Hustler Z XR7 Parts Manual ••••••• Hustler Turf Equipment ••••• P.O. Box 7000 ••• Hesston, Kansas • 67062-2097 106567 Rev.
WARNING: The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. IMPORTANT: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate this engine on any forest-covered, brush-covered, or grass-covered unimproved land. Other states or federal areas may have similar laws. This spark ignition system complies with Canadian ICES-002.
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. . . . . . . . . . . .
Chapter 10 Maintenance & Adjustments Safety Precautions . . . . . . . . . . . . .10-3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-7 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-15 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 1 General Information This Manual covers Hustler XR7 Z models 927723, 927731, 927749, 927756, 927772, 927798, 927806, 927814. Frequently Ordered Parts PART NO. 027912 027920 768341 781443 797696 794685 798496 797928 797720 797936 068478 785261 785279 772079 785634 747303 DESCRIPTION Lubrizol 7 oz. Bottle Lubrizol 10 oz. Bottle Hydraulic Oil Filter Pump Drive Belt Blade, F18.50"-H-F-CW (54" Deck) Blade, F20.50"-H-F-CW (60" Deck) Blade, F22.
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.
106567 7/06 1-3
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Chapter 2 Contents Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rivet Nut Installation 1 2 2 2 3 5 2 4 3 INDEX NO. SERVICE PART NO. MFG. PART NO. QTY. 1 548032 107701 1 TRACTOR FRAME (54") 547760 106211 1 TRACTOR FRAME (60") 547752 106039 1 TRACTOR FRAME (66") N/A 808493 15 3/8-16 THREAD RIVET NUT 2 3 DESCRIPTION 3 N/A 600961 8 1/2-13 THREAD RIVET NUT 4 N/A 808477 2 1/4-20 THREAD RIVET NUT (KAW ONLY) 5 547950 106732 1 XR7 MMZ SEAT SUPPORT NOTES: 1. Seat support 547950 includes rivet nuts.
Footrest Assembly 1 2 3 4 5 6 5 7 1 INDEX NO. SERVICE PART NO. MFG. PART NO. QTY 1 359547 359547 2 2 395533 395533 1 FLOOR 3 305615 305615 2 PLATFORM STEP TREAD 4 086660 086660 2 NT .375-16 HX LK NY DESCRIPTION STEP TREAD 5 767954 767954 4 FW .406 X .812 X .060 SAE HD ZN 6 781880 781880 2 RUBBER BUMPER 7 052860 052860 2 CS .375-16 X 1.250 HX G5 ZN NOTES: 1. Do not tighten, Item 2 (348276 Floor) must be able to pivot on these bolts.
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Chapter 3 Contents Hydraulic System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic System Installation 4 2 3 17 1 16 19 15 20 5 31 18 17 8 6 FRONT 10 14 11 23 7 21 22 12 24 20 30 26 18 25 17 10 11 29 9 28 27 12 11 13 24 3-2 106567 7/06
Hydraulic System Installation ITEM NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 768515 768515 2 FW .281 X .625 X .051/.080 HD ZN/YL 2 055947 055947 2 CS .250-20 X .500 HX G5 ZN 3 032771 032771 1 STRAINER 4 032763 032763 1 BREATHER CAP 5 349860 349860 1 RESERVOIR 6 034272 034272 4 NT .312-18 HX G5 ZN 7 768523 768523 4 FW .343 X .687 X .051/.
HYDRAULIC SYSTEM CHARGING PROCEDURE 1. 2. 3. 4. 5. Set handles in the neutral position. Start engine at idle. Let run for a minimum of 30 seconds. Stroke handles to forward position. 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.
Chapter 4 Contents Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Steering and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Pump Belt and Pulley Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Installation 2 1 3 5 6 1 5 1 7 8 9 9 4 8 TRACTOR FRAME 10 11 11 12 4-2 106567 7/06
Battery Installation INDEX NO. SERVICE PART NO. MFG. PART NO. QTY 1 024927 024927 2 2 771428 771428 1 RED BATTERY CABLE BOOT 3 796219 796219 1 36" NEGATIVE BATTERY CABLE DESCRIPTION NT .250-20 HX GR.5 ZN 4 744276 744276 1 POSITIVE BATTERY CABLE 5 768523 768523 3 FW .343 X .687 X .051/.080 HD ZN/YL 6 058776 058776 2 NT .312-18 HX NL ZN 7 348417 348417 1 BATTERY CLAMP STRAP 8 055939 055939 2 CS .250-20 X .750 HX G5 ZN 9 029868 029868 4 LW .
Deck Lift Assembly 1 2 4 TRACTOR FRAME 6 5 3 4 5 5 11 12 10 4 1 5 6 5 10 1 7 13 10 8 4 1 4 5 4 10 1 9 8 9 4 14 8 4 9 4-4 106567 7/06
Deck Lift Assembly ITEM NO. 2 { SERVICE PART NO. MFG. PART NO. QTY 1 348318 348318 1 STOP HANDLE 2 600437 600437 1 DECK HEIGHT 1/2" PIN W/A 348284 N/A 1 HEIGHT ADJUSTMENT STOP 3/8" DESCRIPTION 3 783001 783001 1 DECK LIFT INDICATOR SUBASSEMBLY 4 704643 704643 8 NT .437-14 HX FLG ZN 5 781294 781294 7 CLIP E, 1.00 X .625 X .050 6 782995 782995 2 DECK LIFT SPRING SUBASSEMBLY 7 781229 781229 1 CE .750 X 2.25 X 1.75 HEADLESS 8 055749 055749 3 CS .437-14 X 1.
Steering and Park Brake Assembly 1 11 12 13 10 2 3 20 19 8 6 3 21 14 6 7 16 5 21 22 6 7 7 4 7 23 30 17 3 3 7 25 18 3 24 38 5 3 15 9 11 4 27 3 26 37 3 10 36 28 40 35 6 3 29 7 28 36 30 7 34 30 3 31 1 39 33 29 3 41 15 TRACTOR FRAME 32 2 4-6 106567 7/06
Steering and Park Brake Assembly ITEM NO. SERVICE PART NO. MFG. PART NO. QTY 1 2 781260 N/A 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 .375-16 X 1.750 HX G5 ZN 6 041152 041152 8 NT .312-24 HX ZN 7 768523 768523 18 FW .343X .687 X .051/.
NOTES: 1. 2. 3. 4. 5. 6. Torque to 350-375 ft.-lbs. Included with wheel motor. Torque brake assembly mounting bolts to 100 ft.-lbs. 781112 used on left wheel. 781351 used on right wheel. Includes Item 1 (781260 Steering Bar Grip). Use 783696 on mowers with serial numbers prior to 06071499.
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Pump Belt and Pulleys Installation TRACTOR FRAME 24 25 26 2 6 6 2 8 8 10 7 5 9 1 2 11 10 7 2 3 23 4 1 6 10 12 10 13 9 14 5 18 19 16 3 15 17 20 21 22 4-10 106567 7/06
Pump Belt and Pulleys Installation INDEX NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 779876 779876 1 ENGINE SC SINGLE PULLEY 2 212076 212076 1 KEY 1/4 SQ X 1.50 LONG 3 787366 787366 1 WARNER CLUTCH 4 783829 783829 1 FW .460 X 1.750 X .250 ZNYC 5 785659 785659 1 CS .437-20 X 2.50 HX G5 ZNYC 6 083196 083196 4 SS .312-18 X .750 SQ-HD ZN 7 768127 768127 2 KEY 5MM X 30MM RADIUS ENDS 8 325308 325308 2 PULLEY & FAN 9 008193 008193 2 NT .
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Chapter 5 Contents Kawasaki Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Honda Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Kohler Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Fuel System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Instrument Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kawasaki Engine Installation TO ENGINE SENSOR 2 YELLOW PART OF ENGINE 16 1 STARTER SELENOID GROUND 2 3 9 5 6 NEGATIVE BATTERY CABLE 7 TO SPADE TERMINAL TO BULLET 2 TERMINALS 8 2 2 RED/BLK 7 6 19 17 18 21 22 3 4 23 17 7 3 6 10 20 24 17 2 11 12 20 3 3 6 13 25 PURPLE 2 14 3 POSITIVE BATTERY CABLE 15 TRACTOR FRAME 26 3 27 23 3 15 28 29 3 31 30 38 PART OF COMMON WIRE HARNESS 9 32 37 36 34 1 39 35 33 5-2 106567 7/06
Kawasaki Engine Installation 5 6 7 106567 7/06 ITEM NO. SERVICE PART NO. MFG. PART NO. QTY 1 777656 777656 1 KAWASAKI 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 LW .312 INT-EXT TOOTH ZN 5 792762 792762 1 BATTERY CABLE 6 768515 768515 5 FW .281 X .625 X .051/.080 HD ZN/YL 7 024927 024927 3 NT .250-20 HX GR.
NOTES: 1. 2. 3. 4. Includes mounting hardware. Part of Item 8 (799312 Wire Harness Adapter). Engine oil capacity; 2 US quarts. Engine RPM to be set at 3600± 50. 5. 6. 7. 8. 23 HP engine used in 927723 and 927731 only. 25 HP engine used in 927772 and 927798 only. Includes one (1) of Item 17 (057661 Hose Clamp). 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. 10.
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Honda Engine Installation 1 PART OF ENGINE 2 YEL 2 BLK 10 8 2 3 4 BRN 3 GRA/PUR 5 7 NEGATIVE BATTERY CABLE 2 6 PUR 3 RED/BLK 12 3 ORG POSITIVE BATTERY CABLE 7 11 13 3 3 11 14 15 13 25 3 16 26 3 3 9 27 17 11 PART OF COMMON WIRE HARNESS 10 2 28 29 3 36 18 19 TRACTOR FRAME 20 3 22 16 3 33 8 9 30 21 24 23 3 31 35 1 32 16 7 8 34 8 5-6 106567 7/06
Honda Engine Installation ITEM NO. 6 SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 785014 785014 1 HONDA 24HP ENGINE 2 058776 058776 4 NT .312-18 HXZY NL 3 768523 768523 23 FW .343 X .687 X .051/.080 HD ZN/YL 4 799320 799320 1 COMMON WIRE HARNESS 5 029876 029876 1 LW .312 INT-EXT TOOTH ZN 6 077545 N/A 1 NT M8-1.25 X 10 HX ZNYC 7 017004 N/A 5 LW .312 MED SPRING ZN 8 799304 799304 1 WIRE HARNESS ADAPTER 9 050161 050161 4 CS .312-18 X 1.
7. Includes one (1) of Item 14 (057661 Hose Clamp). 8. Supplied with engine. 9. When installing lower hose clamp on air cleaner hose, install as low as possible (against carburetor inlet). 10. This connector used for optional hydraulic oil cooler fan. 11.
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Kohler Engine Installation 1 7 2 POSITIVE BATTERY CABLE 6 3 5 11 8 4 BLK 2 NEGATIVE BATTERY CABLE 12 9 4 13 10 PUR (P/O ENGINE) 4 14 RED/BLK 2 8 4 15 12 8 4 3 6 4 16 TRACTOR FRAME 17 23 24 19 4 26 25 18 4 14 6 6 4 20 1 27 PART OF COMMON WIRE HARNESS 2 21 22 14 29 24 28 5-10 106567 7/06
Kohler Engine Installation ITEM NO. SERVICE PART NO. MFG. PART NO. 1 788216 788216 1 KOHLER 27HP ENGINE 2 799320 799320 1 COMMON WIRE HARNESS 3 058776 058776 4 NT .312-18 HXZY NL 4 768523 768523 29 FW .343 X .687 X .051/.080 HD ZN/YL 5 029876 029876 1 LW .312 INT-EXT TOOTH ZN 6 050161 050161 4 CS .312-18 X 1.
Fuel System Installation 1 2 5 1 6 4 15 1 7 3 8 9 10 9 14 8 11 6 13 1 9 12 4 11 4 4 17 7 6 1 14 13 7 1 6 5-12 106567 7/06
Fuel System Installation ITEM NO. SERVICE PART NO. MFG. PART NO. 1 779306 779306 2 3.5" FUEL CAP 2 793240 793240 1 LEFT SIDE FUEL TANK 3 793232 793232 1 RIGHT SIDE FUEL TANK 4 000323 000323 6 CLIP 5 106732 N/A 1 REAR SEAT SUPPORT 6 055822 055822 12 CS .375-16 X .750 HX G5 ZN QTY DESCRIPTION 7 712919 712919 11 FW .406 X 1.00 X .12 HRD ZN 8 036244 036244 2 CS .375-16 X 1.000 HX G5 ZN 9 767954 767954 3 FW .406 X .812 X .
Instrument Panel Assembly 1 2 4 3 5 8 6 7 3 10 4 11 1 7 9 12 13 RIGHT SIDE FUEL TANK 14 13 12 FUSE SIZE AND LOCATION 10a 15a 15a 5-14 106567 7/06
Instrument Panel Assembly ITEM NO. SERVICE PART NO. MFG. PART NO. QTY 1 776476 776476 1 PTO SWITCH 2 083022 N/A 2 IGNITION KEY 2 785808 785808 1 INDAK COATED KEY 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 1 RED INDICATOR LIGHT 6 000430 000430 2 TIE STRAP 7 704932 704932 4 FW .219 X .500 X .048 ZN 8 714998 714998 2 MS #10-24 X .
Electrical Schematic (799320) 13 5-16 106567 7/06
Chapter 6 Contents Front Wheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Front Wheel Breakdown—747782. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Option Semi-Pneumatic Tire/Wheel Breakdown—789537 . . . . . . . . 6-5 Drive Wheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Anti-Rollover Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Wheel Assembly 1 2 TRACTOR FRAME 3 3 4 1 2 3 4 3 5 3 4 6 7 8 5 9 9 3 2 4 10 6 7 9 9 11 8 1 11 6-2 1 106567 7/06
Front Wheel Assembly INDEX NO. SERVICE PART NO. MFG. PART NO. QTY 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 712976 2 FW .531X 1.375X.125 ZNY 4 784223 784223 4 BEARING W/O COLLAR 5 387035 387035 2 SPACER, 1.07 X 1.312 X 2.793 6 045765 045765 2 FW 1.030 X 1.500 X.134 ZN 7 349266 349266 2 FORK 8 041475 041475 2 CS .750-10 X 9.50 HX ZN 9 025296 025296 4 FW .760 X 1.625 X .08 10 061101 061101 2 NT .
Front Wheel Breakdown—747782 1 2 1 3 4 1 5 6 ITEM NO. SERVICE PART NO. MFG. PART NO. QTY 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 SPACER 5 019521 N/A 1 TIRE VALVE 6 015511 N/A 1 GREASE FITTING 45 DEG 1/4 DESCRIPTION NOTES: 1. Inflate tire to 8-10 psi.
Optional Semi-Pneumatic Tire/Wheel—789537 2 1 3 4 1 ITEM NO. SERVICE PART NO. MFG. PART NO.
Drive Wheel Assembly Installation 1 6 1 5 2 3 4 2 INDEX NO. SERVICE PART NO. PART NO. QTY 1 784058 784058 2 2 781245 N/A 3 784066 N/A WHEEL ASSEMBLY 12 X 8.50 FOR 66" 4 019521 N/A TIRE VALVE 5 061077 061077 10 WHEEL NUT (QTY PER TRACTOR) 1 781237 781237 2 WHEEL & TIRE ASSY FOR 60" & 54" (QTY PER TRACTOR) 2 781245 N/A 3 781252 N/A 2 WHEEL ASSEMBLY 12 X 8.
Anti-Rollover Wheel Assembly 1 3 3 4 1 2 3 TRACTOR FRAME 1 3 2 INDEX NO. SERVICE PART NO. MFG. PART NO. QTY 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 DESCRIPTION NOTES: 1. Do not torque, wheel must turn freely.
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Chapter 7 Contents 66" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 66" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 60" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 60" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 54" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
66" Deck Assembly 2 6 5 4 5 4 3 7 1 13 14 8 10 12 11 9 7 14 15 4 1 12 9 12 8 11 10 11 7 10 9 9 16 12 8 11 10 8 16 8 9 11 4 7 5 7 9 10 8 7 16 18 4 7 17 } 20 4 19 Optional Anti-Scalp Wheels 7 7-2 106567 7/06
66" Deck Assembly INDEX NO. 3 SERVICE PART NO. MFG. PART NO. QTY 1 547737 103929 1 66" DECK CRATED 2 798694 798694 1 RUBBER CHUTE ASSEMBLY 3 052860 052860 2 CS .375-19 X 1.250 HX G5 ZN 4 767954 767954 22 FW .406 X .812 .060 SAE HD ZN 5 086660 086660 8 NT .375-16 HX LK NY 6 103010 103010 1 DISCHARGE CHUTE MOUNT BRACKET 7 781708 N/A 6 CS .500-13 X 4.25 HX G5 ZN 8 767962 N/A 12 FW .531 X 1.063 X .
66" Deck Pulley Assembly 1 2 4 3 4 6 9 5 10 4 7 8 13 15 16 4 11 12 4 14 18 16 17 19 20 21 2 17 22 23 17 24 30 BELT GUIDE INDEXING 17 25 26 27 28 30 7-4 1 29 106567 7/06
66" Deck Pulley Assembly ITEM NO. 1. 2. 3. 4. SERVICE PART NO. MFG. PART NO. QTY 1 797936 797936 1 B-SECTION BELT 2 025007 025007 1 CS .625-11 X 1.75 HX G5 ZNYC 3 347443 347443 1 DECK BELT IDLER GUIDE 4 028118 028118 5 FW .62 X 1.00X.134 ZN 5 781856 781856 1 5.00" IDLER PULLEY 6 797910 797910 6 CS .312-18 X 1.
60" Deck Assembly 2 4 5 6 5 4 3 1 4 8 7 12 9 10 12 7 8 15 16 4 13 11 4 5 14 17 4 4 16 1 14 5 4 14 9 10 7 11 11 18 13 8 4 12 10 8 14 11 11 9 8 4 6 8 10 4 9 11 7 12 9 7 10 9 7 18 5 4 20 } 19 22 21 Optional Anti-Scalp Wheels 4 5 7-6 106567 7/06
60" Deck Assembly INDEX NO. SERVICE PART NO. MFG. PART NO. QTY. 1 547745 314021 1 60" DECK CRATED 2 798694 798694 1 RUBBER CHUTE ASSEMBLY 3 052860 052860 2 CS .375-16 X 1.25 HX G5 4 767954 767954 30 FW .406 X .812 X .060 SAE HD ZN 5 086660 086660 18 NT .375-16 HX LK NY 6 103010 103010 1 DISCHARGE CHUTE MOUNT BRACKET 7 781708 N/A 6 CS .500-13 X 4.25 HX G5 ZN 8 767962 N/A 12 FW .531 X 1.063 X .
" Deck Pulley Assembly 1 2 3 4 9 6 10 4 5 4 7 13 8 11 15 4 12 15 4 16 17 14 18 2 16 19 20 17 21 22 17 60" DECK 17 23 28 24 25 26 27 28 BELT GUIDE INDEXING 30 29 7-8 1 106567 7/06
60" Deck Pulley Assembly ITEM NO. 1. 2. 3. 4. SERVICE PART NO. MFG. PART NO. QTY 1 797720 797720 1 B-SECTION BELT 2 025007 025007 1 CS .625-11 X 1.75 HX G5 ZNYC 3 347443 347443 1 DECK BELT IDLER GUIDE 4 028118 028118 5 FW .62 X 1.00X.134 ZN 5 781856 781856 1 5.00" IDLER PULLEY 6 797910 797910 6 CS .312-18 X 1.
54" Deck Assembly 2 4 14 5 9 4 14 7 10 16 3 1 8 11 4 3 17 12 13 4 5 1 4 10 15 8 8 4 5 12 17 11 10 9 13 11 12 4 18 9 16 13 4 12 10 12 11 11 9 8 13 5 10 13 9 11 4 13 10 9 18 6 19 } 21 4 20 Optional Anti-Scalp Wheels 5 7-10 106567 7/06
54" Deck Assembly INDEX NO. SERVICE PART NO. MFG. PART NO. QTY. 1 548008 103317 1 54" DECK CRATED 2 798694 798694 1 54" DISCHARGE CHUTE 3 052860 052860 8 CS .375-16 X 1.25 HX G5 ZN 4 767954 767954 30 FW .406 X .812 X .060 SAE HD ZN 5 086660 086660 18 NT .375-16 HX LK NY 6 N/A 808493 2 3/8-16 THREAD RIVET NUT 7 103010 103010 1 DISCHARGE CHUTE MOUNT BRACKET 8 N/A 808485 4 5/16-18 THREAD RIVET NUT 9 781708 N/A 6 CS .500-13 X 4.
54" Deck Pulley Assembly 1 3 9 10 4 12 4 6 13 7 8 11 2 4 15 14 2 4 5 17 18 16 2 31 19 54" DECK ASSY 5 31 20 21 31 31 22 26 27 25 29 23 24 28 BELT GUIDE POSITIONING 25 28 7-12 25 1 30 106567 7/06
54" Deck Pulley Assembly INDEX NO. 1. 2. 3. 4. SERVICE PART NO. MFG. PART NO. QTY. 1 797928 797928 1 B-SECTION BELT 2 016972 016972 2 NT .625-11 HX G5 ZNYC 3 025007 025007 1 CS .625-11 X 1.50 HX G5 ZN 4 028118 028118 5 FW .62 X 1.00 X .134 ZN 5 781385 781385 2 6.00" IDLER PULLEY 6 797910 797910 6 CS .312-18X1.
Spindle Assembly–796235 1 1 2 3 4 1 2 5 6 INDEX NO. SERVICE PART NO. MFG. PART NO. QTY. 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 GREASE FITTING 5 072272 N/A 1 FW 1.06 X 2.00 X.134 SAE ZN 6 796227 N/A 1 SADDLELESS SPINDLE SHAFT DESCRIPTION NOTES: 1. Install upper bearing with extended inner race up. 2. Install lower bearing with extended inner race down.
Chapter 8 Contents Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Deck Belt Routing and Tensioning. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deck Installation TRACTOR ASSEMBLY 1 4 2 3 5 DECK ASSEMBLY 5 8-2 106567 7/06
Deck Installation ITEM NO. SERVICE PART NO. MFG. PART NO. 1 055749 055749 4 CS .437-14 X 1.750 HX G5 ZN 2 061101 061101 2 NT .750-10 HX NL ZN 3 025296 025296 4 FW .760 X 1.625 X.08 ZN 4 051169 051169 2 CS .750-10 X 3.000 HX G5 ZN 5 704643 704643 8 NT .437-14 HX FLG ZN QTY DESCRIPTION NOTES: 1. 66" Deck installation is shown, 54" and 60" Deck installations are similar.
Deck Belt Routing and Tensioning DECK ASSEMBLY 1 8-4 106567 7/06
NOTES: 1. Spring length after tensioning belt. Measure spring from outside of hook to outside of hook. 2. Route belt as shown.
Seat Installation 17 8 16 14 5 15 1 3 3 4 4 5 1 7 2 1 6 8 13 5 4 10 11 12 9 5 8-6 106567 7/06
Seat Installation INDEX NO. SERVICES PART NO. MFG. PART NO. 1 793661 793661 1 MICHIGAN SEAT 2 350041 350041 1 SEAT PAN 3 000331 000331 3 BLACK CABLE TIE 4 086660 086660 3 NT .375-16 HX LK NY QTY DESCRIPTION 5 767954 767954 7 FW .406 X .812 X .060 SAE HD ZN 6 724716 724716 1 FIBER WASHER 7 350421 350421 1 SEAT PAN STOP 8 036244 036244 3 CS .375-16 X 1.000 HX G5 ZN 9 052860 052860 2 CS .375-16 X1.250 HX G5 ZN 10 768523 768523 4 FW .343 X .687 X .051/.
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Chapter 9 Contents Tractor Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 66" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 60" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 54" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tractor Decals A 17 6 4 8 2 1 5 3 TOP OF SEAT PAN A 9 10 BOTTOM OF SEAT PAN 11 12 13 14 15 7 9-2 106567 7/06
Tractor Decals 16 INDEX NO. SERVICE PART NO. MFG. PART NO. QTY.
66" Deck Decals 8 1 10 9 2 7 3 4 8 6 5 6 INDEX NO. SERVICE PART NO. MFG. PART NO. QTY. 1 799189 799189 1 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 BELT & PULLEY DECAL 6 727438 727438 2 WHIRLING BLADES DECAL 7 781419 781419 1 BELT ROUTING DECAL 8 799353 799353 2 DECK XR7 ID DECAL 9 359547 359547 1 5.00 X 9.
60" Deck Decals 8 1 10 2 9 7 3 4 8 6 5 6 INDEX NO. SERVICE PART NO. MFG. PART NO. QTY. 1 786277 786277 1 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 BELT & PULLEY DECAL 6 727438 727438 2 WHIRLING BLADES DECAL 7 799395 799395 1 BELT ROUTING DECAL 8 799353 799353 2 DECK XR7 ID DECAL 9 359547 359547 1 5.00 X 9.
54" Deck Decals 8 1 10 2 3 9 4 7 8 5 6 5 INDEX NO. SERVICE PART NO. MFG. PART NO. QTY. 1 799171 799171 1 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 BELT & PULLEY DECAL 6 727438 727438 2 WHIRLING BLADES DECAL 7 781419 781419 1 BELT ROUTING DECAL 8 799353 799353 2 DECK XR7 ID DECAL 9 359547 359547 1 5.00 X 9.
Chapter 10 Contents Maintenance & Adjustments Safety Precautions . . . . . . . . . . . . . . .10-3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-7 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SAFETY PRECAUTIONS ▲ ▲ This safety alert symbol is used to call attention to a message intended to provide a reasonable degree of PERSONAL SAFETY for operators and other persons during the normal operation and servicing of this equipment. DANGER – denotes immediate hazards which WILL result in severe personal injury or death. ▲ WARNING - denotes a hazard or unsafe practice which COULD result in severe personal injury or death. ▲ ▲ This manual uses two other words to highlight information.
Using a ramp regularly. ▲ Grass collection system components are subject to wear, damage and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check components and replace with manufacturer’s recommended parts, when necessary. ▲ Use only genuine Hustler replacement parts to ensure that original standards are maintained ▲ Use extreme caution when loading and unloading a unit with a ramp.
Safety and Instruction Decals ▲ Specific safety warning decals are located on the equipment near the immediate areas of potential hazards. These decals should not be removed or obliterated. Replace them if they become non-readable. The following illustrations show the various safety decals that are located on the machine. A brief explanation is shown to help the operator understand the meanings of these decals. Do not smoke while refueling. Do not fill tank with engine running, or while the engine is hot.
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MAINTENANCE MAINTENANCE LOCATOR CHART 6 7 12 11 5 11 9 3 16 10 4 1a 6 1b 1a. Engine Oil Fill & Dipstick (Kawasaki & Honda) 1b. Engine Oil Fill & Dipstick (Kohler) 2. Fuel Filter 3. Engine Air Cleaner 4. Engine Oil Drain Plug 5. Battery 6. Fuel Tanks 7. Hydraulic Oil Reservoir 8. Hydraulic Oil Filter 9. Gauge Wheel Bearing Zerks (2) 10. Engine Oil Filter 11. Deck Height Pivot Zerks (4) 12. Park Brake Switch 13. Drive Tire 14. Pump Idler Zerk (1) 15. Pump Belt 16.
MAINTENANCE LOCATOR CHART 54”/66”/72” XR7 deck 3 1 4 2 3 3 1 4 1. 2. 3. 4.
SERVICE AT INTERVALS INDICATED Verify safety start interlock system Visually inspect unit for loose hardware and/or damaged parts Visually inspect tires Check oil level, engine (1) Clean air intake screen (5) Check fuel level Blades - sharpen & securely fastened Discharge chute - securely in place & in lowest position Clean engine and pump compartment Replace air cleaner paper element (5) Grease deck idler Grease deck pusher arms Grease pump idler Grease deck height pivots Grease gauge wheel bearings Change
3. Grease the deck idler per the Maintenance Schedule. Use SAE multi-purpose grease. 4. Grease the pump idler per the Maintenance Schedule. Use SAE multi-purpose grease. 5. Grease the two deck pusher arm pivots per the Maintenance Schedule. Use SAE multi-purpose grease. 6. Grease the blade spindle assemblies per the Maintenance Schedule. The spindle assemblies require lubrication annually. Each spindle shaft is equipped with a grease zerk located under the deck.
system components. The system filter is located directly in front of the hydraulic reservoir. A standard oil filter wrench is used to change filter, threads are right handed. Use a Hustler approved filter element only. IMPORTANT: Prefill the filter element with clean oil, before installing, to prevent drawing air into the system pump. 1. Fill the filter element with clean system oil. Smear a light coating of oil on upper surface of rubber seal. 2. Install the filter element on base.
Right tank position Pre-cleaner Left tank position Fuel shut-off valve Closed position shown Canister Figure 10-8 Figure 10-10 Engine oil filler tube Engine oil drain plug Engine oil filter Kawasaki engine shown Figure 10-9 The oil drain and oil filter are located at the rear of the engine. Fig. 109 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.
Viewed from bottom for unit 1. Pump belt 2. Engine pulley 3. Pump idler pulley 4. Pump idler arm 5. Pump pulley 6. Electric deck clutch 7. Pump idler spring Reset button 1 5 5 Indicator 4 Figure 10-11 replacement parts is an “alteration” and will not be considered for warranty in the event of engine damage. 7 2, 6 3 Recommended service procedure 1. Release clamps and remove element. Clean the canister with a damp cloth. 2.
2 4 5 5 Resharpening Pattern 2 Do not sharpen to original pattern (below). It is easier to get a straight cutting edge following the resharpening pattern shown above. 2 6 3 5 1 1. 2. 3. 4. 5. 6. Deck Belt Drive Layout Spindle drive belt Deck blade spindle pulley Spindle belt tension idler Spindle belt tension idler spring (9.0" at operation) Deck belt idler Idler arm 60” XR7 deck Figure 10-14 Original Edge dull blade also requires more power from the engine.
ADJUSTMENTS Introduction Control lever in the neutral position Your Hustler Z was adjusted before it left the factory and was checked during predelivery setup. However, after start-up and continued use, a certain amount of break-in wear will cause some adjustments to change. Remain alert for unusual noises, they could be signaling a problem. Visually inspect the machine for any abnormal wear or damage. A good time to detect potential problems is while performing scheduled maintenance service.
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 tractor engine must NOT be running. 2. 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.
Control lever Park brake slot Outside edge Travel slot Bypass valve Figure 10-25 Figure 10-24 5. 6. 7. 8. 9. 10. 11. 12. 13. at this point. Move the control lever to where it is touching the outside edge of the lever’s travel slot. Fig. 10-25 NOTE: When the control lever is against the outside edge of the the slot, the brakes should not be engaged. Rotate the tire. If the brake is adjusted properly the tire will still rotate but friction will start to become noticeable here.
9. Set the amount of threads protruding on the deck lift rod from the lift block at approximately 1". Fig. 10-36 10. Jam both nuts against the block. 11. Push or pull on the deck lift foot pedal until the chain on the left front just becomes tight, making sure that the deck stays tight against the 4" block. 12. While keeping the chain tight, tighten the nuts against the deck lift block on the height indicator rod. Fig. 10-35 13. Go to the right front of the tractor. 14.
Stop handle Height adjusting stop 5/16” bolt Adjuster Jam nut Hardware Figure 10-34 Figure 10-31 Deck lift threaded rod Nut Foot pedal Nut Nuts Chains Figure 10-35 Figure 10-32 Deck lift assist springs Lift block Deck lift threaded rod 1” 1” Nut Nut Chains Deck lift rod Figure 10-36 Figure 10-33 106567_0706 10-19
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INDEX PAGE Access to engine and hydraulic pump..........................10-10 Adjustment introduction...............................................10-15 Belt replacement...........................................................10-13 Control lever adjustment ..............................................10-16 Control lever stops .......................................................10-15 Decals.............................................................................10-5 Deck drive belt adjustment.....
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Numerical Index Part No. Page No. Part No. Page No. Part No. Page No.
Part No. 600189 600221 600437 600899 600961 704163 704643 704742 704932 705137 705178 705186 705954 712257 712919 712976 714998 720177 722199 724716 727008 727016 727172 727420 727438 727453 727756 740696 742684 744276 747303 747741 747782 747832 748756 756270 760637 762195 763318 763946 763953 765339 766204 767954 767962 768127 768333 768341 768515 Page No.
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Part No. Page No. Part No. Page No. i-4 Part No. Page No.
