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HUSTLER Z XR7 manual

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Table of contents for the manual

  • Page 1

    ••••••• Hustler Turf Equipment ••••• P .O. Box 7000 ••• Hesston, Kansas • 67062-2097 Hustler Z XR7 Parts Manual[...]

  • Page 2

    IMP OR T AN T : Th i s e n gi ne i s n o t e q u i pped w i t h a s par k a r r est e r m u ffl er . I t i s a vi ola t i on of Ca li for nia Publ i c Re sour c e C od e S ec t i o n 4442 to us e o r op erate th i s eng ine o n an y fo res t-c o v ered , b rus h-co vered , o r grass -co ver ed uni mp r o ved l and . O t her sta te s or f ede ra l a[...]

  • Page 3

    106567 4/0 7 c-1 T able of Content s Chapter 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Chapter 2 Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Ch[...]

  • Page 4

    c-2 106567 4/07 Chapter 10 Maintenance & Adjustment Safe ty . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 Safe Maintenance & Adjustme nt Practices . . . . . . . . . . . . . . . . . . 10-4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 Adjustment . . . . . . . . . . . . . . . . . .[...]

  • Page 5

    106567 4/ 07 1-1 Chapter 1 General Information This Manual covers Hustler XR7 Z models 927723, 927731, 927749, 927756, 927772, 927798, 927806, 927814 with serial num bers prior to 07020000 . Frequently Ordered Parts Service Literature Note: When ordering p arts, yo u must use the part numbe r as shown for each part, not the index numb er . Always g[...]

  • Page 6

    1-2 106567 4/07 your Hustler dealer for cur re nt information and part s. Hardware Description Codes & Abbreviations The following codes are used throu gho ut this part s manual. Refer to this list when ordering p arts. St an d a r d T o r qu e s The following chart list s the standard torque va lues for the threaded fasteners found in this man[...]

  • Page 7

    106567 4/ 07 2-1 Chapter 2 Content s Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3[...]

  • Page 8

    2-2 106567 4/07 Rivet Nut Installation NOTES: 1. Seat support 547950 includes rivet nut s. INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 548032 107701 1 TRACTOR FRAME (54") 547760 10621 1 1 TRACTOR FRAME (60") 547752 106039 1 TRACTOR FRAME (66") 2 N/A 808493 15 3/8-16 THREAD RIVET NUT 3 N/A 600961 8 1/2-13 THREAD[...]

  • Page 9

    106567 4/ 07 2-3 Footrest Assembly NOTES: 1. Do not tighten, It em 2 (348276 Floor) must be able to pivot on these bolts. INDEX NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 359547 359547 2 STEP TREAD 2 395533 395533 1 FLOOR 3 305615 305615 2 PLA TFORM STEP TREAD 4 086660 086660 2 NT .375-16 HX LK NY 5 767954 767954 4 F W .406 X .812 X .060 [...]

  • Page 10

    2-4 106567 4/07[...]

  • Page 11

    106567 4/ 07 3-1 Chapter 3 Content s Hydraulic System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2[...]

  • Page 12

    3-2 106567 4/07 Hydraulic System Installation 8 22 FRONT 16 1 31 2 3 4 17 18 5 6 7 20 19 17 21 10 11 23 12 24 25 26 9 29 11 10 18 20 14 30 15 17 11 13 27 24 12 28[...]

  • Page 13

    106567 4/ 07 3-3 Hydraulic System Installation NOTES: 1. Add 3.5 oz. Lubrizol ® (027912) when hydraulic oil is changed (see Owner ’s Manual). 2. Hydraulic system capacity is 5 US quart s. Fill reservoir to within 1" of top of Item 3 (032771 S trainer) ITEM NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 768515 768515 2 F W .281 X .625 [...]

  • Page 14

    3-4 106567 4/07 HYDRAULIC SYSTEM CHARGING PROCEDURE 1. Set handles in the neutral position. 2. S tart engine at idle. 3. Let run for a minimum of 30 seconds. 4. S troke handles to forward position. 5. If motors do not turn in 15 seco nds return handles to neutral and repeat step 3 and 4 (one time). 6. If motors do not turn after se cond attempt, s [...]

  • Page 15

    106567 4/ 07 4-1 Chapter 4 Content s Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Steering and Park Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Pump Belt and Pulleys [...]

  • Page 16

    4-2 106567 4/07 Battery Installation 1 TRACTOR FRAME 11 12 9 9 10 8 4 1 3 1 6 5 8 5 7 2 11[...]

  • Page 17

    1065674/07 4-3 Battery Installation NOTES: 1. When performing servic e on mower , disconnect battery ground cable and do not reconnect to battery until engi ne is ready to be started. See Owners Manual. INDEX NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 024927 024927 2 NT .250-20 HX GR.5 ZN 2 771428 771428 1 RED BA TTERY CABLE BOOT 3 796219[...]

  • Page 18

    4-4 106567 4/07 Deck Lift Assembly 1 TRACTOR FRAME 1 1 1 4 1 3 2 5 5 5 5 5 4 4 5 6 8 8 4 4 4 4 14 13 9 7 10 10 4 10 11 12 8 10 6 9 9[...]

  • Page 19

    1065674/07 4-5 Deck Lift Assembly NOTES: 1. Apply grease to zer ks (see owner ’s manual). 2. V erify pin diameter pr ior to ordering replacement part. For mowers with 3/8" diameter pins, order 348284; fo r mowers with 1/2" pins, order 600437. Item 3 includes 600437 (1/2" pin). ITEM NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION[...]

  • Page 20

    4-6 106567 4/07 S teering and Park Brake Assembly TRACTOR FRAME 1 2 3 15 27 10 3 28 3 40 29 30 7 7 6 30 36 36 37 28 34 3 29 33 32 31 39 26 35 3 41 2 3 4 5 7 6 8 9 14 7 6 16 15 3 3 17 18 7 22 23 6 4 24 38 7 7 5 3 3 21 21 30 11 1 10 3 11 12 13 19 20 25[...]

  • Page 21

    1065674/07 4-7 S teering and Park Brake Assembly ITEM NO. SERVIC E PART NO. MFG. PART NO. QTY DESCRIPTION 1 781260 N/A 2 STEERING BAR GRIP 2 348755 348755 2 STEERING BAR 3 767954 767954 48 FW .406 X .812 X .060 SAE HD ZN 4 036244 036244 10 CS .375-16 X 1.000 HX G5 ZN 5 705178 705178 6 CS .375-1 6 X 1.750 HX G5 ZN 6 041 152 041 152 8 NT .31 2-24 HX [...]

  • Page 22

    4-8 106567 4/07 NOTES: 1. T orque to 350-375 f t.-lbs. Included with wheel motor . 2. T orque brake assembly mo unting bolt s to 100 ft.-lbs. 3. 781 1 12 used on left wheel. 4. 781351 used on right wheel. 5. Includes Item 1 (7 81260 S teering Bar Grip). 6. Use 783696 on mowers with serial numbers prior to 06071499.[...]

  • Page 23

    1065674/07 4-9 This p age intentionally lef t blank.[...]

  • Page 24

    4-10 106567 4/07 Pump Belt and Pulleys Installation 3 2 TRACTOR FRAME 1 2 2 1 6 6 7 9 6 4 14 16 17 15 18 19 20 12 10 21 22 2 5 13 8 7 3 10 10 8 11 10 9 23 24 25 26 5 13[...]

  • Page 25

    1065674/07 4-11 Pump Belt and Pulleys Installation NOTES: 1. T orque to 45-48 f t-lbs. 2. T orque to 12-15 f t-lbs. 3. Apply grease at ze rk (see owner ’s manual). 4. Included with Honda 24 HP engine (785014). 5. Electric clutch burnishing procedure: After installing a new clutch it is important to burnish the clutch to in sure maximum deck clutc[...]

  • Page 26

    4-12 106567 4/07[...]

  • Page 27

    106657 4/ 07 5-1 Chapter 5 Content s Kawasaki Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Honda Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Kohler Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Fuel System Installation .[...]

  • Page 28

    5-2 106567 4/07 Kawasaki Engine Installation PURPLE TO EN GI NE SENSOR TO BULLET TERMINALS TO SP ADE TERMINAL Y ELLOW 2 2 RED/BLK 2 2 TRACTOR FRAME POSITIVE BA TTER Y CABLE 2 1 6 2 7 5 18 24 11 16 17 26 3 30 32 29 28 20 3 19 25 38 31 8 4 17 7 7 6 6 NEGA TIVE BA TTERY CABLE 9 ST ARTER SOLENOID GROUND 10 6 12 13 14 3 15 15 3 3 2 17 22 20 3 21 3 23 3 [...]

  • Page 29

    106567 4/ 07 5-3 Kawasaki Engine Installation ITEM NO. SERVICE P ART NO. MFG . P ART NO. QTY DESCRIPTION 1 777656 777656 1 KA W ASAKI 23 HP ENGINE 782318 782318 1 KAWASAKI 25 HP ENGINE (FH721V , 3600 RMP) 2 058776 058776 4 NT .312-18 HXZY NL 3 768523 768523 22 FW .343 X .687 X .051/.080 HD ZN/YL 4 029876 029876 1 L W .312 INT -EXT TOOTH ZN 5 792762[...]

  • Page 30

    5-4 106567 4/07 NOTES: 1. Includes mounting hardware. 2. Part of Item 8 (7993 12 Wire Harness Adapter). 3. Engine oil capacity; 2 US quart s (w/filter). 4. Engine RPM to be set at 3600± 50. 5. 23 HP engine used in 927723 and 927731 only . 6. 25 HP engine used in 927772 and 927798 only . 7. Includes one (1) of Item 17 (057661 Hose Clamp). 8. When i[...]

  • Page 31

    106567 4/ 07 5-5 This p age intentionally lef t blank.[...]

  • Page 32

    5-6 106567 4/07 Honda Engine Installation 3 1 BRN ORG RED/BLK PUR POSITIVE BA TTERY CABLE GRA/PUR 3 3 3 2 7 30 3 10 13 11 12 29 18 1 13 16 21 22 16 24 32 3 2 14 3 25 7 20 3 3 5 15 NEGA TIVE BA TTERY CABLE 8 4 2 BLK 2 YEL 2 6 9 11 11 3 16 3 17 28 3 9 35 19 26 PA R T O F ENGINE 3 23 31 34 27 8 8 33 8 7 TRACTOR FRAME P ART OF COMMON WIRE HARNESS 10 36[...]

  • Page 33

    106567 4/ 07 5-7 Honda Engine Installation NOTES: 1. Includes mounting hardware. 2. Part of Item 4 (799320 T r actor Common Wire Harness). 3. Part of 8 (799304 Wi re Harness Adapter). 4. Engine oil capacity; 2.3 US quart s (with filter). 5. Engine RPM to be set at 3600± 50. 6. Used on 927756 only . ITEM NO. SERVICE P ART NO. MFG. P ART NO. QTY DES[...]

  • Page 34

    5-8 106567 4/07 7. Includes one (1) of Item 14 (057661 Hose Clamp). 8. Supplied with engine. 9. When installing lower hose clamp on air cleaner hose, in stall as low as possible (against carburetor inlet). 10. This connecto r used for optional hydr aulic oil cooler fan. 1 1. Air filter service parts: 785261 MAIN AIR FIL TER ELEMENT 763318 V ACUA TO[...]

  • Page 35

    106567 4/ 07 5-9 This p age intentionally lef t blank.[...]

  • Page 36

    5-10 106567 4/07 Kohler Engine Installation 1 POSITIVE BA TTERY CABLE RED/BLK 2 PUR (P/O ENGINE) 6 6 27 1 7 6 4 BLK 2 2 3 4 5 TRACTOR FRAME 8 8 8 9 10 11 12 4 13 4 4 14 12 15 3 4 4 16 17 6 18 19 4 14 4 14 20 21 22 23 24 24 25 26 28 P ART OF COMMON WIRE HARNESS 2 29 NEGATIVE BA TTER Y CABLE[...]

  • Page 37

    106567 4/07 5-11 Kohler Engine Installation NOTES: 1. Includes mounting hardware. 2. Part of Item 2 (7993 20 Common Wire Harness). 3. Engine oil capacity; 1. 9 US quarts (w/filter). 4. Engine RPM to be set at 3600± 50. 5. Used on 927806, and 927814 only . 6. Supplied with engine. 7. Air filter service part s: ITEM NO. SERVICE P ART NO. MFG . PA R [...]

  • Page 38

    5-12 106567 4/07 Fuel System Installation 1 1 1 2 3 4 4 4 4 5 6 7 1 6 7 1 6 7 8 8 9 10 9 9 1 6 11 11 12 13 14 14 13 15 17[...]

  • Page 39

    106567 4/07 5-13 Fuel System Installation NOTES: 1. T orque to 20 f t.-lbs. 2. Supplied with new fuel tank. 3. Fuel tank service p art not shown: ITEM NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 779306 779306 2 3.5" FUEL CAP 2 793240 793240 1 LEFT SIDE FUEL T ANK 3 793232 793232 1 RIGHT SIDE FUEL T ANK 4 000323 000323 6 CLIP 5 106732 [...]

  • Page 40

    5-14 106567 4/07 Instrument Panel Assembly RIGHT SIDE FUEL T ANK 1 10a FUSE SIZE AND LOCA TION 15a 1 2 4 6 9 11 7 8 7 5 12 13 14 3 4 13 12 15a 3 10[...]

  • Page 41

    106567 4/07 5-15 Instrument Panel Assembly NOTES: 1. Part of 799320 (C ommon Wire Harness) ITEM NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 776476 776476 1 PT O SWITCH 2 785808 785808 1 IGNITION KEY SET 3 045898 045898 1 KEY SWITCH 4 785030 785030 1 Z CHOKE CABLE (KAWASAKI) 786657 786657 1 Z CHOKE CABLE (HONDA & KOHLER) 5 712257 712257[...]

  • Page 42

    5-16 106567 4/07 Electrical Schematic (799320) 13[...]

  • Page 43

    106567 4/ 07 6-1 Chapter 6 Content s Front Wheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Front Wheel Breakdown—747782. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Optional Semi-Pneumatic Tire/Wheel—78953 7 . . . . . . . . . . . . . . . . 6-5 Drive Wheel Assembly Installation . . . . . . . [...]

  • Page 44

    6-2 106567 4/07 Front Wheel Assembly TRACTOR FRAME 1 1 2 3 3 3 3 9 11 10 5 4 6 7 9 9 11 8 1 2 4 5 4 6 7 8 1 2 4 9 3 3[...]

  • Page 45

    1065674/07 6-3 Front Wheel Assembly NOTES: 1. Apply grease to zerks. 2. T orque to 100 f t.-lbs. 3. Assemble with extended inner race toward item 5 (387035 S pacer , 1.07 x 1.312 x 2.793). INDEX NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 705954 705954 2 CS .500-13 X 1.25 HX G5 ZN 2 344267 344267 2 FW .510 X 2.15 X .187 SPL ZN 3 712976 712[...]

  • Page 46

    6-4 106567 4/07 Front Wheel Breakdown—747782 NOTES: 1. Inflate tire to 8-10 p si. ITEM NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 039677 N/A 2 WHEEL BEARING 2 747741 N/A 1 13 X 6.50 TIRE 3 747832 N/A 1 6 X 4.5 WHEEL 4 782771 N/A 1 BEARING SP ACER 5 019521 N/A 1 TIRE V AL VE 6 01551 1 N/A 1 GREASE FITTING 45 DEG 1/4 1 1 1 2 4 3 5 6[...]

  • Page 47

    1065674/07 6-5 Optional Semi-Pneumatic T ire/Wheel—789537 NOTES: ITEM NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 039677 N/A 2 WHEEL BEARING 2 789537 N/A 1 T IRE/WHEEL ASSEMBLY 3 01551 1 N/A 1 GREASE FITTING 45 DEG 1/4 4 782771 N/A 1 BEARING SP ACER 1 1 2 4 3[...]

  • Page 48

    6-6 106567 4/07 Drive Wheel Assembly Installation NOTES: 1. T orque to 65-75 f t. lbs. 2. Inflate tire to 8-10 p si. INDEX NO. SERVICE PART NO. PART NO. QTY DESCRIPTION 1 784058 784058 2 WHEEL & TIRE ASSY FOR 66" (QTY PER TRACTOR) 2 781245 N/A TIRE, 12 X 12 X 24 FOR 66" 3 784066 N/A WHEEL ASSEMBLY 12 X 8.50 FOR 66" 4 019521 N/A T[...]

  • Page 49

    1065674/07 6-7 Anti-Rollover Wheel Assembly NOTES: 1. Do not torque, wh eel must turn freely . INDEX NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 068239 068239 2 CS .500-13 X 4.500 HX G5 ZN 2 031997 031997 2 ANTI-SCALP WHEEL 3 767962 767962 4 FW .531 X 1.063 X .090 SAE HD ZN 4 781567 781567 2 NT .50-13 HX LK NY TRACTOR FRAME 1 1 4 2 1 2 3 3[...]

  • Page 50

    6-8 106567 4/07[...]

  • Page 51

    106567 4/ 07 7-1 Chapter 7 Content s 66" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 66" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 60" Side Discharge Deck Assemb ly . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 60" Deck Pul[...]

  • Page 52

    7-2 106567 4/07 66" Deck Assembly 1 9 7 10 5 4 10 11 7 7 9 11 7 7 9 10 1 4 14 14 13 15 2 3 4 5 6 4 12 12 12 16 5 12 8 8 8 8 8 7 9 9 9 10 10 11 11 11 16 16 4 4 7 17 8 18 } 19 20 Optional Anti-Scalp Wheels 7[...]

  • Page 53

    106567 4/ 07 7-3 66" Deck Assembly NOTES: 1. Do not torque, Item 2 (349324 Discharge Chut e) must pivot freely . 2. Includes 6 each of items 7 through 10. 3. Service part deck includes decals (see ’’66" Deck Decals” in on p age - 4 for listing of decals). 4. For optional anti- scalp wheels order: INDEX NO. SERVICE PA R T N O . MFG. [...]

  • Page 54

    7-4 106567 4/07 66" Deck Pulley Assembly 1 4 2 17 17 17 19 22 23 21 24 26 25 27 29 30 20 1 6 7 3 4 12 13 14 17 9 10 8 11 15 18 5 4 4 28 30 2 BEL T GUIDE INDEXING 16 16 4[...]

  • Page 55

    106567 4/ 07 7-5 66" Deck Pulley Assembly NOTES: 1. T orque to 1 18 ft. lbs. 2. T orque to 67-75 f t. lbs. 3. Apply grease to ze rk (see owner ’s manual). 4. See ’’Deck Belt Routing and T ens ioning” in on page -4 for belt tensioning. 5. See ’ ’S pindle Assembly–796235” in on page -14 for breakdown. ITEM NO. SERVICE PA R T N O [...]

  • Page 56

    7-6 106567 4/07 60" Side Discharge Deck Assembly 3 4 4 9 10 10 16 7 1 7 7 11 9 9 10 8 7 9 11 11 7 4 5 2 4 6 5 16 15 12 12 18 12 12 1 3 4 4 8 9 10 7 8 9 11 13 4 4 5 14 14 14 4 4 14 4 5 8 10 8 11 8 13 11 17[...]

  • Page 57

    106567 4/ 07 7-7 60" Side Discharge Deck Assembly NOTES: 1. Do not torque, Item 2 (798694 Discharge Chut e) must pivot freely . 2. Includes items 7, 8, 9, and 10. 3. Service part deck includes decals (see ’’60" Deck Decals” in on p age - 5 for listing of decals). 4. For optional anti- scalp wheels order: INDEX NO. SERVICE PA R T N O[...]

  • Page 58

    7-8 106567 4/07 60" Deck Pulley Assembly 1 2 4 BEL T GUIDE INDEXING 60" DECK 13 12 19 21 22 18 25 26 27 28 29 10 9 1 6 2 4 17 14 11 3 5 7 4 4 15 15 16 17 17 17 20 23 24 28 30 4 8 16[...]

  • Page 59

    106567 4/ 07 7-9 60" Deck Pulley Assembly NOTES: 1. T orque to 1 18 ft. lbs. 2. T orque to 65-75 f t. lbs. 3. Apply grease to ze rk (see owner ’s manual). 4. See ’’Deck Belt Routing and T ens ioning” in on page -4 for belt tensioning. 5. See ’’S pindle Assembly–796235” in on page -14 for breakdown. ITEM NO. SERVICE PA R T N O .[...]

  • Page 60

    7-10 106567 4/07 54" Deck Assembly 1 9 10 13 13 4 5 11 12 11 11 10 10 9 9 12 13 5 7 11 10 9 13 1 14 15 2 3 4 8 8 8 17 18 12 4 12 4 5 14 4 3 4 5 17 12 4 4 4 16 16 11 10 13 9 9 10 8 11 18 6 4 5 19 13 } 20 21 Optional Anti-Scalp Wheels[...]

  • Page 61

    106567 4/07 7-11 54" Deck Assembly NOTES: 1. Do not torque, Item 2 (798694 Discharge Chut e) must pivot freely . 2. Includes items 9, 10, 1 1, and 13. 3. Secure Item 1 1 (053199 Jam Nut) to bolt with a dr op of Loctite® (271 Red). T ighten Item 1 1 to shank of Item 9 (781708 Cs .500-13 X 4.25 Hx G5 Zn). Anti-scalp w heel must turn freely . 4.[...]

  • Page 62

    7-12 106567 4/07 54" Deck Pulley Assembly BEL T GUIDE POSITIONING 1 4 31 31 31 18 21 20 16 22 23 24 25 30 25 28 26 31 5 17 19 1 2 4 5 8 7 6 10 9 3 11 14 13 15 2 2 12 27 54" DECK ASSY 4 4 25 28 29[...]

  • Page 63

    106567 4/07 7-13 54" Deck Pulley Assembly NOTES: 1. T orque to 1 18 ft. lbs. 2. T orque to 65-75 f t. lbs. 3. Apply grease to zerk. 4. See ’’Deck Belt Routing and T ens ioning” in on page -4 for belt tensioning. 5. See ’’S pindle Assembly–796235” in on page -14 for breakdown. INDEX NO. SERVICE PA R T N O . MFG. P ART NO. QTY . DE[...]

  • Page 64

    7-14 106567 4/07 Spindle Assembly–796235 NOTES: 1. Install upper b earing with extended inner race up. 2. Install lower bearing with extended inner race down. INDEX NO. SERVICE PA R T N O . MFG . PA R T N O . QTY . DESCRIPTION 1 077123 N/A 2 BEARING W/O COLLAR 2 766204 N/A 1 BLADE SPINDLE BUSHING 3 034843 N/A 1 CAST SPINDLE HOUSING 4 012005 N/A 1[...]

  • Page 65

    106567 4/ 07 8-1 Chapter 8 Content s Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Deck Belt Routing and Tensioni ng . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6[...]

  • Page 66

    8-2 106567 4/07 Deck Installation TRACTOR ASSEMBL Y DECK ASSEMBL Y 1 2 3 4 5 5[...]

  • Page 67

    106567 4/ 07 8-3 Deck Installation NOTES: 1. 66" Deck inst allation is shown, 54" and 60" Deck installations are similar . ITEM NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 055749 055749 4 CS .437-14 X 1.750 HX G5 ZN 2 061 101 061 101 2 NT .750-10 HX NL ZN 3 025296 025296 4 FW .760 X 1.625 X.08 ZN 4 051 169 051 169 2 CS .750-[...]

  • Page 68

    8-4 106567 4/07 Deck Belt Routing and T ensioning DECK ASSEMBL Y 1[...]

  • Page 69

    106567 4/ 07 8-5 NOTES: 1. S pring length af ter tensioning belt. Measure spring from out side of hook to outside of hook. 2. Route belt as shown.[...]

  • Page 70

    8-6 106567 4/07 Seat Installation 1 1 10 12 15 1 2 5 5 6 14 16 4 3 17 3 8 5 5 7 8 9 13 4 11[...]

  • Page 71

    106567 4/ 07 8-7 Seat Installation NOTES: 1. Must pivot freely . 2. Service part s available for Michigan S tandard seat; INDEX NO. SERVICES PART NO. MFG. PART NO. QTY DESCRIPTION 1 793661 793661 1 MICHIGAN SEAT 2 350041 350041 1 SEA T P AN 3 000331 000331 3 BLACK CABLE TIE 4 086660 086660 3 NT .375-16 HX LK NY 5 767954 767954 7 FW .406 X .812 X .0[...]

  • Page 72

    8-8 106567 4/07[...]

  • Page 73

    106567 4/ 07 9-1 Chapter 9 Content s Tractor Decals–US Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Tractor Decals–CE Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 66" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 60" Deck De[...]

  • Page 74

    9-2 106567 4/07 T ractor Decals TOP OF S E AT PA N BOTTOM OF S E AT PA N 1 2 6 9 10 13 12 11 3 4 14 5 15 7 A A 8 17[...]

  • Page 75

    106567 4/ 07 9-3 T ractor Decals NOTES: INDEX NO. SERVICE PA R T N O . MFG . PA R T N O . QTY . DESCRIPTION 1 781427 781427 1 DECK HEIGHT INDICA TOR DECAL 2 779280 779280 1 HOT & HYDRAULIC OIL DECAL 3 784702 784702 1 INSTRUMENT P ANEL DECAL (SEPARA TE CHOKE) 4 727008 727008 1 HYD PRESSURE DECAL 5 791830 791830 1 FUEL INDICA TOR DECAL 6 782136 7[...]

  • Page 76

    9-4 106567 4/07 66" Deck Decals NOTES: INDEX NO. SERVICE PA R T N O . MFG . PA R T N O . QTY . DESCRIPTION 1 799189 799189 1 66" SIDE DISCHARGE DECK ID DECAL 2 760637 760637 1 MOWER DECK QUICK REFERENCE DECAL 3 727420 727420 1 DEFLECTOR SHIELD DECAL 4 727172 727172 1 "MADE IN U.S.A." DECAL 5 727453 727453 2 BEL T & PULLEY DE[...]

  • Page 77

    106567 4/ 07 9-5 60" Deck Decals NOTES: INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 786277 786277 1 60" SIDE DISCHARGE DECK ID DECAL 2 760637 760637 1 MOWER DECK QUICK REFERENCE DECAL 3 727420 727420 1 DEFLECTOR SHIELD DECAL 4 727172 727172 1 "MADE IN U.S.A." DECAL 5 727453 727453 2 BEL T & PULLEY DECA[...]

  • Page 78

    9-6 106567 4/07 54" Deck Decals NOTES: INDEX NO. SERVICE PA R T N O . MFG . PA R T N O . QTY . DESCRIPTION 1 799171 799171 1 54" SIDE DISCHARGE DECK ID DECAL 2 760637 760637 1 MOWER DECK QUICK REFERENCE DECAL 3 727420 727420 1 DEFLECTOR SHIELD DECAL 4 727172 727172 1 "MADE IN U.S.A." DECAL 5 727453 727453 2 BEL T & PULLEY DE[...]

  • Page 79

    106567 4/07 10-1 Chapter 10 Content s Maintenance & Adjustment Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Safe Maintenance & Adjustment Practices . . . . . . . . . . . . . . . . . . . . . . . 10-2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 Adjustme[...]

  • Page 80

    10-2 1065674/07[...]

  • Page 81

    10-3 106567 4/07 Maintenance & Adjustment Safety This safety alert symbol is used to call attentio n to a message intended to provide a reason able degree of PERSONAL SAFETY for op era tors and other persons durin g the normal operation and servicing of this equipment. DANGER – denotes immediate hazar ds which WILL result in severe personal i[...]

  • Page 82

    10-4 106567 4/07 Safe Maintenance & Adjustment Practices ▲ This product is capable of amputating hands and f eet and throwing object s. Always follow all safety instructions to avoid serious injury or death. ▲ Unless specifically required, DO NOT have engine running wh en servicing or making adjustment s to tractor . Place control levers in[...]

  • Page 83

    10-5 106567 4/07 off and remove ignit ion switch key for maximum safety . Repairs or maintenance requiring eng ine power should be perfo rm e d by trained personnel on ly . ▲ Use a stick or similar instrument to clean under th e mowe r ma kin g sur e that no part of the body , especially arms and hands are under mower . ▲ Exercise caution when [...]

  • Page 84

    10-6 106567 4/07 Safety and Instruction Decals ▲ S pecific s afety warning decals ar e located on the equipment near the immediate ar eas of potential hazards. These decals should not be removed or obliter ated. Replace them if they become non- readable. The following illustration s show the various safety decals tha t are located on the machine.[...]

  • Page 85

    10-7 106567 4/07 Do not remove or modify stabilizer wheels or rear engine guard or injur y can result. Keep engine and pump compart-ment(s) clean (especially in exhaust area) to prevent fire and pr ovide maximum engine and hydraulic cooling. Hydraulic fluid escaping under pressure can penetrate skin . Hydraulic fluid may also cause infection in a m[...]

  • Page 86

    10-8 106567 4/07 Maintenance FIG . 1 1a 3 2b 8 1b 11 11 10 6 6 12 7 2a 12 9 4 1a. Engine Oil Fill & Dipstick (Kawasaki & Honda) 1b. Engine Oil Fill & Dipstick (Kohler) 2a. Fuel Filter (Honda & Kawasaki) 2b. Fuel Filter (Kohler) 3. Engine Air Cleaner 4. Engine Oil Drain Plug 5. Battery 6. Fuel T anks 7. Hydraulic Oil Reservoir 8. Hyd[...]

  • Page 87

    10-9 106567 4/07 FIG . 2 2 4 4 1 3 2 4 1. Deck Pusher Arm Zer ks (2) 2. Deck Belt 3. Spindle Housing Zerk (3 ) 4. Blades Maintenance Locator Chart 60" XR7 deck 54" & 66" XR7 deck 1 3 3 4 3 3 3 1 1[...]

  • Page 88

    10-10 106567 4/07 NOTES: 1. Initial oil change is after 5 hours of operation. Thereafter , change oil af ter every 40 hours opera tion. Change more of ten under dusty or dirty conditions and during hot weathe r periods. 2. T orque initially and after first 2 hours of operation. 3. Perform initial hydraulic filte r change after 50 hours (one wee k) [...]

  • Page 89

    10-11 106567 4/07 INTRODUCTION Regular maintenance is the best pr even tion for costly downtime or expensive, premature rep air . The following p age s contain suggested mainten ance info rmation and schedu les which the operator should follow on a routine basis. Remain alert for unusual noises, they could be signalin g a problem. Visually insp ect[...]

  • Page 90

    10-12 106567 4/07 Ti re s It is important for level mowing that th e tires have the same amount of air pressure. The recommended pressures are: Drive wheels ........... ... ... ... .......8-12 psi (55-69 KPa) Gauge wheels .................. .......8-12 psi (55-69 KPa) Solid fill tires are not recommended for Hustler turf equipment. On an y machine,[...]

  • Page 91

    10-13 106567 4/07 Electrical system The electrical system is a 12-volt, negative ground. Recommended battery size is a garden tractor BCI group U1R with 225 or better cranking AMP rating. A maintenance-free batter y is recommended. Other- wise, follow battery manufactur er ’s mainte nanc e, safety , storing an d char gin g spec ifica tio ns . The[...]

  • Page 92

    10-14 106567 4/07 W ARNING: Incorrect battery cable routing coul d cause damage to the tractor and ba ttery cables. This can cause sparks which can cause a battery ga s explosion which will result in personal injury . Always disconnect the ne gative (black) battery cable before disconnecting the positive (red) cable. Always connect the positive (re[...]

  • Page 93

    10-15 106567 4/07 Check oil level in hy draulic system after every 50 hours of operation or weekly , whichever occurs first. Check more often if system appe ars to be leaking or otherwise malfunctioning. Fluid level should be 1” from top of reservoir . Use only SAE 10W40 SG , SF/C C, CD service motor oil. Change hydraulic system filter element ( [...]

  • Page 94

    10-16 106567 4/07 Fuel system DANGER: Observe usual fuel handling pr ecautions: Do not smoke while refueling. Do not fill tank with engine ru nning or while engine is hot. Clean up any gasoline spills. Allow engine to cool before st oring machine inside a building. Keep fuel away from open flame or sp ark and store machine away from open flame or s[...]

  • Page 95

    10-17 106567 4/07 Use regular unleaded gasoline with an octane rating of 87 or higher . The fuel filter (FIG . 8) is installed in th e fuel line between fuel tanks and engine fuel pump. Replace filter annually or af ter every 500 hours of operation, wh ichev er occurs first. When replacing the fuel filter , check the fuel line hose s and fuel shut-[...]

  • Page 96

    10-18 106567 4/07 The oil drain and oil filter are locate d at the rear of the engine FIG . 10. Engine air filter Perform engine air filte r maintenance per the scheduled maintenance chart. See “SERVICE A T INTERV ALS INDICA TE D” on page 10. A specially designed dry filte r is standard equipmen t on the Hustler Z and Super Z tractors and su pp[...]

  • Page 97

    10-19 106567 4/07 Air cleaner servicing is an inexpensive mainten anc e check that can prevent costly non-wa rrantable premature engine damage. Overservi cing Overservicing occurs when an air filter element is remove d for cleaning or replacement be fore it is necessary . Each t ime the filter is remove d a small amount of dir t and dust could fall[...]

  • Page 98

    10-20 106567 4/07 Recommended service procedure 1. Release clamps and r emove element. Clean the canister with a damp cloth. 2. Before installing a new elemen t, ins pect it by placing a bright ligh t inside an d rotate the elem en t slow ly , looking for any holes or tea rs in the paper . Also check gaskets for c ut s or t ears. Do not at tempt to[...]

  • Page 99

    10-21 106567 4/07 W ARNING: If the pump belt fails, loss of control will occur especially when operating on a slope. If you lose steering control while ope rating the machine, place the steering contr ol levers in the p ark brake position imme diately . Inspect the mach ine and involve your Hu stler dealer to resolve the pr oblem before continuing [...]

  • Page 100

    10-22 106567 4/07 Mower blade maintenance Check the mower blades daily , they are the key to po wer 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, c[...]

  • Page 101

    10-23 106567 4/07 FIG . 17 FIG . 18 FIG . 16 Resharpening pat- tern Do not sharpen to original pattern (below). It is easier to get a straight cutting edge following the resharpening pattern shown above. Original edge W arped Blade (Repla ce) S traight Blade (Repla ce) Comparison of W arped and S traight Blades Cutting plane Cutting edge Cutting ed[...]

  • Page 102

    10-24 106567 4/07 This p age intentionally lef t blank.[...]

  • Page 103

    10-25 106567 4/07 Adjustment Introduction Y our Hustler Z was adjusted before it left the factory and was checke d during predeliver y setup. However , after st art-up and cont inued use, a certain amount of break- in wear will cause some adjustments to change. Remain alert for unusual noises, they could be signalin g a problem. Visually insp ect t[...]

  • Page 104

    10-26 106567 4/07 If the tractor creep s in the neutral po sition the control linkage m ay be adjusted as follows: 1. Raise and block the tractor up so the dr ive wheels are of f of the floor . W ARNING: Never work under the machine or att achment unless it is safely supported with jack stands. Make cert ain machine is secure when it is raised and [...]

  • Page 105

    10-27 106567 4/07 pump arms are stopping th e forward motion of the c ontrol arms, loosen the jam nut on the adjust able stop of the corresponding side and tu rn the stop (set screw) inward to stop the control levers slightly before the pump bottom s out. Lock in place when the adjustment is correct by re-tighten ing the jam nut. 3. Do this for eac[...]

  • Page 106

    10-28 106567 4/07 Park brake adjustment Occasionally check the park brakes and adjustment using the following method: 1. Position the control levers in the ne utral position. Disen gage the de ck clutch. W ARNING: Never work under the machine or att achment unless it is safely supported with jack stands. Make cert ain machine is secure when it is r[...]

  • Page 107

    10-29 106567 4/07 8. Rotate the tire and at the same time rotate the turnbuckle to sh or te n th e len gt h of th e brake linkage to incre a se the br ak e pr es sure. When you feel the brak e be gin to engage, stop adjusting th e turnbuckle. Re-tighten the jam nuts on the turnbuckle. 9. Place th e control lever in th e park brake slot FIG . 26. Th[...]

  • Page 108

    10-30 106567 4/07 Engine RPM setting The Hustler Z is designed so that the engine will ru n at 3600 rpm static pump load only . At this speed the hydraulic pum ps are runn ing at th eir max imu m rate d spe ed . Deck leveling and height adjustment The mower deck has three area s that may need to be checked and adjusted periodically . Before conside[...]

  • Page 109

    10-31 106567 4/07 4. Set cutting height at 3-1/2" in the height indicator by placing th e he igh t ad jus t ing s to p in the 3-1/2" hole , and tur nin g the he ig ht st op so that the pin side is against the stop handle FIG . 32 5. Clamp the height adjusting st op against the stop handle FIG . 32. This will assure that the height will no[...]

  • Page 110

    10-32 106567 4/07 7. Loosen the two nut s on the front of height indicator so that the foot pedal is free FIG . 36. 8. S tart the leveling process on the left front of the tract or . 9. Set the amount of threads protrudin g on the deck lift rod from the lift block at approximately 1" FIG . 37. 10. Jam both nuts ag ainst th e block. 1 1. Push o[...]

  • Page 111

    106567 4/07 i-1 Numerical Index Part Page No. No. Part Page No. No. Part Page No. No. Index Part Numbers 000323 5 - 1 3 000331 5 - 1 3 , 8-7 000430 5 - 1 5 005116 4 - 7 , 7-7 , 7-11 008193 4 - 1 1 012005 7 - 1 4 015495 4 - 5 , 4-11 , 7-3 , 7-7 , 7-11 015511 6 - 4 , 6-5 015818 5 - 1 3 016527 4 - 1 1 , 5-3 , 5-7 , 5-11 , 5-13 , 7-5 , 7-9 , 7-13 01689[...]

  • Page 112

    Part Page No. No. Part Page No. No. Part Page No. No. i-2 106567 4/07 600893 7 - 1 4 600899 9 - 3 600961 2 - 2 704163 4 - 7 704643 4 - 5 , 8-3 704742 3 - 3 704932 5 - 1 5 705137 5 - 1 1 705178 4 - 7 705186 3 - 3 705954 6 - 3 , 7-5 , 7-9 , 7- 13 712257 5 - 1 5 712919 5 - 1 3 712976 6 - 3 714998 5 - 1 5 720177 5 - 3 , 5-7 722199 8 - 7 724716 8 - 7 72[...]

  • Page 113

    106567 4/07 i-3 Part Page No. No. Part Page No. No. Part Page No. No. 787366 4 - 1 1 787689 5 - 7 787713 5 - 7 , 5-11 788018 5 - 1 1 788026 5 - 1 1 788166 7 - 3 , 7-7 , 7-11 788216 5 - 1 1 788943 5 - 3 , 5-11 788968 9 - 3 789131 5 - 3 , 5-7 , 5-11 789537 6 - 3 791251 4 - 1 1 791830 9 - 3 792002 7 - 5 , 7-9 , 7-13 792192 5 - 3 792762 5 - 3 793232 5 [...]

  • Page 114

    Part Page No. No. Part Page No. No. Part Page No. No. i-4 106567 4/07[...]