4 (Fusion Decal).. Item 5 (Left Side Pulley Cover) includes Item 6 (ID Decal) _

84 60" Deck Belt Routing 8.5" 9.5" 4 NOTES: 4. Spring length after tensioning new belt. Measured from outside of hook to outside of hook. 5. Route belt as shown _1010

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86 Deck Lift TRACTOR FRAME _1010

87 Deck Lift INDEX NO. PART NO. QTY. DESCRIPTION STOP HANDLE HEIGHT ADJUST STOP DECK LIFT SPRING CLIP E 1.00 X.65X NT HX FLG ZN DECK LIFT INDICATOR GREASE FITTING STRAIGHT FW.81X 1.469X.14 THK CS.1-18X1.50 FLTHR G NT.1-18 HX G5 ZNYC DECK LEVELER YOKE CS.47-14X1.750 HX G DECK LIFT CHAIN CE.750X.5 X1.75 HEAD CS.47-14X1.750 FULTH 1. Apply grease to zerks. NOTES: 11167_

88 Deck Installation TRACTOR FRAME DECK ASSEMBLY _1010

89 Deck Installation INDEX NO. PART NO. QTY. DESCRIPTION CS.47-14X1.750 HX G NT HX FLG ZN CS.500-1X.000 G5 ZNY FW.51X 1.06X.090 SAE NT HX G5 ZNYC DECK LEVELING PROCEDURE 1. The mower deck has three areas that may need to be checked and adjusted periodically. Before considering any mower deck leveling adjustments, check tire pressures (8-1 psi) to make certain they are properly inflated before starting to level deck. NOTE: Stop engine. Make sure deck clutch switch is in the down (OFF) position. Remove ignition key. Place control levers in the brake position.. Park the unit on a flat surface.. Raise deck and place " of blocking under all 4 corners of the deck (FIG. 1). This will set the cutting height at ¼". NOTE: Back of deck will automatically be set ¼" higher. 4. Set cutting height at ¼" in the height indicator by placing the height adjusting stop in the " hole, and turning the height stop so that the flat side is against the stop handle (FIG. ). 5. Clamp the height stop against the stop handle. 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. 6. Loosen all nuts on the deck lift threaded rods (FIG. 4), and the hardware holding on the adjuster (on the right front) (FIG. 5), until ALL the deck lift chains are loose, AND the deck is sitting tightly on all four blocks. STOP HANDLE HEIGHT ADJUSTING STOP BLOCKS FIG. 1 FIG. 7. Loosen the two nuts on the front of height indicator so that the foot pedal is free (FIG. ) _

90 8. Start the leveling process on the LEFT FRONT of the tractor. NUTS HEIGHT INDICATOR DECK LIFTING ROD DECK LIFTING CHAIN NUTS FIG. FIG Set the amount of threads protruding on the deck lift rod from the lift block at approximately 1" (FIG. 4). 10. Jam both nuts against the block. 11. Push or pull on the deck lift pedal until the chain on the LEFT FRONT just becomes tight, making sure that the deck stays tight against the " blocks. 1. While keeping the chain tight, tighten the nuts against the deck lift block on the height indicator (FIG. ). 1. Jam nuts tightly together against the deck lift block. 14. Go to the RIGHT FRONT of the tractor. 15. Loosen the 5/16" jam nut on the adjuster, and back the adjuster bolt out to allow the adjuster to move up and down freely. (FIG. 5). ADJUSTER BOLT JAM NUT CHAIN FLANGE NUTS FIG Be sure that adjuster is free to move up and down. 17. Tighten the adjuster bolt until the chain just becomes tight, making sure that the deck stays tight against the " blocks. 18. Tighten the adjuster bolt jam nut to prevent the adjuster from moving. 19. Tighten the hardware holding the chain and adjuster onto the deck lift arm. 0. Go to the RIGHT REAR of the tractor. 1. 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. 6).. Tighten the appropriate nut until the chain just becomes tight, making sure that the deck stays tight against the " blocks (FIG. 6) _1010

91 JAM NUTS CHAIN FIG. 6. Tighten the other nut on the opposite side of the block, and jam them tightly together against the block. 4. Repeat step 1 for the LEFT REAR of the tractor. 5. Compress the deck lift assist springs so that there is ½" of space between the front nut on the spring, and the rear nut on the deck lift block. Typical for both sides (FIG. 7). NUTS ½" FIG When completed, all chains should be tight, and deck cutting height will be set to the deck height indicator _

92 Deck Adjustments DECK DRIVE BELT ADJUSTMENT The spindle belt tension remains constant by means of a tension idler and spring (FIG. 8). 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. 8). Installed spring length should be 8.5" 9.5" originally with adjustments of.60" per chain link (FIG. 8). NOTE: Do not over tension the spring to compensate for a badly worn belt or pulley. ANCHOR BRACKET SPRING TENSION IDLER Spring Extension 8.5" 9.5" CHAIN Normal spring length FIG. 8 FIG _1010

93 Section 8 Seat ROPS _

94 _1010 Seat SUSPENSION SEAT STANDARD SEAT 17 4

95 Seat INDEX NO. PART NO. QTY. DESCRIPTION MICHIGAN STANDARD SEAT MICHIGAN SUSPENSION SEAT SEAT BELT FW.440X 1.000X.08 ZNY (USED ON STANDARD SEAT) FW.440X 1.000X.08 ZNY (USED ON SUSPENSION SEAT) CS.47-0X1.50 G5 ZNY NT.47-0 HX GR5 ZNYC (USED ON STANDARD SEAT) SEAT BELT CROSS BAR (USED ON STANDARD SEAT) SEAT LATCH SEAT LATCH STOP ROD NT HXZY NL TORSION SPRING FW.406X.81 X.060 SAE SEAT PAN SEAT PAN STOP CS.75-16X1.000 HX G FIBER WASHER WIRE TIE, SMALL/SHORT FW.4X.687X.051/.080H (USED ON STANDARD SEAT) FW.4X.687X.051/.080H (USED ON SUSPENSION SEAT) NT.1-18 HX G5 ZNYC SEAT SUPPORT ANGLE CS.75-16X.750 HX G BUMPER,.500X 1.00X GM.50X1.00X.75X CS.75-16X1.50 HX G CS.1-18X.75 HX G5 NOTES: 1. Part of (Standard Seat).. Must pivot freely.. Wire harness connects to seat switch. 4. Standard seats are used on models 991, 9949 and Suspension seats are used on models 99406, and Item 1 (Seat Pan) includes Items 4 7 (decals). 6. Item 19 (Seat Support) includes Items 1 and 9 (bumpers and decals) _

96 Seat 5 TOP VIEW BOTTOM VIEW _1010

97 Seat INDEX NO. PART NO. QTY. DESCRIPTION PUMP BELT WARNING DECAL Z ARMREST WARNING DECAL BATTERY DECAL Z SERVICE DECAL RUBBER BUMPER HOT & HYD OIL DECAL HYDRAULIC PRESSURE DECAL ENGINE COMPARTMENT DECAL FUEL INDICATOR DECAL NOTES: SEAT SERVICE PARTS **STANDARD SEAT ONLY ***SUSPENSION SEAT ONLY 7907 SLIDE KIT 7915 SEAT SWITCH 791 **ARMREST KIT (OPTIONAL SQUARE STYLE) 7949 **L.H. ARMREST ASSEMBLY (SQUARE STYLE W/ BRACKETS) 7956 **R.H. ARMREST ASSEMBLY (SQUARE STYLE W/ BRACKETS) 7965 ***ONE ARMREST (SQUARE STYLE W/O BRACKETS) **ARMREST KIT (OPTIONAL ROUND STYLE) **L.H. ARMREST ASSEMBLY (ROUND STYLE W/ BRACKETS) **R.H. ARMREST ASSEMBLY (ROUND STYLE W/ BRACKETS) ONE ARMREST ONLY (ROUND STYLE W/O BRACKET) 797 ARMREST STOP ASSY 79 ***KNOB KIT 7981 ***BACK CUSHION KIT 7999 ***SEAT CUSION KIT ***SEAT BACK PANEL KIT 11167_

98 ROPS _1010

99 ROPS INDEX NO. PART NO. QTY. DESCRIPTION ROPS HAND KNOB FOR ROPS LYNCH PIN W/ LANYARD CS.500-1X.500 HX G NT UNT LK G8 ZN ROPS STOP CS.500-1X.50 HX G FW.51X 1.06X.090 SAE ROPS SAFETY DECAL (NOT SHOWN) NOTES: 1. Replace decals in the event they become worn or illegible. Item 1 includes necessary decals _

100 _1010

101 MAINTENANCE & ADJUSTMENTS Safe Servicing Practices This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death. Service Unless specifically required, DO NOT have engine running when servicing or making adjustments to tractor. Park the machine on level ground. Place steering control levers in the park brake position, disengage deck clutch, lower deck, remove ignition switch key and disconnect negative battery cable before doing any maintenance. Wait for all movement to stop before adjusting, cleaning or repairing. Repairs or maintenance requiring engine power should be performed by trained maintenance personnel only. To prevent carbon monoxide poisoning, be sure proper ventilation is available when engine must be operated in an enclosed area. Read and observe safety warnings in front of manual. Before working on or under the deck, make certain engine cannot be accidentally started. Shut engine off, remove ignition switch key and disconnect negative battery cable for maximum safety. Repairs or maintenance requiring engine power should be performed by trained maintenance personnel only. Except when changing or checking belt, always keep belt covers on mower deck for safety as well as cleanliness. 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. 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, top of deck, exhaust area, 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 eye protection when servicing the hydraulic system and battery, 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 attempt to start engine when there is a strong odor of gasoline fumes present. Locate and correct cause. Never remove the fuel cap or refuel tractor while engine is running; never refuel near an open flame or near devices which can create a spark. Refuel outdoors. Never refuel or drain the fuel from the machine indoors. 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 tractor drive system, mower deck or any attachment 11167_ while the tractor engine is running or deck clutch is engaged. Repairs or maintenance requiring engine power should be performed by trained maintenance 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. Do not touch hot parts of machine. Keep nuts and bolts tight, especially the blade attachment bolts. Keep equipment in good working condition. Never tamper with safety devices. Check their proper operation regularly. 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! 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. Exercise caution when working under the deck as the mower blades are extremely sharp. Wrap the blade(s) or wear gloves and use extra caution when servicing them. Use only genuine Hustler replacement parts to ensure that original standards are maintained 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. The following pages contain suggested maintenance information and schedules which the operator should follow on a routine basis. For more detailed information order the correct parts manual for your unit. Refer to the Product Literature section of this manual. 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 under the seat platform areas; minute dust particle 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 buildup of grass clippings and dirt, especially when grass is wet or has high moisture content. This build-up will harden, restricting

102 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, using jack stands or blocks, in the full up position 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 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 Blade spindle bolt top Blade spindle bolt bottom Wheel motor nut Lug nuts only - It is recommended that these be checked after the first hours of operation, initially, every 50 hours and following removal for repair or replacement. For all other torques refer to the various tractor parts manuals for standard torque chart. See Product Literature section for ordering information. For engine torque values, see engine owner s manual. Tires It is important for level mowing that the tires have the same amount of air pressure. The recommended pressure are: Drive wheels psi (55-8 KPa) Gauge wheels psi (55-8 KPa) Solid fill tires are not recommended for Hustler turf equipment. On any machine, with solid filled tires, the warranty claim will be denied. Lubrication Use SAE multi-purpose grease. Electrical system The electrical system is a 1 volt, negative ground. Recommended battery size is a garden tractor BCI group U1R with 5 or better cranking AMP rating. A maintenance-free battery is recommended. Otherwise, follow battery manufacturer s maintenance, safety, storing and charging specifications. Figure 9-1 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: Charge batteries in an open well ventilated area, away from sparks and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothing and use insulated tools. Hydraulic filter 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 tractor 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 tractor parts when removing or installing the battery. Do not allow metal tools to short between the battery terminals and metal tractor parts. WARNING: Incorrect battery cable routing could cause damage to the tractor and battery cables. This can cause sparks which can cause a battery gas explosion which will result in personal injury. Always disconnect the negative (black) battery cable(s) before disconnecting the positive (red) cable(s). Always connect the positive (red) battery cable(s) before connecting the negative (black) cable(s). Figure 9-1 Hydraulic reservoir Battery _1010

103 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 fluid escaping under pressure may have sufficient force to penetrate skin and cause serious injury. Foreign fluid injected into the skin must be surgically removed within a few hours by a doctor, familiar with this form of injury, or gangrene may result. 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. Check oil level in hydraulic system after every 50 hours of operation or weekly, whichever occurs first. Check more often if system appears to be leaking or otherwise malfunctioning. Fluid level should be 1 (.54cm) from top of reservoir. Use only SAE 0W50 SL/SM service motor oil. Figure 9-1 Change hydraulic system filter element after first 50 hours of tractor operation, then replace filter and oil in reservoir every 500 hours thereafter. Figure 9-1 The system filter is located 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. IMPORTANT: Prefill the filter element with clean oil, before installing, to prevent drawing air into the system pump. Fuel system Figure 9- Fuel filter DANGER: To avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive. DANGER: Observe usual fuel handling precautions: Do not smoke while refueling. Extinguish all cigarettes, cigars, pipes and other sources of ignition. Do not remove fuel cap or fill tank with engine running or while engine is hot. Clean up any fuel spills. Allow engine to cool before storing machine inside a building. Keep fuel away from open flame or spark and store machine away from open flame or spark or pilot light such as on a water heater or appliances. Use extreme care when handling gasoline and other fuels. They are extremely flammable and vapors are explosive. A fire or explosion from fuel can burn you and others and can damage property. Refuel outdoors. Never refuel or drain the fuel from the machine indoors. Never attempt to start engine when there is a strong odor of gasoline or diesel fuel fumes present. Locate and correct cause. Store fuel in an approved container and keep it out of the reach of children. Never buy more than a 0 day supply of fuel. Do not fill fuel containers inside a vehicle or on a truck or trailer bed with interior carpets or plastic truck bed liners. Always place fuel containers on the ground away from your vehicle before filling. When practical, remove gas-powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground. If this is not possible, then refuel such equipment on the truck or trailer using a portable container and not a fuel 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. Do not use a nozzle lock-open device. Never use gasoline for cleaning parts. Read and observe safety precautions elsewhere in this manual. 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 fuel container opening. Keep gas away from eyes and skin. If fuel is spilled on clothing, change clothing immediately. The fuel tanks are located in the tractor s fenders. Use regular unleaded gasoline with an octane rating of 87 or higher. IMPORTANT: Never use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with gasoline. The fuel filter is an in-line filter located in the fuel line between the fuel tank and the fuel pump. Figure 9- A fuel shut-off valve is located on each tractor. The location and operation of the fuel valve will vary depending upon the unit. Close the fuel valve to prevent fuel flow to the engine. The valve s two other positions will allow fuel to be drawn from either one or the other fuel tank. Figure _

104 Air cleaner Left fuel tank Fuel shutoff valve (shown in closed position) Right fuel tank Figure 9- Engine oil and filter Check engine oil daily and after every 4 hours of operation. Tractor must be setting level when checking oil. Refer to engine manual and maintenance schedule for oil recommendation and capacities. Figure 9-4 Change the engine oil and filter after the first 5 hours of operation, per the engine manufacturer s recommendations after that. If tractor is being operated in extremely dirty conditions, then it is recommended oil be changed more frequently. Figure 9-5 Safety filter Oil filter Oil drain Figure 9-4 Engine oil fill & dipstick Engine air filter Perform engine air filter maintenance per the Service Interval chart shown elsewhere in this manual. A specially designed dry filter is standard equipment on these tractors and supplies clean combustion air to the engine. Figure 9-5. These units are equipped with a safety filter. The filter element slides over the safety filter. Figure 9-6 NOTE: The safety filter does not require servicing unless it becomes contaminated with dirt or moisture. Recommended service procedure 1. Release clamps and remove element. Clean the canister Figure 9-6 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. 4. Check all fittings and clamps periodically for tightness and inspect hoses for holes or cracks. 5. Periodically check the intake hose for signs of ingested dust. Locate and repair the source of ingested dirt. 6. Never operate a machine without an air filter installed. 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 _1010

105 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 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. 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. Belts Inspect 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. 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. 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: Never attempt to straighten a bent blade by heating, or weld a cracked or broken blade as the blade may break and cause serious injury. Replace worn or damaged blades. DANGER: Never 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: Always wear adequate eye protection when grinding mower blades. Do not sharpen to original pattern (below). It is easier to get a straight cutting edge following the resharpening pattern shown above. Figure 9-7 Resharpening pattern Original edge 11167_

106 Warped Blade (Replace) Straight Blade Comparison of Warped and Straight Blades Figure 9-8 Cutting plane Seat adjustment There are two seat options available for this machine; standard and suspension. The following are the adjustments for each of these seats. Standard seat The standard seat has one adjustment; forward and rearward travel. Figure 9-10 Cutting edge Cutting Plane Twisted Blade Edge (replace) Cutting edge Straight Blade Edge End view of blades, comparing twisted and straightened blades Figure 9-9 Mower blade removal Use a 15/16" wrench to remove the 5/8" cap screw holding the blade to the spindle shaft from underneath. NOTE: A blade holding tool (part number 8144) is available from Hustler Turf Equipment. It is designed to prevent the blades from rotating when they are being removed or installed on the spindle. Contact your Hustler dealer for more information. Sharpen the blades on a grinder following pattern as shown (Figure 9-7). 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 1/" 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 (Figure 9-8 & Figure 9-9). Replace any distorted blade. Do not re-use spindle bolts which have stripped, worn or undercut threads. Torque bolts on spindles to 118 foot-pounds (160.0 nm) when reinstalling blades. IMPORTANT: 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. Forward/rearward travel lever Figure 9-10 Suspension seat The suspension seat can be adjusted four different ways to obtain the most comfortable position: 1. Back angle Figure Forward and rearward travel Figure 9-1. Weight Figure Lumbar Figure 9-1 Figure 9-11 Back angle control Control lever adjustment The steering control levers can be adjusted for operator comfort. By loosening the cap screws that attaches the upper control lever to the lower lever (Figure 9-14), the upper control lever can be pivoted to fit the operator s personal preference. The steering control levers should be adjusted so that they align with each other when in the neutral position _1010

107 Weight adjusting control Upper control arm Forward/rearward travel lever Figure 9-1 Cap screws Lumbar control Lower lever. Figure 9-1 Figure _