Hustler Z Parts Manual

Transcription

1 Hustler Z Parts Manual Hustler Turf Equipment P.O. Box 7000 Hesston, Kansas Rev. /0

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3 Table of Contents Chapter General Information Chapter Contents Rivet Nut Installation Footrest Assembly Chapter Contents Hydraulic System Installation Chapter Contents Battery Installation Deck Lift Assembly Steering and Park Brake Assembly (Centering Damper) Pump Belt and Pulleys Installation Chapter Contents Kawasaki Engine Installation Kohler Engine Installation Fuel System Installation Instrument Panel Assembly/Installation Electrical Schematic - Kawasaki (7889) Electrical Schematic - Honda (78700) Electrical Schematic - Kohler (788000) Chapter Contents Front Wheel Assembly Front Wheel Breakdown Drive Wheel Assembly Installation Anti-Rollover Wheel Assembly Chapter 7 Contents 7" Deck Assembly " Deck Pulley Assembly " Deck Assembly " Deck Pulley Assembly " Deck Assembly " Deck Pulley Assembly Spindle Assembly - 09K Chapter 8 Contents Deck Installation Deck Belt Routing and Tensioning Seat Installation Chapter 9 Contents Tractor Decals " and 0" Deck Decals " Deck Decals /0 c-

4 Chapter 0 Contents 7 and 0" Mulch Kits " Mulch Kit Index i- c- 7 /0

5 Chapter General Information This Manual covers Hustler Z models 97 /0, 97 /0, 988 /, 99 /0, 99 /0, 99 /0, 999 /0, 99 /7, 97 7/0, and 970 7/7. Frequently Ordered Parts DESCRIPTION 079 LUBRIZOL 7 OZ. BOTTLE 0790 LUBRIZOL 0 OZ. BOTTLE 78 HYDRAULIC OIL FILTER 78 PUMP DRIVE BELT 7807 B-SECTION BELT, 7" DECK 780 B-SECTION BELT, 0" DECK 789 B-SECTION BELT, " DECK 0878 FUEL FILTER 78 MAIN AIR FILTER ELEMENT 7879 SAFETY AIR FILTER ELEMENT KAWASAKI ENGINE OIL FILTER 78 HONDA ENGINE OIL FILTER 770 KOHLER ENGINE OIL FILTER " CW BLADE FOR SADDLESS 78 " CW BLADE FOR SADDLESS " OFFSET FLATBLADE Service Literature DESCRIPTION 77 HUSTLER Z OWNER S MANUAL 78 KOHLER ENGINE MANUAL 778 KAWASAKI 9/HP OWNERS MANUAL 78 HONDA 8/0/ OWNERS 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. 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. 7 /0 -

6 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 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 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 M 70 NOTE: Loctite 9 to be used on all pipe threads. Lubricate all grease zerks. - 7 /0

7 Chapter Contents Rivet Nut Installation Foot Rest Assembly /0 -

8 Rivet Nut Installation INDEX NO. SERVICE MFG. QTY DESCRIPTION 8 90 TRACTOR FRAME (0") 0 7 TRACTOR FRAME (") 80 7 TRACTOR FRAME (7 ) N/A 8089 /8- THREAD RIVET NUT NOTES: - 7 /0

9 Footrest Assembly 7 INDEX NO. SERVICE MFG. QTY DESCRIPTION STEP TREAD FLOOR 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.. Used on mowers with serial number prior to Used on mowers with serial number and higher. 7 /0 -

10 - 7 /0

11 Chapter Contents Hydraulic System Installation /0 -

12 Hydraulic System Installation FRONT /0

13 Hydraulic System Installation ITEM NO. SERVICE MFG. QTY DESCRIPTION FW.8 X. X.0/.080 HD ZN/YL CS.0-0 X.00 HX G ZN STRAINER BREATHER CAP RESERVOIR NT.-8 HX G ZN FW. X.87 X.0/.080 HD ZN/YL HYDRO-GEAR PUMP, BDP-0A HYDRO-GEAR PUMP BDP-0A NT.7- HX G ZN FW. X.8 X.00 ZN ROSS/PARKER WHEEL MOTOR, MB CS.7- X.7 HX G ZN FILTER ELEMENT FILTER HEAD 787 N/A -STR - 90, PUSHLOC HOSE.7" 7 79 N/A 90, - O-RING/- JIC FITTING N/A -STR - 90, PUSHLOC HOSE,.00" N/A -STR - 90, PUSHLOC HOSE,.00" N/A STR-MORB/-JIC FITTING 789 N/A, -8MORB/-8MSL FITTING 78 N/A 90,-8MORB/-8MSL FITTING 788 N/A STR-8-MORB/HEX PLUG 78 N/A 90, -0MORB/-8MSL FITTING 7800 N/A RIGHT LOOP/RP-BM HYDRO TUBE 789 N/A RIGHT LOOP/LP-TM HYDRO TUBE N/A LEFT LOOP/RP-BM HYDRO TUBE N/A LEFT LOOP/LP-TM HYDRO TUBE 9 78 N/A STR-8MORB/-8MSL FITTING N/A -STR -STR PUSHLOC HOSE, 9.00" 79 N/A - O-RING/-JIC/JIC T FITTING N/A 789 MMZ HYDRAULIC KIT (INCLUDES -) NOTES:. Add. oz. Lubrizol (079) to new system or when hydraulic oil is changed (see Owner s Manual).. Hydraulic system capacity is US quarts. Fill reservoir to within " of top of Item (077 Strainer). Two of Items 7 (79 90, - O-Ring/- JIC Fitting) must be installed to pumps prior to installing pumps in tractor. 7 /0 -

14 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; 777 (BDP0 Overhaul Seal Kit) - 7 /0

15 Chapter Contents Battery Installation Deck Lift Assembly Steering and Brake Assembly (Centering Damper) Steering and Park Brake Assembly (With Anti Reverse) Pump Belt and Pulley Installation /0 -

16 Battery Installation BLACK WIRE, PART OF WIRE HARNESS RED WIRE, PART OF WIRE HARNESS 8 0 TRACTOR FRAME - 7 /0

17 Battery Installation INDEX NO. SERVICE MFG. QTY DESCRIPTION NT.0-0 HX GR. ZN RED BATTERY CABLE BOOT BATTERY GROUND CABLE POSITIVE BATTERY CABLE FW. X.87 X.0/.080 HD ZN/YL 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 CS.-8 X.70 HX G ZN CB.-8 X.00 FUL ZN LW. INT-EXT TOOTH ZN NOTES:. When performing service on mower, disconnect battery ground cable and black wire of harness and do not reconnected to battery until engine is ready to be started. See Owners Manual.. Items (07 NT.-8 HX G ZN) to be tightened against frame to lock Items (77980 CB.-8 X.00 FUL ZN) to frame. 7 /0 -

18 Deck Lift Assembly TRACTOR FRAME /0

19 Deck Lift Assembly ITEM NO. SERVICE MFG. QTY DESCRIPTION STOP HANDLE HEIGHT ADJ STOP DECK LIFT INDICATOR SUBASSEMBLY NT.7- HX FLG ZN CLIP E,.00 X. X DECK LIFT SPRING SUBASSEMBLY CE.70 X. X.7 HEADLESS CS.7- X.70 HX G ZN DECK LIFT CHAIN STRAIGHT GREASE FITTING NT.-8 HX G ZN CS.-8 X.0 FUL THR GR ZN DECK LEVELER YOKE CS.7- X.70 FUL THD G ZN NOTES:. Apply grease to zerks (see owner s manual). 7 /0 -

20 Steering and Park Brake Assembly (Centering Damper) TRACTOR FRAME - 7 /0

21 Steering and Park Brake Assembly (Centering Damper) ITEM NO. SERVICE MFG. QTY DESCRIPTION STEERING BAR GRIP STEERING BAR FW.0 X.8 X.00 SAE HD ZN CS.7- X.000 HX G ZN CS.7- X.70 HX G ZN NT.- HX ZN FW.X.87 X.0/.080 HD ZN/YL STEERING ARM MOUNT STEERLEVER SUPPORT LH STEERLEVER SUPPORT RH CS.7- X.70 HX G ZN SS.00- X.7 SH ZN NT.00- HX JAM ZN STEERING CONTROL PANEL STEERLEVER BUSHING NT.7- HX LK NY BRAKE ROD ASSEMBLY CS 0- X.70 HXFLK ZN PUSH BUTTON SWITCH PUMP ROD ADJUSTER ASSEMBLY CENTERING DAMPER DAMPER BALL STUD CS.0-0 X.00 HX G ZN FW.8 X. X.0/.080 HD ZN/YL NT.0-0 HX NL ZN PUMP ARM ADJUSTABLE PIVOT BUSHING CS.7- X.7 HX G ZN NT.7- HX GRD ZN NT.-8 HX G ZN BRAKE DRUM-HUB ASSEMBLY BRAKE ASSEMBLY BRAKE ASSEMBLY 0 0 CS.-8 X.000 HX G ZN BRAKE ARM EXTENSION L.S. BRAKE PIVOT ARM 0 0 R.S. BRAKE PIVOT ARM BUSHING NT #0- HX NL ZN CS.7- X.7 HX G ZN 9 0 N/A ROSS CASTLE NUT BRAKE LINK TURNBUCKLE 07 N/A ROSS KEY NOTES: 7 /0-7

22 . Torque to 0-7 ft.-lbs. Included with wheel motor.. Torque brake assembly mounting bolts to 00 ft.-lbs.. Pin to be clean and free of rust. Apply thin coat of grease prior to installing Item 7 (78 Bushing).. Do not torque this fastener, should be snug but allow Item (00\0 Brake Pivot Arm) to pivot freely.. Item (8797 Adjustable Pivot) to be adjusted such that Item 9 (8888/87 Steerlever Support) has no end play.. 78 used on left wheel used on right wheel. 8. With Steering Bars in park position, adjust Push Button Switch (Item 8) outboard until switch is activated by Brake Pivot Arm (Item ). Repeat for opposite side. 9. Used on tractors with serial number 00 and higher /0

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24 Steering and Park Brake Assembly (With Anti Reverse) TRACTOR FRAME -0 7 /0

25 Steering and Park Brake Assembly (With Anti Reverse) 7 8 ITEM NO. SERVICE MFG. QTY DESCRIPTION STEERING BAR GRIP STEERING BAR FW.0 X.8 X.00 SAE HD ZN CS.7- X.000 HX G ZN CS.7- X.70 HX G ZN NT.- HX ZN FW.X.87 X.0/.080 HD ZN/YL STEERING ARM MOUNT STEERLEVER SUPPORT LH STEERLEVER SUPPORT RH CS.7- X.70 HX G ZN SS.00- X.7 SH ZN NT.00- HX JAM ZN STEERING CONTROL PANEL STEERLEVER BUSHING NT.7- HX LK NY BRAKE ROD ASSEMBLY NEUTRAL STOP YOKE ASSEMBY CE.7 X.. X.98 ZN CP.D X.70 LG ZN CS 0- X.70 HXFLK ZN PUSH BUTTON SWITCH PUMP ROD ADJUSTER ASSEMBLY DAMPER DAMPER BALL STUD CS.0-0 X.00 HX G ZN FW.8 X. X.0/.080 HD ZN/YL NT.0-0 HX NL ZN L.S PUMP ARM R.S PUMP ARM ADJUSTABLE PIVOT BUSHING CS.7- X.7 HX G ZN NT.7- HX GRD ZN NT.-8 HX G ZN BRAKE DRUM-HUB ASSEMBLY BRAKE ASSEMBLY BRAKE ASSEMBLY 0 0 CS.-8 X.000 HX G ZN BRAKE ARM EXTENSION L.S. BRAKE PIVOT ARM 0 0 R.S. BRAKE PIVOT ARM BUSHING NT #0- HX NL ZN COMPRESSION SPRING NT.7- NYLOCK ZN CS.7- X.7 HX G ZN 0 N/A ROSS CASTLE NUT BRAKE LINK TURNBUCKLE 7 /0 -

26 ITEM NO. SERVICE MFG. QTY 07 N/A ROSS KEY DESCRIPTION NOTES:. Torque to 0-7 ft.-lbs. Included with wheel motor.. Torque brake assembly mounting bolts to 00 ft.-lbs.. Pin to be clean and free of rust. Apply thin coat of grease prior to installing Item 0 (78 Bushing).. Do not torque this fastener, should be snug but allow Item 8 (00/ 0 Brake Pivot Arm) to pivot freely.. Item 9 (8797 Adjustable Pivot) to be adjusted such that Item 9 (8888/87 Steerlever Support) has no end play.. See Fig. for initial installation of Item (damper) used on left wheel used on right wheel. 9. With Steering Bars in park position, adjust Push Button Switch (Item ) outboard until switch is activated by Brake Pivot Arm (Item 8). Repeat for opposite side. 0. Used on tractors with serial prior to 00. NEUTRAL ADJUSTMENT Fig. - 7 /0

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28 Pump Belt and Pulleys Installation TRACTOR FRAME LOCATION OF RUBBER BUMPER SEE NOTE SEE NOTE /0

29 Pump Belt and Pulleys Installation INDEX NO. SERVICE MFG. QTY DESCRIPTION ENGINE SC SINGLE PULLEY KEY / SQ X.0 LONG WARNER CLUTCH ) FW.0 X.70 X.0 ZNYC CS.7-0 X.0 HX G ZNYC SS.-8 X.70 SQ-HD ZN KEY MM X 0MM RADIUS ENDS PULLEY & FAN NT.00- HX G ZNYC FW. X.0 X.090 SAE HD ZN CS.00- X.00 HX G ZNYC 7 7 CLUTCH ANCHOR ANGLE RUBBER BUMPER 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 A-SEC PUMP IDLER BELT N/A N/A OGURA GT CLUTCH (78708) 0 N/A CS.7- X.000 HX G ZN 779 N/A FW.0 X.8 X.00 SAE HD ZN 099 N/A CS.0-0 X.70 HX G ZN 7 9 N/A CLUTCH ANCHOR BRACKET N/A. WIRING CLAMP 9 78 N/A FW.8 X. X.0/.080 HD ZN/YL N/A NT.0-0 HX GR. ZN 00 N/A NT.7- HX GRD ZN 8 N/A CLUTCH ANCHOR BRACKET 7787 N/A CS.7-0 X.0 G ZNYC 788 N/A GM.7 X. X.0 X.8 GROMMET N/A N/A OGURA GT CLUTCH (788) HARNESS, CLUTCH PIGTAIL(DIODE) NOTES:. Coat ID with anti seize.. Set blade tips."±.0" from surface of engine plate.. Torque to -8 ft-lbs.. Use Loctite on threads.. Apply grease at zerk (see owner s manual).. Torque to - ft-lbs. 7 /0 -

30 7. Do not torque Item 7 (NT.70-0 HX NL ZN), Item (97 Pump Idler Arm) should pivot freely. 8. Included with Honda HP engine (780). 9. Alternative use clutch (Ogura GT). 0. Alternative use clutch (Ogura GT).. Order 7809K for replacement clutch.. Electric clutch burnishing procedure: After installing a new clutch it is important to burnish the clutch to insure maximum deck clutch life. In an open area with no bystanders set the engine speed to half throttle. Cycle the deck clutch on for seconds, and then off for seconds. Repeat this operation 0 times, it will require about minutes to complete. - 7 /0

31 Chapter Contents Kawasaki Engine Installation Honda Engine Installation Kohler Engine Installation Fuel System Installation Instrument Panel Assembly/Installation Electrical Schematic - Kawasaki (7889) Electrical Schematic - Honda (78700) Electrical Schematic - Kohler (788000) /0 -

32 Kawasaki Engine Installation TO BULLET TERMINALS 7 0 TO STARTER SELENOID 7 TO SPADE TERMINAL 7 8 TAN/RED BLK RED/BLK 9 HOUR METER CONNECTION 0 8 PURPLE TO ENGINE SENSOR YELLOW P/O ENGINE POSITIVE BATTERY CABLE TRACTOR FRAME /0

33 Kawasaki Engine Installation 7 ITEM NO. SERVICE MFG. QTY DESCRIPTION KAWASAKI HP ENGINE (FH80V, 00 RPM) KAWASAKI HP ENGINE (FH7V, 00 RMP) MUFFLER CS M 8-. X HXFL ZN KAW () EXHAUST PIPE CLAMP KAW () MUFFLER GASKET MUFFLER MANIFOLD HEAT SHIELD LW. MED SPRING ZN NT M8-. HX STAINLESS STEEL DONALDSON AIR CLEANER CAP HOSE CLAMP AIR CLEANER AIR FILTER INDICATOR MOUNTING BAND NT.-8 HX G ZN FW. X.87 X.0/.080 HD ZN/YL CS.-8 X.00 HX G ZNYC 8 REMOTE AIR CLEAN MOUNT BRACKET REMOTE AIR FILTER HOSE OIL DRAIN ADPT O-RING KAWASAKI OIL DRAIN EXTENSION HOUR METER LW. INT-EXT TOOTH ZN CS.-8 X.00 HX G ZN FW. X.0 X.090 SAE HD ZN CS.00- X.00 HX G ZN CS.-8 X. HX G ZN MUFFLER GUARD ENGINE CAGE MOUNT PLATE CS.0-0 X.00 HX G ZN FW.8 X. X.0/.080 HD ZN/YL STARTER SOLENOID RED BATTERY CABLE BOOT NT.0-0 HX GR. ZN 0 0 NT #0- HX ZN BATTERY CABLE TRACTOR WIRE HARNESS STARTER RELAY GROUND WIRE 7 /0 -

34 NOTES:. Includes mounting hardware.. Part of Item (7898 Tractor Wire Harness).. Engine oil capacity; US quarts.. Engine RPM to be set at 00± 0.. HP engine used in 988CE, 988, 99, 99, only.. HP engine used in 99, 999, and 99 only. 7. Includes one () of Item (07 Hose Clamp). 8. When installing lower hose clamp on air cleaner hose, install as low as possible (against carburetor inlet). 9. Air filter service parts: 78 MAIN AIR FILTER ELEMENT 78 VACUATOR VALVE - 7 /0

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36 Honda Engine Installation TAN/RED BLK 7 0 HOUR METER CONNECTION 0 PART OF 9 WIRE HARNESS 7 RED/BLK ORG 9 BRN GRA PUR POSITIVE BATTERY CABLE 7-7 /0

37 Honda Engine Installation ITEM NO. QTY DESCRIPTION 780 HONDA HP ENGINE 788 MUFFLER 7077 CS M 8-. X HXFL ZN HONDA OIL DRAIN VALVE " LOW PRESSURE HOSE,.00" LONG " MUFFLER CLAMP 7 N/A LW. MED SPRING ZN 8 N/A NT M8-. HX STAINLESS STEEL 9 N/A HONDA (0) MUFFLER GASKET MUFFLER MANIFOLD 787 DONALDSON AIR CLEANER CAP 787 MOUNTING BAND 787 AIR CLEANER 07 HOSE CLAMP 07 NT.-8 HX G ZN 78 FW. X.87 X.0/.080 HD ZN/YL 7 9 CS.-8 X. HX G ZNYC 8 REMOTE AIR CLEANER MOUNT BRACKET REMOTE AIR FILTER HOSE 0 79 HOUR METER 0987 LW. INT-EXT TOOTH ZN 087 CS.-8 X.00 HX G ZN 7 7 ENGINE CAGE MOUNT PLATE MUFFLER GUARD 779 FW. X.0 X.090 SAE HD ZN 07 CS.00- X.00 HX G ZNYC 78 FW.8 X. X.0/.080HD ZNYC N/A NT M8-. X 0 HX ZNYC HONDA HUSTLER Z WIRE HARNESS 0077 CS.0-0 X.00 HX G ZNYC 0708 LW.0 MED SPRING ZNYC 097 NT.0-0 HX GR. ZNYC N/A HONDA 0 AMP RECTIFIER 7799 MMZ ROLLER HEAT SHIELD 789 HUSTLER Z FAN CONNECTION CAP NOTES: 7 /0-7

38 . Includes mounting hardware.. Part of Item 9 (78700 Tractor Wire Harness).. Engine oil capacity; US quarts.. Engine RPM to be set at 00± 0.. Used on 97 & 97only.. Includes one () of Item (07 Hose Clamp). 7. Supplied with engine. 8. When installing lower hose clamp on air cleaner hose, install as low as possible (against carburetor inlet). 9. This connector used for optional hydraulic oil cooler fan. 0. Air filter service parts: 78 MAIN AIR FILTER ELEMENT 78 VACUATOR VALVE -8 7 /0

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40 Kohler Engine Installation TAN/RED BLK 8 HOUR METER CONNECTION RED/BLK POSITIVE BATTERY CABLE PUR (P/O ENGINE) -0 7 /0

41 Kohler Engine Installation ITEM NO. SERVICE MFG. QTY DESCRIPTION KOHLER 7HP ENGINE 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 REMOTE AIR CLEANER MOUNT BRACKET NT.-8 HX G ZN FW. X.87 X.0/.080 HD ZN/YL CS.-8 X.00 HX G ZNYC REMOTE AIR FILTER HOSE DRAIN HOSE FITTING, 90-FNPT-FNPT HOUR METER LW. INT-EXT TOOTH ZN CS.-8 X.00 HX G ZN MMZ ROLLER HEAT SHIELD 7 7 ENGINE CAGE MOUNT PLATE CS.00- X.00 HX G ZNYC FW. X.0 X.090 SAE HD ZN MUFFLER GUARD HUSTLER Z KOHLER WIRE HARNESS AIR FILTER INDICATOR NOTES:. Includes mounting hardware.. Part of Item 7 ( Hustler Z Kohler Wire Harness).. Engine oil capacity; US quarts.. Engine RPM to be set at 00± 0.. Used on 97 and 970 only.. Supplied with engine. 7. Air filter service parts: 78 MAIN AIR FILTER ELEMENT 78 VACUATOR VALVE 7 /0 -

42 Fuel System Installation TRACTOR FRAME WITH ENGINE - 7 /0

43 Fuel System Installation ITEM NO. SERVICE QTY DESCRIPTION FUEL TANK CAP LEFT SIDE FUEL TANK RIGHT SIDE FUEL TANK REAR SEAT SUPPORT FW.0 X.8 X.00 SAE HD ZN CS.7- X.70 HX G ZN CLAMP CS.7- X.000 HX G ZN HOSE CLAMP " N/A 90 FUEL TANK FITTING FUEL LINE 0" TOTAL FUEL LINE TOTAL (" FOR KOHLER ONLY) FUEL LINE 7" TOTAL CLIP CS.00- X.00 HX G ZN 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.. Supplied with new fuel tank.. Fuel valve kit for tractors without valve: 78 7 /0 -

44 Instrument Panel Assembly/Installation RIGHT SIDE FUEL TANK a a (KAW) 0a (HONDA) a (KOHLER) FUSE SIZE AND LOCATION 0a - 7 /0

45 Instrument Panel Assembly/Installation ITEM NO. SERVICE MFG. QTY DESCRIPTION PTO SWITCH 080 N/A IGNITION KEY INDAK COATED KEY KEY SWITCH NT #0- HX NL ZN 07 N/A RELAY 79 N/A DELAY MODULE FW.9 X.00 X.08 ZN MS #0- X. HX ZN THROTTLE/CHOKE CABLE RED INDICATOR LIGHT CS.0-0 X.00 HX G ZN FW.8 X. X.0 /.080 HD ZN/YL INSTRUMENT PANEL Z CHOKE CABLE (KAWASAKI) Z CHOKE CABLE (HONDA & KOHLER) NOTES:. Part of 7889, or (Tractor Wire Harness) 7 /0 -

46 Electrical Schematic - Kawasaki (7889) - 7 /0

47 Electrical Schematic - Kawasaki (7889) 7 /0-7

48 Electrical Schematic - Honda (78700) OPTIONAL FAN -8 7 /0

49 Electrical Schematic - Honda (78700) 7 /0-9

50 Electrical Schematic - Kohler (788000) -0 7 /0

51 Electrical Schematic - Kohler (788000) 7 /0 -

52 - 7 /0

53 Chapter Contents Front Wheel Assembly Front Wheel Breakdown Drive Wheel Assembly Anti-Rollover Wheel Assembly /0 -

54 Front Wheel Assembly TRACTOR FRAME /0

55 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.7 X. ZNYC 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.. Torque to 00 ft.-lbs.. Assemble with extended inner race toward item (870 Spacer,.07 x. x.79). 7 /0 -

56 Front Wheel Breakdown ITEM NO. SERVICE MFG. QTY 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 DESCRIPTION. Inflate tire to 8-0 psi. NOTES: - 7 /0

57 Drive Wheel Assembly Installation INDEX NO. QTY DESCRIPTION 7808 WHEEL & TIRE ASSY FOR 7" (QTY PER TRACTOR) N/A TIRE, X X FOR 7 N/A WHEEL ASSEMBLY X 8.0 FOR 7 N/A TIRE VALVE 0077 WHEEL NUT (QTY PER WHEEL) 787 WHEEL & TIRE ASSY FOR 0"(QTY PER TRACTOR) N/A TIRE, X X FOR 0" N/A WHEEL ASSEMBLY X 8.0 FOR 0 N/A TIRE VALVE 0077 WHEEL NUT (QTY PER WHEEL) WHEEL & TIRE ASSY FOR " N/A TIRE, X 9.0- FOR N/A WHEEL ASSEMBLY X 7.00 FOR N/A TIRE VALVE 0077 WHEEL NUT (QTY PER WHEEL) N/A 0 /" WHEEL LUG STUD (QTY PER TRACTOR). Torque to -7 ft. lbs.. Inflate tire to 8-0 psi. NOTES: 7 /0 -

58 Anti-Rollover Wheel Assembly TRACTOR 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: - 7 /0

59 Chapter 7 Contents 7" Deck Assembly " Deck Pulley Assembly " Deck Assembly " Pulley Assembly " Deck Assembly " Deck Pulley Assembly Spindle Assembly - 09K /0 7-

60 7" Deck Assembly /0

61 7" Deck Assembly INDEX NO. SERVICE MFG. QTY DESCRIPTION " DECK CRATED 9 9 DISCHARGE CHUTE 080 CS.7-9 X.0 HX G ZN FW.0 X.8.00 SAE HD ZN 00 8 NT.7- HX G ZN 9 DISCHARGE CHUTE MOUNT BRACKET NT.7- HX LK NY /-8 THREAD RIVET NUT 9 N/A CS.00- X. HX G ZN PUSHER N/A NT.00- HX JAM ZN N/A 8 FW. X.0 X.090 SAE HD ZN 787 NT.0- HX LK NY 09 STRAIGHT GREASE FITTING N/A ANTI-SCALP WHEEL BUMPER CS.7- X.000 HX G ZN 788 ANTI SCALP WHEEL ASSY NOTES:. Secure Item (099 Nt..00- Hx Jam Zn) to bolt with a drop of Loctite (7 Red). Tighten Item to shank of Item 9 (78708 Cs.00- x. Hx G Zn). Anti-scalp wheel must turn freely.. Do not torque, Item (9 Discharge Chute) must pivot freely.. Factory assembled in top hole for shipping purposes.. Item 0 (980 Pusher) installed as shown with zerks pointing upward, apply grease to zerks (see owners manual).. Includes items 9,,,. Service part deck includes decals, see 7" and 0" Deck Decals in Chapter 9 on page 9- for listing of decals. 7 /0 7-

62 7" Deck Pulley Assembly APPROXIMATE LOCATION OF BUMPERS BELT GUIDE POSITIONING /0

63 7" Deck Pulley Assembly ITEM NO. MFG. QTY DESCRIPTION B-SECTION BELT 097 NT.- HX G ZNYC 088 FW. X.00X. ZN " IDLER PULLEY, 0087 CS.00- X.00 HX G ZN FW.0 X.0 X.9 HRD ZN 7 0 DECK IDLER BUSHING 8 09 STRAIGHT GREASE FITTING IDLER ARM IDLER SPRING 79 SIDE MOUNT CHAIN 7887 CS.- X. HX G ZN 7 TOP IDLER DECK BELT GUIDE " IDLER PULLEY RUBBER BUMPER 87 R.S. PULLEY COVER 8 L.S. PULLEY COVER 7900 /-8 X /"MALE KNOB 079 N/A CLAMP KNOB 7899 CS.-8 X.0 FLT SH ZNYC IDLER CLAMP 07 CS.00- X.00 HX G ZN 0788 FW.0 X.70 X.8 ZN 880 DRIVE PULLEY 779 FW. X.0 X.090 SAE HD ZN 09 SPINDLE HOUSING ASSEMBLY 7 KEY / SQ X.00 LONG " OFFSET FLAT BLADE 7878 N/A OPTIONAL " GATOR BLADE CW 787 CW..0 X.87 PNT 7878 CS.- X.00 FULL HX G ZN 099 CS.- X.00 HX G ZNYC NOTES:. Apply grease to zerk (see owners manual).. Torque to 8 ft. lbs.. Apply antisieze to pulley bore.. Assemble spindles with grease zerk oriented forward.. See Spindle Assembly - 09K in Chapter 7 on page 7- for breakdown.. See Deck Belt Routing and Tensioning in Chapter 8 on page 8- for belt tensioning. 7. Torque to 7-7 ft. lbs. 8. Used on mowers with serial number prior to /0 7-

64 0" Deck Assembly /0

65 0" Deck Assembly INDEX NO. QTY. DESCRIPTION " DECK CRATED 9 9 DISCHARGE CHUTE 080 CS.7- X.0 HX G ZN FW.0 X.8 X.00 SAE HD ZN 00 8 NT.7- HX GRD ZN 9 DISCHARGE CHUTE MOUNT BRACKET NT.7- HX LK NY /-8 THREAD RIVET NUT 9 N/A CS.00- X. HX G ZN PUSHER N/A NT.00- HX JAM ZN N/A 8 FW. X.0 X.090 SAE HD ZN 787 NT.0- HX LK NY 09 STRAIGHT GREASE FITTING N/A ANTI-SCALP WHEEL BUMPER CS.7-X.000 HX G ZN 788 ANTI SCALP WHEEL ASSY NOTES:. Secure Item (099 Nt.00- Hx Jam Zn) to bolt with a drop of Loctite (7 Red). Tighten Item to shank of Item 9(78708 Cs.00- x. Hx G Zn). Anti-scalp wheel must turn freely.. Do not torque, Item (9 Discharge Chute) must pivot freely.. Factory assembled in top hole for shipping purposes.. Item 0 (980 Pusher) installed as shown with zerks pointing upward, apply grease to zerks (see owners manual).. Includes items 9,,, and.. Service part deck includes decals, see 7" and 0" Deck Decals in Chapter 9 on page 9- for listing of decals. 7 /0 7-7

66 0" Deck Pulley Assembly " DECK BELT GUIDE POSITIONING APPROXIMATE LOCATION OF BUMPERS /0

67 0" Deck Pulley Assembly INDEX NO. MFG. QTY. DESCRIPTION B-SECTION BELT 097 NT.- HX G ZNYC 7887 CS.- X. HX G ZN 7 TOP IDLER DECK BELT GUIDE 088 FW. X.00X. ZN " IDLER PULLEY, CS.00- X.00 HX G ZN CS.-8X.0 FLT SH ZNYC IDLER CLAMP FW.0 X.0 X.9 HRD ZN 0 DECK IDLER BUSHING 09 STRAIGHT GREASE FITTING 998 IDLER ARM " IDLER PULLEY 780 IDLER SPRING 79 SIDE MOUNT CHAIN 7 98 R.S. PULLEY COVER L.S. PULLEY COVER /-8 X /"MALE KNOB 079 N/A CLAMP KNOB FW.0 X.70 X.8 ZN 788 B-SECTION.0 E.O.D PULLEY 09 SPINDLE HOUSING ASSEMBLY 7 KEY / SQ X.00 LONG 78 "X D X0. CW BLADE N/A OPTIONAL "X GATOR X0. CW BLADE 787 CW..0 X.87 PNT 07 CS.00- X.00 HX G ZN FW. X.0 X.090 SAE HD ZN RUBBER BUMPER 7878 CS.- X.00 FULL HX G ZN 099 CS.- X.00 HX G ZNYC NOTES:. Apply grease to zerk (see owners manual).. Torque to 8 ft. lbs.. Apply antisieze to pulley bore.. Assemble spindles with grease zerk oriented forward.. See Spindle Assembly - 09K in Chapter 7 on page 7- for breakdown.. See Deck Belt Routing and Tensioning in Chapter 8 on page 8- for belt tensioning. 7. Torque to -7 ft. lbs. 8. Used on mowers with serial number prior to /0 7-9

68 7-0 7 /0 " Deck Assembly

69 " Deck Assembly INDEX NO. SERVICE MFG. QTY. DESCRIPTION 79 " DECK CRATED " DISCHARGE CHUTE CS.7- X. HX G ZN FW.0 X.8 X.00 SAE HD ZN NT.7- HX GRD ZN NT.7- HX LK NY DISCHARGE CHUTE MOUNT BRACKET 8 N/A 8088 /-8 THREAD RIVET NUT N/A CS.00- X. HX G ZN N/A 8 FW. X.0 X.090 SAE HD ZN 099 N/A NT.00- HX JAM ZN NT.0- HX LK NY 0997 N/A ANTI-SCALP WHEEL STRAIGHT GREASE FITTING PUSHER CS.7- X.00 HX G ZN BUMPER ANTI-SCALP WHEEL ASSEMBLY NOTES:. Secure Item (099 Jam Nut) to bolt with a drop of Loctite (7 Red). Tighten Item to shank of Item 9 (78708 Cs.00- X. Hx G Zn). Anti-scalp wheel must turn freely.. Do not torque, Item (797 Discharge Chute) must pivot freely.. Factory assembled in top hole for shipping purposes.. Item (980 Pusher) installed as shown with zerks pointing upward, apply grease to zerks (see owners manual).. Includes items 9, 0,, and.. Service part deck includes decals, see " Deck Decals in Chapter 9 on page 9- for listing of decals. 7 /0 7-

70 " Deck Pulley Assembly " DECK BELT GUIDE POSITIONING /0

71 " Deck Pulley Assembly INDEX NO. QTY. DESCRIPTION 789 B-SECTION BELT 097 NT.- HX G ZNYC 7887 CS.- X. HX G ZN 088 FW. X.00 X. ZN " IDLER PULLEY 0087 CS.00- X.0 HX G ZN FW.0 X.0 X.9 HRD ZN 8 0 DECK IDLER BUSHING 9 7 DECK BELT IDLER TOP GUIDE " IDLER PULLEY 998 DECK IDLER ARM 79 SIDE MOUNT CHAIN 780 IDLER SPRING 09 STRAIGHT GREASE FITTING 7898 RS " DECK PULLEY COVER 7900 /-8 X /"MALE KNOB 079 N/A CLAMP KNOB 7 07 CS.00- X.00 HX G ZN FW.0 X.7 X.8 ZN DECK DRIVE PULLEY FW. X.0 X.090 SAE HD ZN 79 LS " DECK PULLEY COVER 7 KEY / SQ X.00 LONG 09 DECK SPINDLE ASSY CW BLADE N/A OPTIONAL 8"X GATOR X0. CW BLADE 787 CW. X.0 X.87 PNT CS.- X.00 SH.0"MIN TH CS.-X.00 FULL HX G ZN CS.- 8X.0 FLT SH ZNYC IDLER CLAMP CS.- X.00 HX G ZNYC NOTES:. Apply grease to zerk.. Torque to 8 ft. lbs. Apply antisieze to pulley bore.. Assemble spindles with grease zerk oriented forward.. See Spindle Assembly - 09K in Chapter 7 on page 7- for breakdown.. See Deck Belt Routing and Tensioning in Chapter 8 on page 8- for belt tensioning. 7. Torque to -7 ft. lbs. 8. Used on mowers with serial number prior to Used with mulch kit only. 7 /0 7-

72 Spindle Assembly - 09K INDEX 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 077 N/A FW.0 X.00 X. SAE ZN 7887 N/A SADDLELESS SPINDLE SHAFT NOTES:. Install upper bearing with extended inner race up.. Install lower bearing with extended inner race down. 7-7 /0

73 Chapter 8 Contents Deck Installation Deck Belt Routing and Tensioning Seat Installation /0 8-

74 Deck Installation TRACTOR ASSEMBLY DECK ASSEMBLY 8-7 /0

75 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:. 0" Deck installation is shown, " and 7" Deck installations are similar. 7 /0 8-

76 Deck Belt Routing and Tensioning DECK ASSEMBLY 8-7 /0

77 NOTES:. Spring length after tensioning belt.. Route belt as shown. 7 /0 8-

78 Seat Installation /0

79 Seat Installation INDEX NO. SERVICES MFG. QTY DESCRIPTION MICHIGAN STANDARD SEAT 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 NT.-8 HX G ZN BUMPER GM.0 X.00 X.7 X. GROMMET LATCH SPRING PLUNGER 0 0 SEAT LATCH BRACKET RUBBER BUMPER " WIDE SCOTCH POLYURETHANE." LONG NOTES:. Must pivot freely.. Used on 97, 988, 99, and 99 only.. Used on 97, 99, 999, 99, 97, and 970 only.. Use quantity of for 97, 988, 99, and 99 and quantity of for 97, 99, 999, 99, 97, and 970 (do not use rear strap for 97, 99, 999, 99, 97, and 970).. Service parts available for Michigan Standard seat; DESCRIPTION 799 SLIDE KIT 799 L.H. ARMREST ASSMBLY 79 R.H. ARMREST ASSMBLY 79 SEAT SWITCH 79 MOLDED ARMREST KIT (INCLUDES BOTH ARMRESTS) 797 ARMREST STOP ASSY. Service parts available for Michigan Suspension seats: DESCRIPTION 7907 SLIDE KIT 79 KNOB KIT 798 BACK CUSHION KI 7999 SEAT CUSHION KIT 79 SEAT SWITCH 79 MOLDED ARMREST (FITS BOTH SIDES) 7 /0 8-7

80 797 ARMREST STOP ASSEMBLY 7. Service parts available for Milsco seats: DESCRIPTION DESCRIPTION 78 ADJUSTER, STANDARD AND LOW PROFILE SUSPENSION SEAT 78 ARMREST FOR STANDARD SEAT 789 ARMREST FOR LOW PROFILE SUSPENSION SEAT 7877 OPERATOR PRESENCE SWITCH FOR BOTH SEATS 788 CUSHION/PAN FOR LOW PROFILE SUSPENSION SEAT 787 Z ARMREST ONLY KIT /0

81 Chapter 9 Contents Tractor Decals " and 0" Deck Decals " Deck Decals /0 9-

82 Tractor Decals 7 8 TOP OF SEAT PAN 9 0 BOTTOM OF SEAT PAN 9-7 /0

83 Tractor Decals INDEX NO.. QTY. DESCRIPTION 787 DECK HEIGHT INDICATOR DECAL HOT & HYDRAULIC OIL DECAL 7870 INSTRUMENT PANEL DECAL (SEPARATE CHOKE) HYD PRESSURE DECAL FUEL INDICATOR DECAL 78 Z OPERATION DECAL ENGINE COMPARTMENT DECAL Z ARMREST WARNING DECAL BATTERY DECAL Z SERVICE DECAL 0 77 STABILIZER DECAL 777 MADE IN USA DECAL N/A 0879 TURF PROD SERIAL NO PLATE FIRST ZERO TURN DECAL HUSTLER Z ID DECAL NOTES: 7 /0 9-

84 7" and 0" Deck Decals 7 INDEX NO.. QTY. DESCRIPTION " SIDE DISCHARGE DECK ID DECAL " SIDE DISCHARGE DECK ID DECAL 789 BELT ROUTING DECAL 778 WHIRLING BLADES DECAL 77 BELT & PULLEY DECAL 770 DEFLECTOR SHIELD DECAL "MADE IN U.S.A." DECAL MOWER DECK QUICK REFERENCE DECAL NOTES: 9-7 /0

85 " Deck Decals 7 INDEX NO. QTY. DESCRIPTION " SIDE DISCHARGE DECK ID DECAL 789 BELT ROUTING DECAL 778 WHIRLING BLADES DECAL 77 BELT & PULLEY DECAL 770 DEFLECTOR SHIELD DECAL "MADE IN U.S.A." DECAL MOWER DECK QUICK REFERENCE DECAL NOTES: 7 /0 9-

86 9-7 /0

87 Chapter 0 Contents 7 and 0" Mulch Kits " Mulch Kit /0 0-

88 7 and 0" Mulch Kits INDEX NO. SERVICE MFG. PART NO. QTY. DESCRIPTION NT.7- HX GRD ZN FW.0 X.8 X.00 SAE HD ZN 0 0 CS.7- X.00 HX G ZN CB.7- X.70 STD ZN 0 0 RIGHT MULCH BAFFLE 0 0 0" COMMON MULCH BAFFLE COMMON MULCH BAFFLE. 0" Mulch Kit -. 7" Mulch Kit NOTES: 0-7 /0

89 " Mulch Kit - 99 INDEX NO. SERVICE MFG. PART NO. QTY. DESCRIPTION NT.7- HX GRD ZN FW.0 X.8 X.00 SAE HD ZN 0 0 CS.7- X.00 HX G ZN CB.7- X.70 STD ZN RIGHT MULCH BAFFLE 9 9 COMMON MULCH BAFFLE, NOTES: 7/0 0-

90 0-7 /0

91 Numerical Index Part No. Page No. Index Numerics , , , , -, , -, -, , -, , -, , , -, , , -, -, -7, -, -, -, , -, -, - 0-7, -, -, -, 7-, 8-7, 0-, , , , 7-, , -, , -, -, 7-, 0-, , , -, , - Part No. Page No , -, - -, , -, , -, , , - 0-7, , , 7-9, , -7, -, 7-, , , , -8, -, , , -8, -, , , - Part No. Page No , -8, -, , , -8, -, , , , - -, -7, , , , /0 i-

92 Part No. Page No. Part No. Page No. Part No. Page No , , , -8, , , -7, -, -, -, 7-, 8-7, 0-, , -, -, -, -, , , -7, -, -, -, , -, -7, -, -, -, , - -, , , , -8, -, , , , , , , , , , , , 7-, , , , , -, , -, -8, , , , , -, , i- 7 /0

93 Part No. Page No. Part No. Page No. Part No. Page No , 7-7, , -8, , , CE , , -, 8-7 -, -, , -, , -, , -, , /0 i-