Hustler ATZ Parts Manual ······· Hustler Turf Equipment ····· P.O. Box 7000 ··· Hesston, Kansas · 67062-2097 397505 Rev. 5/06 Table of Contents Chapter 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Chapter 2 Contents Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Chapter 3 Contents Hydraulic System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Chapter 4 Contents Battery Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering and Park Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . Pump Belt and Pulleys Installation . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 5 Contents Kohler 27 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Panel Assembly/Installation . . . . . . . . . . . . . . . . . . . . . Electrical Schematic - Kohler (788000). . . . . . . . . . . . . . . . . . . . . . 4-2 4-4 4-6 4-10 5-2 5-6 5-8 5-10 5-12 Chapter 6 Contents Front Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Drive Wheel Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Anti-Rollover Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Chapter 7 Contents Weight Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 ROPS Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Chapter 8 Contents 72" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spindle Assembly - 350595 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spindle Assembly­796235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 8-4 8-6 8-8 8-10 8-11 Chapter 9 Contents Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Deck Belt Routing and Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 Chapter 10 Contents Tractor Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 72" and 60" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Chapter 11 Contents Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1 397505 5/06 397505 5/06 Chapter 1 General Information This Manual covers Hustler ATZ model 927178 & Hustler ATZ model 927186 Frequently Ordered Parts PART NO. 027912 027920 783936 781443 784207 781310 068478 785261 785279 747303 783977 782516 DESCRIPTION LUBRIZOL 7 OZ. BOTTLE LUBRIZOL 10 OZ. BOTTLE FILTER ELEMENT PUMP DRIVE BELT B-SECTION BELT, 72" DECK B-SECTION BELT, 60" DECK FUEL FILTER MAIN AIR FILTER ELEMENT SAFETY AIR FILTER ELEMENT KOHLER ENGINE OIL FILTER 24" OFFSET FLAT BLADE 21" CW BLADE Service Literature PART NO. 397463 742684 DESCRIPTION ATZ OWNER'S MANUAL KOHLER ENGINE 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. 397505 5/06 1-1 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 .250 .312 .375 .438 .500 .562 .625 .750 .875 1.00 FT-LBS 8.2 17 30 48 73 105 145 260 420 625 NM 11.1 23 40 65 99 143 200 350 565 850 SIZE M3 M4 M5 M6 M8 M10 M12 M16 M20 M24 FT-LBS 1 2.2 4.5 7.7 18.5 37 64 160 320 555 NM 1.3 3 6.1 10.4 25 50 87 215 435 750 NOTE: Loctite 592 to be used on all pipe threads. Lubricate all grease zerks. 1-2 397505 5/06 Chapter 2 Contents Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 397505 5/06 2-1 Rivet Nut Installation 1 2 2 INDEX NO. 1 2 SERVICE PART NO. 546572 N/A MFG. PART NO. 381848 808493 QTY. 1 10 DESCRIPTION ATZ FRAME RIVET NUT, 3/8-16 THREAD NOTES: 2-2 397505 5/06 Footrest Assembly 1 2 3 4 5 7 5 6 1 INDEX NO. 1 2 3 4 5 6 7 SERVICE PART NO. 359547 395533 305615 086660 767954 052860 781880 MFG. PART NO. 359547 395533 305615 086660 767954 052860 781880 QTY. 2 1 2 2 4 2 2 DESCRIPTION STEP TREAD FLOOR PLATE STEP TREAD NT .375-16 HX LK NY FW .406 X .812 X .060 SAE HD ZN CS .375-16 X 1.25 HX G5 ZNYC RUBBER BUMPER NOTES: 1. Do not tighten, Floor must be able to pivot on these bolts. 397505 5/06 2-3 2-4 397505 5/06 Chapter 3 Contents Hydraulic System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 397505 5/06 3-1 Hydraulic System Installation 1 2 SUPER Z HOOD 3 4 7 8 5 21 2 4 6 22 23 24 13 14 15 25 33 36 28 11 12 26 27 20 16 32 29 17 19 15 18 21 10 9 2 30 31 24 25 22 23 13 14 15 15 18 35 34 19 HUSTLER SUPER Z FRAME SHOWN, ATZ FRAME SIMILAR 36 3-2 397505 5/06 Hydraulic System Installation INDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 SERVICE PART NO. 705608 768515 713198 783704 033035 068551 032763 032771 055947 357616 034272 768523 788042 008193 767962 783928 783936 077859 789339 700484 784132 784124 784108 784082 781534 781658 784025 783993 764126 783985 784116 782870 782880 782458 782441 781526 N/A MFG. PART NO. 705608 768515 713198 783704 033035 068551 032763 032771 055947 357616 034272 768523 788042 008193 767962 783928 783936 077859 789339 700484 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 783720 QTY 4 10 2 2 2 4 1 1 2 1 4 4 2 4 12 1 1 8 2 2 2 2 2 2 4 1 1 1 1 1 1 1 1 1 1 4 1 DESCRIPTION CS .250-20 X 2.25 HX G5 ZNYC FW .281 X .625 X .051/.080 HD ZNYC SEAL 3/8 X 3/4 X 7.25" LONG OIL COOLER WEATHERSTRIP 1/8 X 3/4 X 5.88" LONG NT .250-20 HX NL ZNYC BREATHER CAP STRAINER CS .250-20 X .50 HX G5 ZNYC SUPER Z RESERVOIR NT .312-18 HX G5 ZNYC FW .343 X .687 X .051/.080 HD ZNYC PUMP, HYDRO-GEAR BDP-21L-408 NT .500-13 HX G5 ZNYC FW .531 X 1.063 X .090 SAE HD ZN ZAF SERIES FILTER HEAD FILTER ELEMENT CS .500-13 X 3.250 HX G5 ZNYC WHITE MOTOR RC28 HOSE CLAMP RETURN HOSE ASSY, #6 17.375" LONG RETURN HOSE, #6 16.5" LONG FITTING, #6 BEADED TUBE-ORB 45° FITTING, #8 BEADED TUBE-ORB 90° FITTING, STR-8MORB/-8MSL HEX PLUG FITTING, STR-8MORB SUCTION HOSE ASSY, FILTER-PUMP SUCTION HOSE, TANK-FILTER FITTING, T -8MJIC/8MJIC/8MORIN FITTING, 10 FX05-S SUCTION HOSE, #12 16" LONG TUBE, HYDRAULIC LINE TUBE, HYDRAULIC LINE TUBE, HYDRAULIC LINE TUBE, HYDRAULIC LINE FITTING, 90-10MORB/-8MSL HYDRO KIT (INCLUDES ITEMS 21-37) NOTES: 1. Add 3.5 oz. Lubrizol (027912) to new system or when hydraulic oil is changed (see Owner's Manual). 2. Hydraulic system capacity is 5 US quarts. Fill reservoir to within 1" of top of Item 8 (032771 Strainer). 397505 5/06 3-3 HYDRAULIC SYSTEM CHARGING PROCEDURE 1. Set handles in the neutral position. 2. Start engine at idle. 3. Let run for a minimum of 30 seconds. 4. Stroke handles to forward position. 5. If motors do not turn in 15 seconds return handles to neutral and repeat step 3 and 4 (one time). 6. If motors do not turn after second attempt, shut off the engine and check for oil at the pump. 7. 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 pump; 784983 (BDP21L Overhaul Seal Kit) 3-4 397505 5/06 Chapter 4 Contents Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Steering and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Pump Belt and Pulley Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 397505 5/06 4-1 Battery Installation 1 BLACK WIRE, PART OF WIRE HARNESS 2 1 4 1 3 5 6 5 7 8 RED WIRE, PART OF WIRE HARNESS 3 14 9 9 10 5 8 12 TRACTOR FRAME 11 11 13 HUSTLER SUPER Z FRAME SHOWN, ATZ FRAME SIMILAR 4-2 397505 5/06 Battery Installation ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 SERVICE PART NO. 024927 771428 768820 744276 768523 058776 348417 055939 029868 740696 034272 034280 779850 029876 MFG. PART NO. 024927 771428 768820 744276 768523 058776 348417 055939 029868 740696 034272 034280 779850 029876 QTY 2 1 1 1 3 2 1 2 4 1 2 1 2 1 DESCRIPTION NT .250-20 HX GR 5 ZN RED BATTERY CABLE BOOT BATTERY GROUND CABLE POSITIVE BATTERY CABLE FW .343 X .687 X .051/.080 HD ZNYC NT .312-18 HX NL ZN BATTERY CLAMP STRAP CS .250-20 X .750 HX G5 ZN LW .250 INT-EXT TOOTH ZN BATTERY NT .312-18 HX G5 ZN CS .312-18 X.750 HX G5 ZN CB .312-18 X 3.00 FUL ZN LW .312 INT-EXT TOOTH ZN NOTES: 1. When performing service on mower, disconnect battery ground cable and black wire of harness and do not reconnect to battery until engine is ready to be started. See Owners Manual. 397505 5/06 4-3 Deck Lift Assembly 1 2 4 6 5 TRACTOR FRAME 3 4 5 10 7 5 11 12 4 13 4 7 1 1 5 4 5 6 8 4 7 8 1 4 5 8 14 9 4 7 1 9 HUSTLER SUPER Z FRAME SHOWN, ATZ FRAME SIMILAR 4-4 397505 5/06 Deck Lift Assembly INDEX NO. 1 SERVICE PART NO. 348318 348284 600437 3 4 5 6 7 8 9 10 11 12 13 14 783001 704643 781294 782995 015495 055749 348391 756270 034272 348458 781229 781831 MFG. PART NO. 348318 348284 600437 783001 704643 781294 782995 015495 055749 348391 756270 034272 348458 781229 781831 QTY 1 1 1 1 8 7 2 4 3 4 1 1 1 1 1 STOP HANDLE HEIGHT ADJUSTMENT STOP (3/8" DIA PIN) HEIGHT ADJUSTMENT STOP (½" DIA PIN) DECK LIFT INDICATOR NT .437-14 HX FLG ZN CLIP E, 1.00 X.625X .050 DECK LIFT SPRING ASSEMBLY STRAIGHT GREASE FITTING CS .437-14X1.750 HX G5 ZNYC DECK LIFT CHAIN CS .312-18 X 1.50 FLTHR GR5 ZNYC NT .312-18 HX G5 ZNYC DECK LEVELER YOKE W/A CE .750X2.25 X1.75 HEADLESS CS .437-14 X 1.750 FULTH G5 ZNYC DESCRIPTION 22 2 NOTES: 1. Apply grease to zerks (see owners manual). 2. Order replacement pin to match holes in Deck Lift Indicator. 397505 5/06 4-5 Steering and Park Brake Assembly 1 6 7 8 17 5 3 26 9 10 11 4 11 13 3 14 15 6 28 29 27 12 16 3 10 3 4 25 24 23 27 21 27 19 11 18 20 21 11 10 22 19 2 3 3 5 11 10 31 34 24 37 2 30 3 32 11 33 3 41 42 39 40 36 38 15 3 34 33 35 11 24 1 43 HUSTLER SUPER Z FRAME SHOWN, ATZ FRAME SIMILAR 4-6 397505 5/06 ...