Home

Hustler Turf Z XR7 User's Manual

1. N Viewed from bottom of tractor FIG 1 10 8 106567 4 07 Maintenance 54 amp 66 XR7 deck 1 Deck Pusher Arm Zerks 2 2 Deck Belt 3 Spindle Housing Zerk 3 4 Blades 60 XR7 deck 10 9 106567 4 07 SERVICE AT INTERVALS INDICATED WEEKLY OR 50 HOURS MONTHLY OR 100 HOURS ANNUALLY OR 500 HOURS Verify safety start interlock system Visually inspect unit for loose hardware and or damaged parts Daily Daily Visually inspect tires Daily Check oil level engine 1 Daily or every 4 hours Clean air intake screen 5 Daily or every 4 hours Check fuel level Blades sharpen amp securely fastened Daily Daily Discharge chute securely in place amp in lowest position Daily Clean engine and pump compartment Daily Replace air cleaner paper element 5 As needed Grease deck idler Grease deck pusher arms Grease pump idler Grease deck height pivots Grease gauge wheel bearings Change engine oil and filter 1 4 Clean cylinder and head fins a Check battery connections Check tire pressure with a gauge Check hydraulic oil level Clean engine exterior a gt pa Pai pi P lt ai gt gt gt gt gt lt Clean amp regap spark p
2. Deck Belt Drive Layout 1 Spindle drive belt 2 Deck blade spindle pulley 3 Spindle belt tension idler 4 Spindle belt tension idler spring 54 amp 66 XR7 DECK 9 0 at operation Deck belt idler Idler arm Deck Belt Drive Layout 1 Spindle drive belt Deck blade spindle pulley Spindle belt tension idler Spindle belt tension idler spring 9 0 at operation 60 XR7 DECK 5 Deck belt idler 6 Idler arm D FIG 15 WARNING If the pump belt fails loss of control will occur especially when operating on a slope If you lose steering control while operating the machine place the steering control levers in the park brake position immediately Inspect the machine and involve your Hustler dealer to resolve the problem before continuing to operate Inspect the belt pulley grooves and flanges for wear A new belt or one in good condition should never run against the bottom of the groove Replace the pulley when this is the case otherwise belt will lose power and slip excessively Never pry a belt to get it on a pulley as this will cut or damage the fibers of the belt covering Keep oil and grease away from belts and never use belt dressings Any of these will destroy the belt composition in a very short time 10 21 106567 4 07 Mower blade maintenance Check the mower blades dai
3. o O 106567 4 07 7 2 66 Deck Assembly INDEX SERVICE NO PART NO EP 547737 2 798694 3 052860 4 767954 5 086660 6 103010 7 781708 8 767962 9 031997 10 053199 11 781567 12 808485 13 314104 14 015495 15 052860 16 025395 17 103713 18 N A EP 788166 MFG PART NO 103929 798694 052860 767954 086660 103010 N A N A N A N A 781567 808485 314104 015495 052860 025395 103713 808493 788166 QTY DESCRIPTION 1 66 DECK CRATED 1 RUBBER CHUTE ASSEMBLY 2 CS 375 19 X 1 250 HX G5 ZN 22 FW 406 X 812 060 SAE HD ZN 8 NT 375 16 HX LK NY 1 DISCHARGE CHUTE MOUNT BRACKET 6 CS 500 13 X 4 25 HX G5 ZN 12 FW 531 X 1 063 X 090 SAE HD ZN 6 ANTI SCALP WHEEL 6 NT 500 13 HX JAM ZN 6 NT 50 13 HX LK NY 4 5 16 18 THREAD RIVET NUT 1 PUSHER 2 STRAIGHT GREASE FITTING 6 CS 375 16 X 1 25 HX G5 6 CB 375 16 X 1 00 STD CD 2 66 AIR FLOW FLOOR 2 RIVET NUT 3 8 16 THREAD 4 ANTI SCALP WHEEL ASSY NOTES 1 Do not torque Item 2 349324 Discharge Chute must pivot freely 2 Includes 6 each of items 7 through 10 3 Service part deck includes decals see 66 Deck Decals in on page 4 for listing of decals 4 For optional anti scalp wheels order SERVICE INDEX NO Pant NO EP 788166 20 781567 106567 4 07 MFG PART NO 788166 781567 QTY 2 2 DESCRIPTION ANTI SCALP WHEEL ASSEMBLY NT 500 13 H8ZY NL 7 3 66 Deck Pulley Assembl
4. 348276 Floor must be able to pivot on these bolts 106567 4 07 2 3 2 4 106567 4 07 106567 4 07 Chapter 3 Contents Hydraulic System Installation 3 1 Hydraulic System Installation 3 2 106567 4 07 Hydraulic System Installation ITEM SERVICE MFG NO PART NO PART NO QIY 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 051 080 HD ZN YL 8 781062 781062 1 HYDRO GEAR PUMP BDP 10A 300 9 781047 781047 1 HYDRO GEAR PUMP BDP 10A 400 10 041707 041707 4 NT 437 14 HX G5 ZN 11 704742 704742 8 FW 453 X 812 X 060 ZN 12 781054 781054 2 ROSS PARKER WHEEL MOTOR MB 15 13 705186 705186 4 CS 437 14 X 1 375 HX G5 ZN 14 768341 768341 1 FILTER ELEMENT 15 768333 768333 1 FILTER HEAD 16 781575 N A 1 6STR 6 90 PUSHLOC HOSE 4 75 17 763946 N A 3 90 6 O RING 6 JIC FITTING 18 778985 N A 2 6STR 6 90 PUSHLOC HOSE 13 00 19 781591 N A 1 6STR 6 90 PUSHLOC HOSE 15 00 20 779132 N A 2 STR 6MORB 6JIC FITTING 21 781559 N A 1 45 8MORB 8MSL FITTING 22 781542 N A 1 90 8MORB 8MSL FITTING 23 781658 N A 1 STR 8 MORB HEX PLUG 24 781526 N A 4 90 10MORB 8MSL FITTING 25 781500 N A 1 RIGHT LOOP RP BM HYDRO TUBE 26 781492 N A 1 RIGHT LOOP LP TM HYDRO TUBE 27 781484 N A 1 LE
5. Major overhaul or repair of the starting motor or charging system should be performed by trained technicians only Access to engine and hydraulic pumps The hydraulic pumps are accessed by lifting the seat platform The seat platform is hinged at the front To raise it release seat latch and tilt seat platform up and forward The seat platform catch FIG 5 will prevent the seat from going all the way over However if more access is desired under the seat platform the seat platform catch can be raised allowing the seat to pivot more Make certain to place the control arms in the park brake position and pivot the arm rests upward before placing the seat platform in the full forward position to prevent arm rest damage EAT PLATFORM A WARNING Always wear adequate eye protection when servicing the hydraulic system and battery Hydraulic system IMPORTANT Never use hydraulic or automatic transmission fluid in this system use only motor oil as specified Remember dirt is the primary enemy of any hydraulic system WARNING Hydraulic oil escaping under pressure can penetrate skin Hydraulic oil may cause A infection in a minor cut or opening in the skin If exposed to hydraulic fluid see a doctor at once Before applying pressure to hydraulic system make sure all connections are tight and all hoses and lines are in good condition To find a leak under pressure use a piece of cardboard or wood never use your hands Relieve all pres
6. Repairs or maintenance requiring engine power should be performed by trained personnel only Use a stick or similar instrument to clean under the mower making sure that no part of the body especially arms and hands are under mower Exercise caution when working under the deck as the mower blades are extremely sharp Wearing gloves or wrapping the blade s is advisable when working around or with the blades Do not touch hot parts of machine Keep nuts and bolts tight especially the blade attachment bolts Keep equipment in good condition Never tamper with safety devices Check their proper operation 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 Using a ramp A A Use extreme caution when loading and unloading a unit with a ramp Use only a single full width ramp do not use individual ramps for each side of the unit Having a full width ramp provides a surface for the tractor frame to contact if the unit starts to tip backwards It also reduces the risk of a wheel going off and the machine tipping over A Do not exceed a 15 degree angle between the ramp and the ground or between the ramp and the trailer or truck A When on a ramp avo
7. Steering and Park Brake Assembly 4 6 Pump Belt and Pulleys Installation 4 10 Chapter 5 Kawasaki Engine Installation 5 2 Honda Engine Installation 5 6 Kohler Engine Installation 5 10 Fuel System Installation 5 12 Instrument Panel Assembly 5 14 Electrical Schematic 799320 5 16 Chapter 6 Front Wheel Assembly 6 2 Front Wheel Breakdown 747782 6 4 Optional Semi Pneumatic Tire Wheel 789537 6 5 Drive Wheel Assembly Installation 6 6 Anti Rollover Wheel Assembly 6 7 Chapter 7 66 Deck Assembly 7 2 66 Deck Pulley Assembly 7 4 60 Side Discharge Deck Assembly 7 6 60 Deck Pulley Assembly 7 8 54 Deck Assembly 7 10 54 Deck Pulley Assembly 7 12 Spindle Assembly 796235 7 14 Chapter 8 Deck Installation 8 2 Deck Belt Routing and Tensioning 8 4 Seat Installation ova e pae Lie pa dettes 8 6 Chapter 9 Trac
8. The mowing conditions will determine the frequency of air filter element changing Improper installation of an air filter element Dust must not leak past the seals on each end of the air filter element The filter must be aligned within the canister and properly seated for an effective seal so that no dirt can enter the engine Damaged filter seals or canister Never bang or bump the filter element against the tire or any solid object as dust and dirt particles will be forced through the media causing continual passing of dirt into the engine Visually inspect the outside of the air cleaner canister periodically for external damage and replace if necessary Incorrect air cleaner element Use only the correct Donaldson air filter element Hustler part number 785261 which is designed to fit the canister properly Hustler air filter elements have the correct media composition filter area micron size and dimensions Always use genuine Hustler filters Many aftermarket filters have been found to be incompatible with Hustler s canisters and engines The air filter must remain intact to block passage of dirt and foreign particles from entering the engine Being inclined to disbelieve the need for more expensive air filter elements used on gasoline engines may cause some individuals to opt for a less expensive part The filter element must be sufficient size and construction to withstand stresses caused by rapid cycling of the air volume dema
9. ground first and replace it last Do not overfill battery Whirling blades Keep hands Electrolyte may overflow and A DANGER and feet away damage paint wiring or structure Beware of thrown objects When cleaning the battery use soap and water Be careful not to m get soap and water into the battery Use soda mixed in water to clean corrosion off the terminals Never operate the mower deck with side deflector removed or in raised position except when the 10 6 106567 4 07 Do not remove or modify I Keep shields or covers in place AWARNING stabilizer wheels or rear engine A WARNING while machine is in operation moaty siobiizerwees guard or injury can result Keep hands away from rotating pulleys and belts Part Number 727453 Part Number 771436 If you lose steering control Keep engine and pump NINE white operating the machine compart ment s clean place the steering control levers especially in exhaust area to in the park brake position Part Number prevent fire and provide Part Number immediately Inspect the 788268 maximum engine and hydraulic an machine and involve your Hustler cooling dealer to resolve the problem before continuing to operate If pump belt fails steering FIT Hydraulic fluid escaping under control will be lost Refer to I pressure can penetrate skin owner s manual for inspection Hydraulic fluid may also cause and replacement intervals and Aw infection in a minor cut
10. 000331 PN 799197 QTY OO 2 N i Geh N A 20 0 0 N DESCRIPTION 3 5 FUEL CAP LEFT SIDE FUEL TANK RIGHT SIDE FUEL TANK CLIP REAR SEAT SUPPORT CS 375 16 X 750 HX G5 ZN FW 406 X 1 00 X 12 HRD ZN CS 375 16 X 1 000 HX G5 ZN FW 406 X 812 X 060 SAE HD ZN HOSE CLAMP 1 3 WAY NYLON FUEL VALVE FUEL SHUT OFF BRACKET CS 500 13 X 1 00 HX G5 ZN FW 531 X 1 063 X 090 SAE HD ZN FUEL LINE 45 5 FUEL LINE 26 5 FUEL LINE 22 5 KAWASAKI FUEL LINE 36 HONDA FUEL LINE 38 KOHLER BLACK CABLE TIE NOT SHOWN NOTES DESCRIPTION SZ HOSE ASSY SUCTION 5 13 Instrument Panel Assembl e Le FUEL TANK FUSE SIZE AND LOCATION 10a 15a 5 14 106567 4 07 Instrument Panel Assembly er ea DESCRIPTION 1 776476 776476 1 PTO SWITCH 2 785808 785808 1 IGNITION KEY SET 3 045898 045898 1 KEY SWITCH 4 785030 785030 i Z CHOKE CABLE KAWASAKI 786657 786657 1 Z CHOKE CABLE HONDA amp 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 625 HX ZN 9 059832 059832 2 NT 10 24 HX NL ZN 10 769166 769166 1 HOUR METER 11 778365 778365 1 THROTTLE CHOKE CABLE 12 055947 055947 3 CS 250 20 X 500 HX G5 ZN 13 768515 768515 3 FW 281 X 625 X 051 080 HD ZN YL 14 106633 106633 1 INSTRUMENT PANEL 026237 N A 6 RELAY NOT SHOWN 762195 N A 1 DELAY MODULE NOT SHOWN NOTES
11. 1 Partof 799320 Common Wire Harness 106567 4 07 5 15 Electrical Schematic 799320 a O Ss go E tx r Le Cio pe o fot lt co FE Ng gt of 4 J See EH VG d c EM N N mE NG E olo Y Er Lo gt a aalas LI Ng JIE pa SEN o xl N o es LU cc LUI ESE a oo 4 SS po d KS EE MAU MEN CHE gt 5 Dei DE m m 3 a 2 _ At ac po E 2 ori FEE 5 16 106567 4 07 106567 4 07 Chapter 6 Contents Front Wheel Assembly 6 2 Front Wheel Breakdown 747782 6 4 Optional Semi Pneumatic Tire Wheel 789537 6 5 Drive Wheel Assembly Installation 6 6 Anti Rollover Wheel Assembly 6 7 6 1 Front Wheel Assembl TRACTOR FRAME IN EN NN ca ANS N gt e He 49 Ho NY ke I 106567 4 07 6 2 Front Wheel Assembly INDEX SERVICE NO PART NO 705954 344267 712976 784223 387035 045765 349266 041475 025296 061101 747782 789537 0 o N O
12. 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 50FLT SH ZY 7 600189 600189 1 IDLER SLIDE UHMW RS 8 600171 600171 1 IDLER SLIDE UHMW LS 9 347443 347443 1 DECK BELT IDLER TOP GUIDE 10 781856 781856 1 5 00 IDLER PULLEY 11 350884 350884 1 DECK IDLER 12 373191 059931 1 SIDE MOUNT CHAIN 21 LINKS 13 781302 781302 1 IDLER SPRING 14 786335 786335 1 UHMW 03 THICK 15 103986 103986 1 RS 54 PULLEY COVER 16 103994 103994 1 LS 54 PULLEY COVER 17 016527 016527 3 CS 500 13 X 1 00 HX G5 ZN 18 752386 752386 3 CW 515X2 25X 204 ZN 19 798967 798967 3 DECK DRIVE PULLEY 20 705954 705954 12 CS 500 13X1 25 HX G5 ZY 21 767962 767962 12 FW 531X 1 063X 090 SAE 22 212472 212472 3 KEY 1 4 SQ X 1 00 LONG 23 796235 796235 3 DECK SPINDLE ASSY 24 797696 797696 3 BLADE F18 50 H F CW 797712 N A 3 OPTIONAL BLADE 18 50 GAT F CW 797704 N A 3 OPTIONAL BLADE 18 50 MUL F CW 25 782474 782474 5 CW 631 X 2 250 X 187 PNT 26 768523 768523 6 FW 343X 687X 051 080H 27 058776 058776 6 NT 312 18 HXZY NL 28 783738 783738 2 CS 625 11X3 00 FULL HX G5 ZN 29 769257 769257 1 FW 656X 1 250X 250 ZNY 30 029934 029934 3 CS 625 11 X 3 00 HX G5 ZNYC 31 792002 792002 4 5 16 18 X 3 4 MALE KNOB NOTES 1 Torque to 118 ft lbs 2 Torque to 65 75 ft lbs 3 Apply grease to zerk 4 See Deck Belt Routing and Tensioning in on page 4 for belt tensioning 5 See Spindle Assembly
13. 4 07 INTRODUCTION Regular maintenance is the best prevention for costly downtime or expensive premature repair The following pages contain suggested maintenance information and schedules which the operator should follow on a routine basis Remain alert for unusual noises they could be signaling a problem Visually inspect the machine for any abnormal wear or damage A good time to detect potential problems is while performing scheduled maintenance service Correcting the problem as quickly as possible is the best insurance Clear away heavy build up of grease oil and dirt especially in the engine and hydraulic reservoir areas minute dust particles are abrasive to close tolerance engine and hydraulic assemblies Daily inspect mower for grass clippings and wire and string tangles The underside of the mower deck will collect a build up of grass clippings and dirt especially when grass is wet or has high moisture content This build up will harden restricting blade and air movement and will probably show a poorer quality of cutting Therefore it should be removed routinely To do this it will be necessary to raise and block the deck in the full up position using jack stands or blocks and scrape the build up from underneath Some repairs require the assistance of a trained service mechanic and should not be attempted by unskilled personnel Consult your Hustler service center when assistance is needed Torque values nuts and blade spi
14. 7 5 7 9 6 6 4 11 6 3 8 3 4 7 5 3 4 7 4 7 6 7 1 1 4 7 7 14 5 7 8 7 5 15 4 11 9 3 2 3 4 7 7 3 7 7 7 41 8 7 7 3 7 7 7 11 7 7 7 11 7 9 7 9 7 11 7 11 7 3 7 5 7 5 7 3 7 13 7 13 2 2 2 2 5 15 2 2 5 13 2 2 4 11 7 5 7 9 7 13 2 3 727 Part No 314104 325308 344267 347443 347989 348284 348318 348391 348417 348458 348714 348755 348797 348862 348888 348946 348987 349266 349704 349761 349860 350041 350264 350272 350330 350371 350397 350421 350462 350884 359547 360693 365742 366443 366765 367557 373191 377994 382168 387035 395533 547737 547745 547752 547760 547950 548008 548032 600171 600189 600221 600437 Page No 7 3 7 7 7 11 4 11 6 3 7 5 7 9 7 13 5 13 4 5 4 5 4 5 4 3 4 5 4 7 4 7 4 7 4 7 4 7 4 7 4 7 6 3 5 3 4 11 3 3 8 7 4 7 4 7 4 7 5 3 4 7 8 7 8 7 7 5 7 9 7 13 2 3 9 4 9 5 9 6 5 3 5 7 5 11 5 3 5 7 5 11 4 11 4 7 7 5 7 9 7 13 5 11 5 7 5 11 6 3 2 3 7 3 7 7 2 2 2 2 2 2 7 11 2 2 7 5 7 9 7 13 7 5 7 9 7 13 4 7 4 5 600893 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 752386 756270 760637 762195 763318 763946 763953 7653
15. 781724 781732 781765 781831 781856 781880 781922 782128 782136 782318 782474 782573 782649 782664 782763 782771 782979 782995 783001 783696 783738 783829 784058 784066 784223 784702 784843 784918 784959 785014 785030 785188 785261 785279 785378 785477 785543 785634 785642 785659 785675 785741 785808 786038 786277 786335 786426 786657 786673 3 3 8 7 3 3 7 3 7 7 7 11 4 7 5 3 5 3 4 7 4 5 4 11 7 5 7 9 7 13 2 3 8 7 4 7 9 3 9 3 5 3 7 5 7 9 7 13 9 3 5 3 5 3 5 7 5 3 5 7 5 11 6 4 6 5 4 7 4 5 4 5 4 7 7 5 7 9 7 13 4 11 6 6 6 6 6 3 9 3 5 7 4 11 5 7 5 7 5 15 9 3 1 1 5 4 5 8 5 11 1 1 5 7 5 11 5 7 5 7 1 1 1 1 4 11 5 7 5 3 5 7 5 11 5 15 5 3 9 5 7 5 7 9 7 13 9 3 5 15 5 3 5 11 106567 4 07 Part No 787366 787689 787713 788018 788026 788166 788216 788943 788968 789131 789537 791251 791830 792002 792192 792762 793232 793240 793273 793307 793315 793331 793349 793356 106567 4 07 Page Part Page No 4 11 5 7 5 7 5 11 5 11 5 11 7 3 7 7 7 11 5 11 5 3 5 11 9 3 5 3 5 7 5 11 6 3 4 11 9 3 7 5 7 9 7 13 5 3 5 3 5 13 5 13 8 7 8 7 8 7 8 7 8 7 8 7 Part No 798496 798504 798512 798694 798967 798975 799171 799189 799197 799304 799312 799320 799353 799395 808477 808485 808493 927723 927731 927756 927772 927798 927806 9278
16. N DESCRIPTION STEERING BAR GRIP STEERING BAR FW 406 X 812 X 060 SAE HD ZN CS 375 16 X 1 000 HX G5 ZN CS 375 16 X 1 750 HX G5 ZN NT 312 24 HX ZN FW 343X 687 X 051 080 HD ZN YL STEERING ARM MOUNT STEERLEVER SUPPORT LH STEERLEVER SUPPORT RH CS 375 16 X 750 HX G5 ZN SS 500 13 X 1 75 SH ZN NT 500 13 HX JAM ZN STEERING CONTROL PANEL STEERLEVER BUSHING NT 375 16 HX LK NY BRAKE ROD ASSEMBLY CS 10 24 X 750 HXFLK ZN PUSH BUTTON SWITCH PUMP ROD ADJUSTER ASSEMBLY CENTERING DAMPER CENTERING DAMPER DAMPER BALL STUD CS 250 20 X 2 00 HX G5 ZN FW 281 X 625 X 051 080 HD ZN YL NT 250 20 HX NL ZN PUMP ARM ADJUSTABLE PIVOT BUSHING CS 375 16 X 1 375 HX G5 ZN NT 375 16 HX GRD 5 ZN NT 312 18 HX G5 ZN BRAKE DRUM HUB ASSEMBLY BRAKE ASSEMBLY BRAKE ASSEMBLY CS 312 18 X 1 000 HX G5 ZN BRAKE ARM EXTENSION L S BRAKE PIVOT ARM R S BRAKE PIVOT ARM BUSHING NT 10 24 HX NL ZN CS 375 16 X 4 75 HX G5 ZN ROSS CASTLE NUT BRAKE LINK TURNBUCKLE ROSS KEY 4 7 QE Oi CE NOTES Torque to 350 375 ft Ibs Included with wheel motor Torque brake assembly mounting bolts to 100 ft Ibs 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 4 8 106567 4 07 This page intentionally left blank 1065674 07 4 9 Pump Belt and Pulleys Installation T
17. Q OON o MFG PART NO 705954 344267 712976 784223 387035 045765 349266 041475 025296 061101 747782 N A o E lt N N N N N N N D N N DESCRIPTION CS 500 13 X 1 25 HX G5 ZN FW 510 X 2 15 X 187 SPL ZN FW 531X 1 375X 125 ZNY BEARING W O COLLAR SPACER 1 07 X 1 312 X 2 793 FW 1 030 X 1 500 X 134 ZN FORK CS 750 10 X 9 50 HX ZN FW 760 X 1 625 X 08 ZN NT 750 10HX NL ZN WHEEL amp TIRE ASSY OPTIONAL SEMI PNEUMATIC WHEEL TIRE ASSEMBLY 1065674 07 Apply grease to zerks Torque to 100 ft Ibs Assemble with extended inner race toward item 5 387035 Spacer 1 07 x 1 312 x 2 793 NOTES 6 3 Front Wheel Breakdown 747782 ITEM SERVICE MFG NO PART NO PART NO STE 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 SPACER 5 019521 N A 1 TIRE VALVE 6 015511 N A 1 GREASE FITTING 45 DEG 1 4 NOTES 1 Inflate tire to 8 10 psi 6 4 106567 4 07 Optional Semi Pneumatic Tire Wheel 789537 2 NG 4 ITEM SERVICE MFG NO PART NO PART NO SIX DESCRIPTION 1 039677 N A 2 WHEEL BEARING 2 789537 N A 1 TIREWHEEL ASSEMBLY 3 015511 N A 1 GREASE FITTING 45 DEG 1 4 4 782771 N A 1 BEARING SPACER NOTES 1065674 07 6 5 Drive Wheel Assembly Installation INDEX SERVICE NO PART NO PART NO QTY DESCRIPTION 1 784058 784058 2 WHEEL amp TIRE ASSY FOR 66 Q
18. Store gasoline in an approved container and keep it out of the reach of children Never buy more than a 30 day supply of gasoline Always place gasoline containers on the ground away from your vehicle before filling Do not fill gasoline containers inside a vehicle or on a truck or trailer as interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge When practical remove equipment from the truck or trailer and refuel the equipment with its wheels on the ground If this is not possible then refuel the equipment on the truck or trailer using a portable container and not a gasoline dispenser nozzle If a gasoline dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete WARNING Gasoline is harmful or fatal if swallowed Long term exposure to vapors can cause serious injury and illness Avoid prolonged breathing of vapors Keep face away from nozzle and gas tank or conditioner opening Keep gas away from eyes and skin Ge A awasaki Engine Shown W VIA FIG 7 FIG 8 The fuel tanks are located in the tractor s fenders FIG 7 Total capacity for the fuel tanks is 15 U S gallon 56 8 liter 10 16 106567 4 07 Use regular unleaded gasoline with an octane rating of 87 or higher The fuel filter FIG 8 is installed in the fuel line between fuel tanks and engine fuel pump Replace filte
19. assembly as an explosion may occur Welding can weaken or deform a wheel WARNING Explosive separation of a tire and rim can cause serious injury or death When inflating tires stand to one side and not in front of or over the tire assembly Check tires for low pressure blemishes damaged rims or missing lug bolts and nuts Hour meter To recognize when your machine needs servicing check the hour meter and the maintenance schedule The hour meter shows the number of hours the engine has run and the maintenance schedule lists the service intervals FIG 3 FIG 3 Lubrication _ Grease the front gauge wheel bearings per the Maintenance Schedule Use SA multi purpose grease Grease the four deck lift pivots located to the side of the operator s footrest per the Maintenance Schedule Use SAE multi purpose grease Grease the deck idler per the Maintenance Schedule Use SAE multi purpose grease Grease the pump idler per the Maintenance Schedule Use SAE multi purpose grease Grease the two deck pusher arm pivots per the Maintenance Schedule Use SAE multi purpose grease 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 Use no more than one or two ounces of SAE multi purpose grease 1 to 2 pumps on an average grease gun Do not force lubricant into grease zerks Bearings are sealed
20. is not adjustable FIG 24 2 Raise and block the tractor up so the drive wheels are off of the floor 3 Open the hydraulic pump s bypass valve FIG 25 on the side that is being adjusted by turning bypass valves counter clockwise one half to one revolution The valve stems on each hydraulic pump are located near the top and are identified as a hex stud le a ta FRONT BRAKE LINK acer SIDE k s FIG 24 FIG 25 4 Rotate the tire The tire should rotate Remember hydraulic oil resistance will prevent the tire from rotating freely even with the bypass valves open There should be no resistance from the brakes at this point 5 Move the control lever to where it is just inside 1 8 the park brake slot FIG 26 NOTE When the control lever is against the outside edge of the the slot the brakes should not be engaged 6 Rotate the tire If the brake is adjusted properly the tire will still rotate but friction will start to become noticeable here However if no brake resistance is noticed the brake needs adjusted as follows 7 Loosen the brake linkage jam nuts FIG 27 ATURNBUCKLER FIG 26 10 28 106567 4 07 8 Rotate the tire and at the same time rotate the turnbuckle to shorten the length of the brake linkage to increase the brake pressure When you feel the brake begin to engage stop adjusting the turnbuckle Re tighten the jam nuts on the turnbuckle 9 Place the control lever in the park brake sl
21. or opening refer to above paragraph for Part Number in the skin if exposed to hydraulic emergency procedures 727008 fluid see a doctor at once Before applying pressure to hydraulic system make sure all Hot surface connections are tight and all ES AWARNING hoses and lines are in good condition z Relieve all pressure in the system rt before disconnecting or working 779280 on hydraulic lines To find a leak under pressure use a piece of cardboard or wood never use your hands To relieve all pressure in system turn engine off and lower attachment 10 7 106567 4 07 Maintenance Maintenance Locator Chart 6 6 la Engine Oil Fill amp Dipstick Kawasaki amp Honda 1b Engine Oil Fill amp Dipstick Kohler 2a Fuel Filter Honda amp Kawasaki 2b Fuel Filter Kohler 3 Engine Air Cleaner 4 Engine Oil Drain Plug 5 Battery 6 Fuel Tanks 7 8 Hydraulic Oil Reservoir Hydraulic Oil Filter 9 Gauge Wheel Bearing Zerks 2 10 Engine Oil Filter 11 Deck Height Pivot Zerks 4 12 Park Brake Switch 2 13 Drive Tire 14 Pump Idler Zerk 1 15 Pump Belt
22. 0 5 ENGINE OIL A FILLER TUBE m a _ ENGINE OIL DRAIN PLUG nai Kawasaki Engine Shown 39 FIG 10 Engine air filter Perform engine air filter maintenance per the scheduled maintenance chart See SERVICE AT INTERVALS INDICATED on page 10 A specially designed dry filter is standard equipment on the Hustler Z and Super Z tractors and supplies clean combustion air to the engine FIG 11 ENGINE OIL FILTER E gt Kawasaki Engine Shown FIG 11 RECOMMENDED SERVICE PROCEDURE CARON Many engine failures can be attributed to improper air cleaner servicing Ingested dust and dirt will cause cylinder piston and bearing damage in a few hours Dusted engines will result from Overservicing the air filter element Improper installation Damaged filter seals or canister Incorrect air filter element size Use of poorly designed aftermarket air filter elements 10 18 106567 4 07 Air cleaner servicing is an inexpensive maintenance check that can prevent costly non warrantable premature engine damage Overservicing Overservicing occurs when an air filter element is removed for cleaning or replacement before it is necessary Each time the filter is removed a small amount of dirt and dust could fall in the intake system This accumulated dirt can cause a dusted engine It only takes a few grams of ingested dirt over the normal service life of an engine to cause a dusted engine Do n
23. 090 SAE HD ZN 11 053199 N A 6 NT 500 13 HX JAM ZN 12 781567 781567 6 NT 50 13 HX LK NY 13 031997 N A 6 ANTI SCALP WHEEL 14 015495 015495 2 STRAIGHT GREASE FITTING 15 314104 314104 1 PUSHER 16 005116 005116 4 CS 375 16X1 375 HX G5 17 103184 103184 2 REAR ANTI SCALP BRACKET 18 025395 025395 6 CB 375 16X 1 00 STD CD 19 103572 103572 2 54 AIR FLOW BAFFLE EP 788166 788166 6 ANTI SCALP WHEEL ASSEMBLY NOTES Do not torque Item 2 798694 Discharge Chute must pivot freely Includes items 9 10 11 and 13 Secure Item 11 053199 Jam Nut to bolt with a drop of Loctite 271 Red Tighten Item 11 to shank of Item 9 781708 Cs 500 13 X 4 25 Hx G5 Zn Anti scalp wheel must turn freely Assemble in top hole for shipping purposes Item 15 314104 Pusher installed as shown with zerks pointing upward apply grease to zerks Service part deck includes decals see 66 Deck Decals in on page 4 for listing of decals and item 2 Discharge Chute For optional anti scalp wheels order SERVICE MFG INDEX NO PART NO PART NO QTY DESCRIPTION EP 788166 788166 2 ANTI SCALP WHEEL ASSEMBLY 21 781567 781567 2 NT 500 13 H8ZY NL 106567 4 07 7 11 54 Deck Pulley Assembly 54 DECK ASSY A AR i e e n BELT GUIDE L Ag POSITIONING NG 7 12 106567 4 07 54 Deck Pulley Assembly INDEX SERVICE MFG NO PART NO PART NO QTY DESCRIPTION 1 797928 797928 1 B SECTION BELT 2 016972 016972 2 NT 625 11 HX G5 ZNYC
24. 14 Page No 1 1 7 5 7 5 7 5 7 3 7 7 7 11 7 13 7 5 9 6 9 4 5 13 5 7 5 3 5 3 5 7 5 11 5 15 9 4 9 5 9 6 9 5 2 2 7 3 7 7 7 11 2 2 7 3 7 7 7 11 5 4 1 1 5 4 5 7 1 1 5 4 5 4 1 1 5 11 1 1 106567 4 07
25. 14 781831 781831 1 CS 437 14 X 1 750 FUL THD G5 ZN NOTES 1 Apply grease to zerks see owner s manual 2 Verify pin diameter prior to ordering replacement part For mowers with 3 8 diameter pins order 348284 for mowers with 1 2 pins order 600437 Item 3 includes 600437 1 2 pin 1065674 07 4 5 Steerina and Park Brake Assembl 106567 4 07 Steering and Park Brake Assembly ITEM NO o o O A OON 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 IE 33 34 35 36 37 38 39 40 41 1065674 07 SERVICE PART NO 781260 348755 767954 036244 705178 041152 768523 348946 348888 348714 055822 781716 053199 348987 348862 086660 781583 063198 781211 781286 600221 783696 781922 704163 768515 068551 367557 348797 781153 005116 054502 034272 781765 781112 781351 036236 350272 350330 350264 765339 059832 782979 065516 350397 064337 MFG PART NO N A 348755 767954 036244 705178 041152 768523 348946 348888 348714 055822 781716 053199 348987 348862 086660 781583 063198 781211 781286 600221 783696 781922 704163 768515 068551 367557 348797 781153 005116 054502 034272 781765 781112 781351 036236 350272 350330 350264 765339 059832 782979 N A 350397 N A QTY a i N o 2 O e o N N N N NN FH FAN FH N O BN N N ANA D N N D N OO ND RO
26. 34272 6 NT 312 18 HX G5 ZN 14 782763 782763 1 AIR CLEANER 15 366443 366443 1 REMOTE AIR CLEANER MOUNT BRACKET 16 036236 036236 9 CS 312 18 X 1 HX G5 ZNYC 17 785675 785675 1 REMOTE AIR FILTER HOSE 18 787689 787689 1 HONDA OIL DRAIN VALVE 19 787713 787713 1 0 50 LOW PRESSURE HOSE 3 00 LONG 20 382168 382168 1 MUFFLER GUARD 21 377994 377994 1 MMZ ROLLER HEAT SHIELD 22 365742 365742 1 ENGINE CAGE MOUNT PLATE 23 767962 767962 6 FW 531 X 1 063 X 090 SAE HD ZN 24 016527 016527 6 CS 500 13 X 1 00 HX G5 ZNYC 25 017038 017038 2 LW 250 MED SPRING ZNYC 26 024927 024927 2 NT 250 20 HX GR 5 ZNYC 27 785477 N A 1 HONDA 20 AMP RECTIFIER 28 768515 768515 2 FW 281 X 625 X 051 080HD ZNYC 29 056077 056077 2 CS 250 20 X 1 00 HX G5 ZNYC 30 784843 784843 1 MUFFLER 31 720177 720177 2 CS M 8 1 25 X 20 10 9 HXFL ZN 32 785378 785378 1 1 50 MUFFLER CLAMP 33 785543 N A 2 HONDA 20 MUFFLER GASKET 34 782664 N A 4 NT M8 1 25 HX STAINLESS STEEL 35 784959 784959 1 MUFFLER MANIFOLD 36 789131 789131 1 HUSTLER Z FAN CONNECTION CAP NOTES Includes mounting hardware Part of Item 4 799320 Tractor Common Wire Harness Part of 8 799304 Wire Harness Adapter Engine oil capacity 2 3 US quarts with filter Engine RPM to be set at 3600 50 Used on 927756 only O de AS 106567 4 07 5 7 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 ag
27. 39 766204 767464 767954 767962 768127 768333 76834 1 768515 7 14 9 3 2 2 4 7 4 5 8 3 3 3 5 15 5 11 4 7 3 3 6 3 7 5 7 9 7 13 5 15 5 13 6 3 5 15 5 3 5 7 8 7 8 7 9 3 9 3 9 3 9 4 9 5 9 6 9 4 9 5 9 6 9 4 9 5 9 6 9 4 9 5 9 6 3 4 4 3 1 1 4 3 1 1 6 4 6 3 6 4 8 7 7 5 7 9 7 13 4 5 9 4 9 5 9 6 5 15 5 4 5 8 5 11 3 3 3 3 4 7 7 14 8 7 2 3 4 7 5 13 7 3 7 7 7 11 8 7 4 11 5 3 5 7 5 11 5 13 6 7 7 3 7 5 7 7 7 9 7 11 7 13 4 11 3 3 1 1 3 3 3 3 4 7 5 3 5 7 5 15 768523 769166 769257 770842 770859 771428 771436 772079 775353 776476 777656 778365 778423 778985 779132 779280 779306 779850 779876 780841 781047 781054 781062 781112 781153 781211 781229 781237 781245 781252 781260 781286 781294 781302 781351 781385 781419 781427 781443 781469 781476 781484 781492 781500 781518 781526 781534 781542 781559 781567 781575 781583 3 3 4 3 4 7 4 11 5 3 5 7 5 11 7 5 7 9 7 13 8 7 5 15 7 13 7 9 6 6 4 3 5 3 9 3 1 1 5 7 5 15 5 3 5 15 1 1 3 3 3 3 9 3 5 13 4 3 4 11 5 3 3 3 3 3 3 3 4 7 4 7 4 7 4 5 6 6 6 6 6 6 4 7 4 7 4 5 4 11 7 5 7 9 7 13 4 7 7 5 7 9 7 13 9 4 9 6 9 3 1 1 4 11 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 6 7 7 3 7 7 7 11 3 3 4 7 781591 781617 781658 781708 781716
28. 4 5 6 1 438 48 65 M6 7 7 10 4 500 73 99 M8 18 5 25 562 105 143 M10 37 50 625 145 200 M12 64 87 750 260 350 M14 80 108 5 875 420 565 M16 160 215 1 00 625 850 M20 320 435 M24 555 750 NOTE Loctite 592 to be used on all pipe threads Lubricate all grease zerks 1 2 106567 4 07 106567 4 07 Chapter 2 Contents Rivet Nut Installation Footrest Assembly 2 1 Rivet Nut Installation SERVICE MFG PART INDEX NO PART NO NO QTY DESCRIPTION 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 3 N A 600961 8 1 2 13 THREAD RIVET NUT N A 808477 2 1 4 20 THREAD RIVET NUT KAW ONLY ED 5 547950 106732 1 XR7 MMZ SEAT SUPPORT NOTES 1 Seat support 547950 includes rivet nuts 2 2 106567 4 07 Footrest Assembly INDEX SERVICE MFG NO PART NO PART NO TY DESCRIPTION 1 359547 359547 2 STEP TREAD 2 395533 395533 1 FLOOR 3 305615 305615 2 PLATFORM STEP TREAD 4 086660 086660 2 NT 375 16 HX LK NY 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
29. 500 13 X 1 25 HX G5 ZNYG FW 531 X 1 063 X 090 SAE HD ZN FW 343 X 687 X 051 080 HD ZN NT 312 18 HXZY NL KEY 1 4 SQ X 1 00 LONG SPINDLE HOUSING ASSEMBLY BLADE F22 50 H F CW OPTIONAL BLADE F24 50 H F CW OPTIONAL BLADE 22 50 MUL F CW CW 631 2 250 X 187 PNT CS 625 11 X 3 00 HX G5 ZNYC CS 625 11 X 3 00 FULL HX G5 ZN NOTES 5 See Spindle Assembly 796235 in on page 14 for breakdown 106567 4 07 7 5 60 Side Discharge Deck Assembl 7 6 106567 4 07 60 Side Discharge Deck Assembly SERVICE INDEX NO Pant NO gt 547745 2 798694 3 052860 4 767954 5 086660 6 103010 7 781708 8 767962 9 031997 10 053199 11 781567 12 808485 13 103184 14 005116 15 314104 16 015495 17 808493 EP 788166 MFG PART NO 314021 798694 052860 767954 086660 103010 N A N A N A N A 781567 808485 103184 005116 314104 015495 808493 788166 QTY DESCRIPTION 1 60 DECK CRATED 1 RUBBER CHUTE ASSEMBLY 8 CS 375 16 X 1 25 HX G5 30 FW 406 X 812 X 060 SAE HD ZN 24 NT 375 16 HX LK NY 1 DISCHARGE CHUTE MOUNT BRACKET 6 CS 500 13 X 4 25 HX G5 ZN 12 FW 531 X 1 063 X 090 SAE HD ZN 6 ANTI SCALP WHEEL 6 NT 500 13 HX JAM ZN 6 NT 50 13 HX LK NY 4 5 16 18 THREAD RIVET NUT 2 REAR ANTI SCALP BRACKET 4 CS 375 16 X 1 375 HX G5 ZNYC 1 PUSHER 2 STRAIGHT GREASE FITTING 2 3 8 16 THREAD RIVET NUT 4 ANTI SCALP WHEEL ASSY NOTES 1 Do not torque Item 2 798694 Discharge Chute must pivot freely 2 Incl
30. 796235 in on page 14 for breakdown 106567 4 07 7 13 Spindle Assembly 796235 INDEX SERVICE MFG NO PARTNO PARTNO TY 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 GREASE FITTING 5 600893 N A 1 BEARING DUST COVER 6 796227 N A 1 SADDLELESS SPINDLE SHAFT NOTES 1 Install upper bearing with extended inner race up 2 Install lower bearing with extended inner race down 7 14 106567 4 07 106567 4 07 Deck Installation Chapter 8 Contents Deck Belt Routing and Tensioning seen Seat Installation 8 1 Deck Installation TRACTOR ASSEMBLY DECK ASSEMBLY 8 2 106567 4 07 Deck Installation E ee UM DESCRIPTION 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 NOTES 1 66 Deck installation is shown 54 and 60 Deck installations are similar 106567 4 07 8 3 Deck Belt Routing and Tensionin 9 3 3 H DECK ASSEMBLY J d pu Td i n d cu Uk CA Z u 8 4 106567 4 07 NOTES 1 Spring length after tensioning belt Measure spring from outside of hook to outsi
31. 8515 5 FW 281 X 625 X 051 080 HD ZN YL 7 024927 024927 3 NT 250 20 HX GR 5 ZN 8 799312 799312 1 WIRE HARNESS ADAPTER 9 799320 799320 1 COMMON WIRE HARNESS 10 044255 044255 1 NT 10 32 HX ZN 11 030817 030817 1 STARTER SOLENOID 12 055947 055947 2 CS 250 20 X 500 HX G5 ZN 13 792192 792192 1 STARTER RELAY GROUND WIRE 14 771428 771428 1 RED BATTERY CABLE BOOT 15 050161 050161 4 CS 312 18 X 1 75 HX G5 16 786673 786673 1 DONALDSON AIR CLEANER CAP 17 057661 057661 3 HOSE CLAMP 18 788943 788943 1 AIR FILTER INDICATOR 19 785741 785741 1 MOUNTING BAND 20 034272 034272 6 NT 312 18 HX G5 ZN 21 782763 782763 1 AIR CLEANER 22 366443 366443 1 REMOTE AIR CLEAN MOUNT BRACKET 23 036236 036236 6 CS 312 18 X 1 00 HX G5 ZNYC 24 786038 786038 1 REMOTE AIR FILTER HOSE 25 796524 796524 1 OIL DRAIN M20 X 2 5 VALVE 26 350371 350371 1 MUFFLER GUARD 27 349704 349704 1 ENGINE CAGE MOUNT PLATE 28 767962 767962 6 FW 531 X 1 063 X 090 SAE HD ZN 29 016527 016527 6 CS 500 13 X 1 00 HX G5 ZN 30 064006 064006 2 CS 312 18 X 625 HX G5 ZN 31 781732 781732 1 MUFFLER MANIFOLD 32 781724 781724 1 MUFFLER 33 720177 720177 2 CS M 8 1 25 X 20 10 9 HXFL ZN 34 782649 782649 1 KAW 23 EXHAUST PIPE CLAMP 35 782664 782664 4 NT M8 1 25 HX STAINLESS STEEL 36 017004 017004 4 LW 312 MED SPRING ZN 37 360693 360693 1 HEAT SHIELD 38 780841 780841 2 KAW 23 MUFFLER GASKET 39 789131 789131 d HUSTLER Z FAN CONNECTOR CAP 106567 4 07 5 3 RD Ur Nr 9 NOTES Includes mount
32. BELT GUIDE INDEXING 106567 4 07 66 Deck Pulley Assembly ITEM NO ON OO Od BR Go N D N N ND N N N N gt AA GD NO OD G ND O O O Q ND o 28 29 30 NES SERVICE PART NO 797936 025007 347443 028118 781856 797910 600189 600171 373191 781302 350884 786335 103721 103739 016972 781385 792002 016527 752386 798975 705954 767962 768523 058776 212472 796235 798496 798512 798504 782474 029934 783738 Torque to 118 ft lbs Torque to 67 75 ft lbs Apply grease to zerk see owner s manual See Deck Belt Routing and Tensioning in on page 4 for belt tensioning MFG PART NO 797936 025007 347443 028118 781856 797910 600189 600171 059961 781302 350884 786335 103721 103739 016972 781385 792002 016527 752386 798975 705954 767962 768523 058776 212472 796235 798496 N A N A 782474 029934 783738 QTY 2 2 WWW PM ON 3 2 a a a 4 O 202 uu N N N O1 Od GO O Go GO O O DESCRIPTION B SECTION BELT CS 625 11 X 1 75 HX G5 ZNYG DECK BELT IDLER GUIDE FW 62 X 1 00X 134 ZN 5 00 IDLER PULLEY CS 312 18 X 1 50 FLT SH ZNYG RS UHMW IDLER SLIDE LS UHMW IDLER SLIDE SIDE MOUNT CHAIN 21 LINKS IDLER SPRING DECK IDLER 03 THICK UHMW RS 66 XR7 PULLEY COVER LS 66 XR7 PULLEY COVER NT 625 11 HX G5 ZNYC 6 00 IDLER PULLEY 5 16 18 X 3 4 MALE KNOB CS 500 13 X 1 00 HX G5 ZN CW 515X 2 25X 204 ZN B SEC 6 32 EOD PULLEY CS
33. ECAL FUEL INDICATOR DECAL Z OPERATION DECAL ENGINE COMPARTMENT DECAL Z ARMREST WARNING DECAL Z SERVICE DECAL BATTERY DECAL STABILIZER DECAL MADE IN USA DECAL TURF PROD SERIAL NO PLATE FIRST ZERO TURN DECAL HUSTLER NAME PLATE HUSTLER Z ID DECAL PUMP BELT WARNING DECAL NOTES 9 3 66 Deck Decals Va i E Hm a 10 i 2 i J gt E E wre om Besen 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 BELT amp 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 00 STEP TREAD 10 797845 797845 1 FUSION DECAL NOTES 9 4 106567 4 07 60 Deck Decals INDEX SERVICE MFG NO PART NO PART NO an DESERIETION 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 BELT amp 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 00 STEP TREAD 10 797845 797845 1 FUSION DECAL NOTES 106567 4 07 9 5 54 Deck Decals INDEX SERVICE MFG NO PART NO PART NO MER DESCR
34. FT LOOP RP BM HYDRO TUBE 28 781476 N A 1 LEFT LOOP LP TM HYDRO TUBE 29 781534 N A 2 STR 8MORB 8MSL FITTING 30 781518 N A 1 6STR 6STR PUSHLOC HOSE 9 00 31 763953 N A 1 6 O RING 6JIC 6JIC T FITTING N A 781469 1 MMZ HYDRAULIC KIT INCLUDES 16 31 NOTES 1 Add 3 5 oz Lubrizol 027912 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 3 032771 Strainer 106567 4 07 3 3 Note gi dee dM D HYDRAULIC SYSTEM CHARGING PROCEDURE 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 If motors do not turn after second attempt shut off the engine and check for oil at the pump Increase throttle to half apace and work handles through forward and reverse position until the motor operates smoothly throughout the entire speed range Seal Kit for hydraulic pump 727756 BDP10 Overhaul Seal Kit 3 4 106567 4 07 106567 4 07 Chapter 4 Contents Battery Installation 4 2 Deck Lift Assembly 4 4 Steering and Park Brake Assembly 4 6 Pump Belt and Pulleys Installation 4 10 4 1 Battery Installation TRACTOR FRA
35. Hustler ZXR7 Parts Manual HUSTLER P O Box 7000 Hesston Kansas 67062 2097 A WARNING A 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 Itis 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 The Engine Owner s Manual provides information regarding the U S Environmental Protection Agency EPA and the California Emission Control Regulation of emission systems maintenance and warranty Keep Engine Owner s Manual with your unit Should the Engine Owner s Manual become damaged or illegible re place immediately Replacements may be ordered per the information found in the Product Information section of the owner s manual Table of Contents Chapter 1 General Information cv suc ee E P las 1 1 Chapter 2 Rivet Nut Installation 2 2 Footrest A ssembly sira cid tegen tee e ited han ee eee 2 3 Chapter 3 Hydraulic System Installation 3 2 Chapter 4 Battery Installation 2222 desi beh te dent Je eos 4 2 Deck Lift Assembly 4 4
36. IPTION 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 BELT amp 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 00 STEP TREAD 10 797845 797845 1 FUSION DECAL NOTES 9 6 106567 4 07 106567 4 07 Chapter 10 Contents Maintenance Adjustment Safety 10 1 Safe Maintenance amp Adjustment Practices 10 2 Maintenance nara oa due sera Vin A EAS 10 6 POU STING T on etree ae AA a TT TT 10 23 10 1 1065674 07 Maintenance amp Adjustment Safety 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 IMPORTANT calls attention to special mechanical information and NOTE emphasizes general information worthy of special attention All operators should read this manual or be instructed about safe operating and maintenance pro
37. LER GUARD 19 365742 365742 1 ENGINE CAGE MOUNT PLATE 20 377994 377994 1 MMZ ROLLER HEAT SHIELD 21 016527 016527 6 CS 500 13 X 1 00 HX G5 ZNYC 22 767962 767962 6 FW 531 X 1 063 X 090 SAE HD ZN 23 029751 029751 2 CS 375 16 X 1 00 HXFLK ZNYC 24 705137 705137 4 FW 391 X 1 250 X 060 ZNYC 25 788018 788018 1 MUFFLER 26 788026 788026 1 MUFFLER MANIFOLD 27 785378 785378 1 1 50 MUFFLER CLAMP 28 016899 016899 2 NT 375 16 HXFLK ZNYC 29 789131 789131 1 HUSTLER Z FAN CONNECTION CAP NOTES Includes mounting hardware Part of Item 2 799320 Common Wire Harness Engine oil capacity 1 9 US quarts w filter Engine RPM to be set at 3600 50 Used on 927806 and 927814 only Supplied with engine Air filter service parts 785261 MAIN AIR FILTER ELEMENT 763318 VACUATOR VALVE RO ES ALIS 106567 4 07 5 11 Fuel System Installation VW J 106567 4 07 5 12 Fuel System Installation ITEM NO DJ o Om O ND St ei A Leti TO AR ON o SERVICE PART NO 779306 793240 793232 000323 106732 055822 712919 036244 767954 045088 797084 347989 016527 767962 015818 015818 015818 015818 015818 000331 1 Torque to 20 ft Ibs 2 Supplied with new fuel tank 3 Fuel tank service part not shown 106567 4 07 MFG PART NO 779306 793240 793232 000323 N A 055822 712919 036244 767954 045088 797084 347989 016527 767962 015818 015818 015818 015818 015818
38. MBLY ROUND STYLE W BRACKETS R H ARMREST ASSMBLY ROUND STYLE W BRACKETS ONE ARMREST ONLY ROUND STYLE W O BRACKET ARMREST STOP ASSY 8 7 8 8 106567 4 07 106567 4 07 Chapter 9 Contents Tractor Decals US Version 9 2 Tractor D cals CE Version 9 4 66 Deck Decals n Susann 9 6 60 Deck Decals US Version 9 7 60 Deck Decals CE Version 9 8 54 Deck Decals US Version 9 9 54 Deck Decals CE Version 9 10 9 1 Tractor Decals N J 0 TOP OF SEAT PAN 0 0 9 2 BOTTOM OF SEAT PAN 106567 4 07 Tractor Decals 106567 4 07 INDEX NO 0 M O Q Go ND mr YOU Aa ON o SL SERVICE MFG PART NO PART NO 781427 781427 779280 779280 784702 784702 727008 727008 791830 791830 782136 782136 788968 788968 785188 785188 782128 782128 727016 727016 771436 771436 727172 727172 N A 083279 782573 782573 793588 793588 786426 786426 600899 600899 QTY i i i y 4 i i DESCRIPTION DECK HEIGHT INDICATOR DECAL HOT amp HYDRAULIC OIL DECAL INSTRUMENT PANEL DECAL SEPARATE CHOKE HYD PRESSURE D
39. ME 4 2 106567 4 07 Battery Installation noe M ee DESCRIPTION 1 024927 024927 2 NT 250 20 HX GR 5 ZN 2 771428 771428 1 RED BATTERY CABLE BOOT 3 796219 796219 1 36 NEGATIVE BATTERY CABLE 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 250 INT EXT TOOTH ZN 10 740696 740696 1 BATTERY 11 034272 034272 2 NT 312 18 HX G5 ZN 12 779850 779850 2 CB 312 18X 3 00 FUL ZN NOTES 1 When performing service on mower disconnect battery ground cable and do not reconnect to battery until engine is ready to be started See Owners Manual 1065674 07 4 3 Deck Lift Assembl TRACTOR FRAME 4 4 106567 4 07 Deck Lift Assembly ee M dm DESCRIPTION 1 348318 348318 1 STOP HANDLE 2 600437 600437 1 DECK HEIGHT 1 2 PIN W A EP 348284 N A 1 HEIGHT ADJUSTMENT STOP 3 8 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 1 750 HX G5 ZN 9 348391 018846 4 DECK LIFT CHAIN 10 015495 015495 4 STRAIGHT GREASE FITTING 11 034272 034272 1 NT 312 18 HX G5 ZN 12 756270 756270 1 CS 312 18 X 1 50 FUL THR GR5 ZN 13 348458 348458 1 DECK LEVELER YOKE
40. RACTOR FRAME 106567 4 07 4 10 Pump Belt and Pulleys Installation BA Mo 1065674 07 pu P em 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 amp FAN 9 008193 008193 2 NT 500 13 HX G5 ZNYC 10 767962 767962 4 FW 531 X 1 063 X 090 SAE HD ZN 11 016527 016527 2 CS 500 13 X 1 00 HX G5 ZNYC 12 366765 366765 1 CLUTCH ANCHOR ANGLE 13 784918 784918 2 RUBBER BUMPER 14 349761 349761 1 PUMP IDLER ARM 15 015495 015495 1 STRAIGHT GREASE FITTING 16 025296 025296 1 FW 760 X 1 625 X 08 ZN 17 061101 061101 1 NT 750 10 HX NL ZN 18 781856 781856 1 IDLER PULLEY 19 028118 028118 1 FW 62 X 1 00 X 134 ZN 20 794446 794446 1 CS 625 11 X 1 50 HX G5 ZN 21 781302 781302 1 IDLER SPRING 22 781443 781443 1 A SEC PUMP IDLER BELT 23 791251 791251 1 HARNESS CLUTCH PIGTAIL DIODE 24 036236 036236 1 CS 312 18X1 000 HX G5 ZNYC 25 768523 768523 1 FW 343 X 687 X 051 080 HD ZNYC 26 034272 034272 1 NT 312 18 HX G5 ZNYC NOTES Torque to 45 48 ft lbs Torque to 12 15 ft lbs Apply grease at zerk see owner s manual Included with Honda 24 HP engine 785014 Electric clutch burnishing procedure After installing a new clutch it is import
41. TION BELT CS 625 11 X 1 75 HX G5 ZNYC DECK BELT IDLER GUIDE FW 62 X 1 00X 134 ZN 5 00 IDLER PULLEY CS 312 18 X 1 50 FLT SH ZNYC RS UHMW IDLER SLIDE LS UHMW IDLER SLIDE SIDE MOUNT CHAIN 21 LINKS IDLER SPRING DECK IDLER 03 THICK UHMW RS 60 XR7 PULLEY COVER LS 60 XR7 PULLEY COVER NT 625 11 HX G5 ZNYC 6 00 IDLER PULLEY 5 16 18 X 3 4 MALE KNOB CS 500 13 X 1 00 HX G5 ZN CW 515X 2 25X 204 ZN DECK DRIVE PULLEY CS 500 13 X 1 25 HX G5 ZNYC FW 531 X 1 063 X 090 SAE HD ZN FW 343 X 687 X 051 080 HD ZN NT 312 18 HXZY NL KEY 1 4 SQ X 1 00 LONG SPINDLE HOUSING ASSEMBLY BLADE F20 50 H F CW OPTIONAL BLADE 20 50 GAT F CW OPTIONAL BLADE 20 50 MUL F CW CW 631 2 250 X 187 PNT CS 625 11 X 3 00 HX G5 ZNYC CS 625 11 X 3 00 FULL HX G5 ZN NOTES 5 See Spindle Assembly 796235 in on page 14 for breakdown 106567 4 07 7 9 54 Deck Assembly Optional Anti Scalp Wheels 7 10 106567 4 07 54 Deck Assembly SERVICE MFG INDEX NO PART NO PART NO QTY DESCRIPTION 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 25 HX G5 ZN 10 767962 N A 12 FW 531 X 1 063 X
42. TY PER TRACTOR 2 781245 N A TIRE 12X 12 X 24 FOR 66 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 6 770859 N A 10 1 2 WHEEL LUG STUD 1 781237 781237 2 WHEEL 8 TIRE ASSY FOR 60 amp 54 QTY PER TRACTOR 2 781245 N A TIRE 12 X 12 X 24 FOR 60 amp 54 3 781252 N A 2 WHEEL ASSEMBLY 12 X 8 50 FOR 60 amp 54 4 019521 N A 2 TIRE VALVE 5 061077 061077 10 WHEEL NUT QTY PER TRACTOR 6 770859 N A 10 1 2 WHEEL LUG STUD 1 Torque to 65 75 ft lbs 2 Inflate tire to 8 10 psi NOTES 6 6 106567 4 07 Anti Rollover Wheel Assembly HE TRACTOR FRAME KOO 6 k NJ CE ee 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 NOTES 1 Do not torque wheel must turn freely 1065674 07 6 7 6 8 106567 4 07 106567 4 07 Chapter 7 Contents 66 Deck Assembly 7 2 66 Deck Pulley Assembly 7 4 60 Side Discharge Deck Assembly 7 6 60 Deck Pulley Assembly 7 8 54 Deck Assembly 7 10 54 Deck Pulley Assembly ooo 7 12 Spindle Assembly 796235 7 14 7 1 66 Deck Assembl 2 bo O ei i lt Es c
43. adjuster lift chain FIG 35 and back the adjuster bolt out to allow the adjuster to move up and down freely Be sure that adjuster is free to move up and down Tighten the adjuster bolt until the chain just becomes tight making sure that the deck stays tight against the 4 block Tighten the adjuster bolt jam nut to prevent the adjuster bolt from moving FIG 35 Tighten the hardware holding the chain and adjuster onto the deck lift arm Go to the right rear of the tractor Make sure that there is still slack in the chain If not loosen the two nuts on the block holding the threaded rod until there is slack in the deck lift chain FIG 34 Tighten the appropriate nut until the chain just becomes tight making sure that the deck stays tight against the 3 block Tighten the other nut on the opposite side of the block and jam them tightly together against the block Go to the left rear of the tractor Make sure that there is still slack in the chain If not loosen the two nuts on the block holding the threaded rod until there is slack in the deck lift chain FIG 33 Tighten the appropriate nut until the chain just becomes tight Tighten the other nut on the opposite side of the block and jam them tightly together against the block Compress the deck lift assist springs so that there is 1 of space between the front nut and on the spring and the rear nut on the deck lift block FIG 37 Typical b
44. ainst carburetor inlet 10 This connector used for optional hydraulic oil cooler fan 11 Air filter service parts 785261 MAIN AIR FILTER ELEMENT 763318 VACUATOR VALVE 5 8 106567 4 07 This page intentionally left blank 106567 4 07 5 9 Kohler Engine Installation x EA d J Na Y 2 A N NEGATIVE CABLE gr BATTERY N 9 CABLE UR P O ENGINE TRACTOR FRAME PART OF COMMON WIRE HARNESS y ES A M e 6 us Ne N N e N L X N N NS N 5 VAN No A we MR a L d e LAA p 5 10 106567 4 07 Kohler Engine Installation ITEM SERVICE MFG NO PART NO PART NO QTY DESCRIPTION EP 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 75 HX G5 7 786673 786673 1 DONALDSON AIR CLEANER CAP 8 057661 057661 3 HOSE CLAMP 9 788943 788943 AIR FILTER INDICATOR 10 782763 782763 1 AIR CLEANER 11 785741 785741 1 MOUNTING BAND 12 034272 034272 6 NT 312 18 HX G5 ZN 13 366443 366443 1 REMOTE AIR CLEANER MOUNT BRACKET 14 036236 036236 9 CS 312 18 X 1 00 HX G5 ZNYC 15 795310 795310 1 REMOTE AIR FILTER HOSE STRAIGHT 16 796672 796672 1 3 8 18 OIL DRAIN VALVE 17 787713 787713 1 0 50 LOW PRESSURE HOSE 18 382168 382168 1 MUFF
45. and do not require much lubricant m Oo Or ES 10 12 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 battery is recommended Other wise follow battery manufacturer s maintenance safety storing and charging specifications The battery is located under the seat platform FIG 4 gt gt WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling WARNING Avoid skin and clothing contact with battery acid Always wear eye protection when checking the battery acid can cause serious injury to skin and eyes If contact occurs flush area with clean water and call physician immediately Acid will also damage clothing Do not drink the battery electrolyte Do not allow open flame near the battery when charging Hydrogen gas forms inside the battery This gas is both toxic and flammable and may cause an explosion if exposed to flame Always remove the negative ground first and replace it last Do not overfill battery Electrolyte may overflow and damage paint wiring or structure When cleaning the battery use soap and water Be careful not to get soap and water into the battery Clean the battery terminals with a solution of four pa
46. ant 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 15 seconds and then off for 15 seconds Repeat this operation 10 times it will require about 5 minutes to complete 4 12 106567 4 07 106657 4 07 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 5 14 Electrical Schematic 99320 5 16 5 1 Kawasaki Engine Installation TO ENGINE PART OF SENSOR EN ENGINE IU ih STARTER SOLENOID 1 GROUND s I doo en x Boun A TO BULLET TERMINALS POSITIVE u CABLE 5 2 M b So gt A gt ST Ng a gt o Kk gt na TG d Pa 1 f H d a u d LU i Z I I hee e WIRE HARNESS EN 106567 4 07 Kawasaki Engine Installation Er ee de a DESCRIPTION EP 1 777656 777656 1 KAWASAKI 23 HP ENGINE ED 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 76
47. ator s station clean of accumulated trash grass clippings and other debris Always clean up spilled fuel and oil Always wear adequate ear protection such as earplugs when operating this equipment as prolonged exposure to uncomfortable or loud noises can cause impairment or loss of hearing Do not wear radios or music headphones while operating the machinery Safe operation requires your full attention A Never put hands or feet under any part of the machine while it is running A Except when changing or checking belt always keep belt covers on mower for safety as well as gt gt gt gt gt gt gt gt gt gt cleanliness Stop the engine before removing the grass catcher or unclogging the discharge chute Never clear the discharge chute with the engine running Turn off the engine and be sure the blades have stopped before cleaning Use a stick to clear a plugged discharge area Never use your hand Exercise caution when loading or unloading the machine onto a trailer or truck Always wear safety goggles or safety glasses with side shields when operating the mower Never leave machine unattended with ignition key in switch especially with children present Be alert and turn the machine off if children enter the area Always wear adequate eye protection when servicing the battery hydraulic system cooling system or when grinding mower blades and removing accumulated debris Use extra caution when handling gaso
48. cedures This is the owner s responsibility Improper use or maintenance by the operator mechanic or owner can result in injury To reduce the potential for injury comply with these safety instructions and always pay attention to the safety alert symbol which means DANGER or WARNING personal safety instructions Failure to comply with the instructions may result in personal injury or death Incorrect usage of this machine may result in severe injury Personnel operating and maintaining it should be trained in the proper use and should read the manuals completely and thoroughly before attempting to set up operate adjust or service this machine The Quick Reference Decals located in front of and to the right of the seat are designed to give the operator mechanic brief information needed in the daily operation and service of the machine These decals are not intended to be used in place of this manual but instead is to be used as an extension of this manual These decals should not be removed or obliterated Replace these decals if they become unreadable It is the owner s responsibility to make certain that the operator mechanic reads and understands this manual and all decals before operating this machine It is also the owner s responsibility to make certain that the operator mechanic is a qualified and physically able individual properly trained in the operation of this equipment Local regulations may restrict the age of the op
49. de of hook 2 Route belt as shown 106567 4 07 8 5 Seat Installation 75 f Ug e 106567 4 07 Seat Installation INDEX SERVICES MFG 1 NO PART NO PART NO SE DESCRIPTION 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 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 051 080 HD ZN Y 11 034272 034272 4 NT 312 18 HX G5 ZN 12 781880 781880 2 BUMPER 13 080358 080358 1 GM 50 X 1 00 X 75 X 12 GROMMET 14 748756 748756 1 LATCH SPRING PLUNGER 15 350462 350462 1 SEAT LATCH BRACKET 16 781617 781617 3 RUBBER BUMPER 17 722199 722199 1 2 WIDE SCOTCH POLYURETHANE 5 55 LONG NOTES Must pivot freely 2 Service parts available for Michigan Standard seat 106567 4 07 PART NO 793307 793315 793331 793349 793356 797456 767464 797472 797480 793273 DESCRIPTION SLIDE KIT SEAT SWITCH ARMREST KIT OPTIONAL SQUARE STYLE L H ARMREST ASSMBLY SQUARE STYLE W BRACKETS R H ARMREST ASSMBLY SQUARE STYLE W BRACKETS ARMREST KIT OPTIONAL ROUND STYLE L H ARMREST ASS
50. erator mechanic The owner should also ensure that the operator mechanic knows that they are responsible for their own safety as well as the safety of other persons within the vicinity Remember the operator mechanic is responsible for accidents or hazards occurring to other people or their property 10 3 106567 4 07 Safe Maintenance amp Adjustment Practices A This product is capable of amputating hands and feet and throwing objects Always follow all safety instructions to avoid serious injury or death A Unless specifically required DO NOT have engine running when servicing or making adjustments to gt gt tractor Place control levers in the park brake position disengage deck clutch remove ignition switch key and disconnect the negative battery cable Repairs or maintenance requiring engine power should be performed by trained personnel only To prevent carbon monoxide poisoning be sure proper ventilation is available when engine must be operated in an enclosed area Follow daily and weekly checklists making sure hoses are tightly secured and bolts are tightened Keep your machine clean and remove any deposits of trash and clippings which can cause engine fires and hydraulic overheating as well as excessive belt wear Clean up oil or fuel spillage Allow machine to cool before storing Clean flammable material from machine Prevent fires by keeping engine compartment battery hydraulic lines fuel line fuel tank and oper
51. ering is made with the adjustable pump linkage rods located between the control lever and pump arms FIG 20 Neutral is properly adjusted when the control levers are in the neutral position and the drive wheels are not turning 10 25 106567 4 07 bh x FA PUMP LINKAGE Da FIG 20 FIG 21 If the tractor creeps in the neutral position the control linkage may be adjusted as follows 1 A Bom Raise and block the tractor up so the drive wheels are off of the floor WARNING Never work under the machine or attachment unless it is safely supported with jack stands Make certain machine is secure when it is raised and placed on the jack stands The jack stands should not allow the machine to move when the engine is running and the drive wheels are rotating Use only certified jack stands Use only appropriate jack stands with a minimum weight rating of 2000 pounds to block the unit up Use in pairs only Follow the instructions supplied with the vehicle stands Position the control lever in the neutral position Disengage the deck clutch Start the engine and observe which way the wheels are rotating If wheel s are rotating forward loosen the jam nuts on the pump linkage rods and rotate the rod to lengthen the steering control linkage until the wheel s come to a stop FIG 20 Repeat for the opposite side if necessary NOTE The left linkage controls the left hydraulic pump and the right linkage controls the right hydraulic
52. g height at 3 1 2 in the height indicator by placing the height adjusting stop in the 3 1 2 hole and turning the height stop so that the pin side is against the stop handle FIG 32 5 Clamp the height adjusting stop against the stop handle FIG 32 This will assure that the height will not move during the setting process Otherwise spring pressure from the deck lift springs will tend to pull the stop away from the handle STOP HANDLE FIG 32 6 Loosen all nuts on the deck lift threaded rods and the hardware on the adjuster on the right front until all the deck lift chains are loose and the deck is sitting tightly on DECK LIFT 4 i HREADED ROD ex r v B Ares so A D all four blocks FIG 33 FIG 34 FIG 35 Dou 5 16 BOLT HARDWARE 10 31 106567 4 07 Loosen the two nuts on the front of height indicator so that the foot pedal is free FIG Start the leveling process on the left front of the tractor Set the amount of threads protruding on the deck lift rod from the lift block at approximately 1 FIG 37 Jam both nuts against the block 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 While keeping the chain tight tighten the nuts against the deck lift block on the height indicator rod FIG 36 Go to the right front of the tractor Loosen the 5 16 jam nut on the
53. he 10 26 106567 4 07 pump arms are stopping the forward motion of the control arms loosen the jam nut on the adjustable stop of the corresponding side and turn the stop set screw inward to stop the control levers slightly before the pump bottoms out Lock in place when the adjustment is correct by re tightening the jam nut 3 Do this for each side To adjust the stops for driving straight when control levers are against the stops during operation 1 Determine which drive tire is rotating too fast when both control levers are against the stops Then stop the tractor and loosen the lock nut on the side which is rotating too fast and turn the stop set screw inward to stop the control lever sooner Tighten the lock nut on the stop and test again Repeat this procedure until unit drives straight NOTE Since this is a hydrostatic drive variables such as temperature of oil efficiency of pumps and motors tire pressure etc may effect the consistency of the ability to rely on the stops to drive straight without the operator making minor steering adjustments with the control arms Steering dampener The steering dampener FIG 22 is spring loaded to return the control levers to the neutral position from the reverse position This gives the operator a sense of neutral during operation To set the steering dampeners in the correct operating position follow these steps Place the control lever in the neutral position Loosen the steering da
54. id sudden acceleration 10 5 106567 4 07 Safety and Instruction Decals A 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 expla nation for those requiring one is shown to help the operator understand the meanings of these decals Read Owner s Manual and Quick Reference Decal before attempting to operate this machine Do not smoke while refueling Do not fill tank with engine running or while the engine is hot Allow engine to cool before storing machine inside a building Store away from open flame or spark if there is fuel in tank Clean up any gasoline spills Do not refuel while in enclosed trailer or other enclosed areas Avoid skin contact with battery acid Always wear eye protection when checking the battery acid can cause serious injury to skin and eyes If contact occurs flush area with clean water and call Past Number physician immediately Acid will 727016 also damage clothing A WARNING Do not allow open flame near the battery when charging Hydrogen gas forms inside the grass catcher attachment is being battery This gas is both toxic Eart yom bet used and flammable and may cause an explosion if exposed to flame Always remove the negative
55. ilter seal makes contact with the filter head then tighten an additional 3 4 1 turn with an oil filter wrench DO NOT OVERTIGHTEN Start tractor engine and let run at approximately 2 3 throttle for a few minutes to work any trapped air out of the system before engaging the steering control lever Stop the engine and check the filter and connections for leaks Check the hydraulic reservoir for specified oil level Add clean oil as necessary Clean or replace hydraulic reservoir cap annually Cap may be cleaned by dipping in or flushing with cleaning solvent Follow manufacturer s instructions and warnings for application of solvent type selected 10 15 106567 4 07 Fuel system 72 a n eae IPUEL TANK DANGER Observe usual fuel handling precautions Do not smoke while refueling Do not fill tank with engine running or while engine is hot Clean up any gasoline spills Allow engine to cool before storing machine inside a building Keep fuel away from open flame or spark and store machine away from open flame or spark if there is fuel in the tank Use extra caution when handling gasoline and other fuels They are flammable and vapors are explosive A fire or explosion from gasoline can burn you and others and can damage property Refuel outdoors preferably or in well ventilated areas Never attempt to start engine when there is a strong odor of gasoline fumes present Locate and correct cause
56. ing hardware Part of Item 8 799312 Wire Harness Adapter Engine oil capacity 2 US quarts w filter Engine RPM to be set at 3600 50 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 This connector used for optional hydraulic oil cooler fan 10 Air filter service parts 785261 MAIN AIR FILTER ELEMENT 763318 VACUATOR VALVE 5 4 106567 4 07 This page intentionally left blank 106567 4 07 5 5 Honda Engine Installation PART OF ENGINE j Pai LE o gt POSITIVE UR BATTERY CABLE NEGATIVE BATTERY CABLE BD REDL PART OF COMMON WIRE HARNESS Ti TRACTOR FRAME 5 6 106567 4 07 Honda Engine Installation ITEM SERVICE MFG NO PART NO PART NO ene DESCRIPTION EP 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 75 HX G5 10 775353 775353 1 DONALDSON AIR CLEANER CAP 11 057661 057661 3 HOSE CLAMP 12 785741 785741 1 MOUNTING BAND 13 034272 0
57. line and other fuels They are flammable and vapors are explosive Never refuel tractor while engine is running never refuel near an open flame or near devices which can create a spark Refuel outdoors preferably or in well ventilated areas Never attempt to start engine when there is a strong odor of gasoline fumes present Locate and correct cause Never run the engine in an enclosed area unless exhaust is vented to the outside Exhaust gases contain carbon monoxide which is odorless and deadly poison Never attempt to make any adjustments or repairs to the tractor drive system mower deck or any attachment while the tractor engine is running or deck clutch is engaged Repairs or maintenance requiring engine power should be performed by trained personnel only Never work under the machine or attachment unless it is safely supported with jack stands Make certain machine is secure when it is raised and placed on the jack stands The jack stands should not allow the machine to move when the engine is running and the drive wheels are rotating Use only certified jack stands Use only appropriate jack stands with a minimum weight rating of 2000 pounds to block the unit up Use in pairs only Follow the instructions supplied with the vehicle stands Before working on or under the deck make certain engine cannot be accidentally started Shut engine 10 4 106567 4 07 Pb b b gt gt A off and remove ignition switch key for maximum safety
58. lugs a Check pump and deck belt tension and condition 6 Check fuel and hydraulic lines 7 Check fuel valve and grommet 7 Tighten lug nuts on wheels 2 gt lt lt gt Change fuel filter Clean or replace hydraulic fill cap Change hydraulic oil and filter 3 Grease deck spindle housings Replace spark plugs gt gt lt lt lt lt NOTES 1 Initial oil change is after 5 hours of operation Thereafter change oil after every 40 hours operation Change more often under dusty or dirty conditions and during hot weather periods 2 Torque initially and after first 2 hours of operation 3 Perform initial hydraulic filter change after 50 hours one week of operation 4 Change engine oil filter per the engine manufacturer s recommendations Refer to Engine Owner s Manual for recommendations and other maintenance items 5 Service more often under dusty or dirty conditions Use caution when servicing to prevent dust contamination in the engine Do not clean filter element Replace with a new one Pump drive belt only Inspect every 100 hours and replace if worn or cracking is noticed Otherwise replace every 400 hours or 2 years whichever comes first Check fuel line hoses fuel valve and grommets for any cracks or leaks REFERENCES a Refer to Engine Owner s Manual NOTE After completing maintenance cycle 500 hours repeat cycle 10 10 106567
59. ly they are the key to power efficiency and well groomed turf Keep them sharp a dull blade will tear rather than cut the grass leaving a brown ragged top on the grass within a few hours A dull blade also requires more power from the engine Replace any blade which is bent cracked or broken WARNING INever attempt to straighten a bent blade by heating or weld a cracked or broken blade as the blade may break and cause serious injury DANGER INever work with blades while engine is running or deck clutch switch is engaged on Always place deck clutch switch in the disengaged position place control levers in the park brake posi tion and turn engine off and disconnect negative battery cable Block up mower when you must work under it Wear gloves when handling blades Always check for blade damage if mower strikes rock branch or other foreign object during mowing WARNING Always wear adequate eye protection when grinding mower blades Mower blade removal Use a 15 16 wrench to remove the 5 8 cap screw holding the blade to the spindle shaft from underneath Sharpen the blades on a grinder following pattern as shown FIG 16 Touch up sharpening can be done with a file Check the blades for balance following grinding A commercial balancing tool is available through most hardware supply stores or balancing can be done by placing the blade on an inverted line punch or 1 2 bolt Blade should not lean or tilt Spin the blade slo
60. m 76 cm originally with adjustments of 60 15 2mm per chain link FIG 30 IMPORTANT Do not over tension the spring to compensate for a badly worn belt or pulley 10 29 106567 4 07 ENSION IDLER J SPRING EXTENSION L 9 0 d ER S z i NN FIG 31 FIG 29 Engine RPM setting The Hustler Z is designed so that the engine will run at 3600 rpm static pump load only At this speed the hydraulic pumps are running at their maximum rated speed Deck leveling and height adjustment The mower deck has three areas that may need to be checked and adjusted periodically Before considering any mower deck leveling adjustments check that the tire air pressure is within the specified range Deck level adjustments Leveling the deck must be done in the following manner and order 1 Check tire pressures to make certain they are properly inflated before starting to level deck The recommended pressures are as follows Drive wheels tire pressure 8 12 psi Gauge wheels tire pressure 8 12 psi WARNING Stop engine Make sure deck clutch switch is in the down OFF position Place control levers in the brake position before leaving machine 2 Park the unit on a flat surface 3 Raise deck and place 3 block under the back of the deck and a 4 block under the front of the deck FIG 31 This will set the cutting height at 3 1 2 NOTE Back of deck will automatically be set 1 4 higher 10 30 106567 4 07 4 Set cuttin
61. mpener s front ball stud Pull the dampener spring housing pass the point that the internal spring is engaged Release the dampener spring housing and allow the internal spring to bring the housing back to the neutral position Tighten the nut on the steering dampener s front ball stud ao BINA 7 SPRING HOUSING lt 4 FIG 22 FIG 23 Control lever adjustment The control levers can be adjusted for operator comfort By loosening the cap screws that attaches the upper control lever to the lower lever FIG 23 the upper control lever can be pivoted to fit the operator s personal preference The control levers should be adjusted so that they align with each other when in the neutral position 10 27 106567 4 07 Park brake adjustment Occasionally check the park brakes and adjustment using the following method 1 Position the control levers in the neutral position Disengage the deck clutch WARNING Never work under the machine or attachment unless it is safely supported with jack A stands Make certain machine is secure when it is raised and placed on the jack stands The jack stands should not allow the machine to move when the engine is running and the drive wheels are rotating Use only certified jack stands Use only appropriate jack stands with a minimum weight rating of 2000 pounds to block the unit up Use in pairs only Follow the instructions supplied with the vehicle stands NOTE The front brake link
62. nded by the engine without cracking or tearing under fatigue and pressure especially diesel engines Therefore Hustler Turf Equipment and the engine manufacturers have carefully selected a reliable filter designed to fit the needs of the engines The filter specified is a Donaldson filter Hustler part number 785261 Owners should be reminded that failure to use original equipment replacement parts is an alteration and will not be considered for warranty in the event of engine damage 10 19 106567 4 07 Recommended service procedure 1 2 oar w Release clamps and remove element Clean the canister with a damp cloth Before installing a new element inspect it by placing a bright light inside and rotate the element slowly looking for any holes or tears in the paper Also check gaskets for cuts or tears Do not attempt to use a damaged element which will allow abrasive particles to enter the engine Reinstall the dust cup Make sure it seals all the way around the air cleaner body then tighten the clamps Check all fittings and clamps periodically for tightness and inspect hoses for holes or cracks Periodically check the intake hose for signs of ingested dust Locate and repair the source of ingested dirt Never operate a machine without an air filter installed Air restriction indicator Any unit with a Kohler or Kawasaki engine will have an air restriction indicator installed in the air cleaner FIG 12 Replace the elemen
63. ndle bolts Failure to correctly torque these items may result in the loss of a wheel WARNING Particular attention must be given to tightening the drive wheel lug nuts wheel motor A or blade which can cause serious damage or personal injury Torque values are given below Ft Ibs Nm Wheel lug NU S een 65 75 88 14 101 7 Wheel motor Nut aasa 290 310 393 2 420 4 Blade spindle bolt top 65 75 88 14 101 7 Blade spindle bolt bottom Bees 160 01 It is recommended that these be checked after the first 2 hours of operation initially every 50 hours and following removal for repair or replacement For all other torques refer to the various tractor parts manuals for standard torque charts NOTE For engine torque values see engine owner s manual 10 11 106567 4 07 Tires It is important for level mowing that the 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 any machine with solid filled tires the warranty claim will be denied Do not attempt to mount a tire without the proper equipment and experience to perform the task Always maintain the correct tire pressure and never over inflate Never weld or heat a wheel and tire
64. ome 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 Correcting the problem as quickly as possible is the best insurance Clear away heavy build up of grease oil and dirt especially in the area of reservoir and oil and engine combustion air minute dust particle are abrasive to close tolerance engine and hydraulic assemblies Some repairs require the assistance of a trained service mechanic and should not be attempted by unskilled personnel Consult your Hustler service center when assistance is needed Steering linkage The neutral adjustment for the control levers in the neutral position is discussed in this section The tractor steering has been factory adjusted to eliminate creeping when the control levers are in the neutral position FIG 19 However should the tractor begin to creep the control lever linkage can be adjusted as follows CONTROL LEVER IN HE NEUTRAL POSITIONS EB PARK BRAKE SLOT Control Lever Neutral Adjustment Before considering any adjustment check the tire air pressure and make certain hydraulic system oil is at operating temperature Unequal tire pressure will cause the tractor to drift to one side Refer to tire pressure information in the Maintenance section of this manual Fine adjustment to the unit s ste
65. ot FIG 26 The tire should not rotate when the control lever is in the park brake position 10 Place the control lever in the neutral position The tire should rotate freely 11 Close the hydraulic pump s bypass valve 12 Repeat steps 3 thru 11 for the other side 13 Remove the jack stands and lower the unit It is now ready to operate Hydraulic pump belt adjustment The pump drive belt tension remains constant by means of a tension idler and spring FIG 28 There is no tension adjustment of this belt NOTE Replace the belt every 400 hours or every two 2 years whichever comes first WARNING If the pump belt fails loss of control will occur especially when operating on a slope If A you lose steering control while operating the machine place the steering control levers in the park brake position immediately Inspect the machine and involve your Hustler dealer to resolve the problem before continuing to operate SPRING N b Wey MS AN Deck drive belt adjustment The spindle belt tension remains constant by means of a tension idler and spring FIG 29 The spring tension should be such that the belt does not slip under normal operating load conditions assuming the belt is not excessively worn or damaged As belt stretches and wears in adjustment may become necessary To increase belt tension move the spring chain one or more link s at the anchor bracket FIG 29 Installed spring length should be 9 0 3 22 8 c
66. ot clean element replace with a new element only Cleaning used air filter elements through improper cleaning procedures can get dust on the inside of the filter causing dirt ingestion and engine failure It is important to note that whenever an air filter element is cleaned by any method the person or company performing the cleaning assumes responsibility for the integrity of the filter from then on The Donaldson warranty for air filters expires upon cleaning or servicing in any manner because the condition of the filter after servicing is completely out of their control Therefore on a dust ingested engine failure there will be no warranty consideration if the air filter element has been cleaned or serviced in any manner A partially dirty air filter element works better than a new element Therefore a dirty filter element is not bad for the engine unless it is excessively restricting the air flow and engine performance is affected The reason is simple The media in the filter must be porous to allow air to pass through it When dirty air passes through the filter the dirt plugs some of the holes in the media and actually acts as part of the filter media When the next round of dirt enters the first dirt helps filter out even smaller particles making the filter more efficient at stopping dirt from entering the engine This is referred to as barrier filtration Of course at some point the filter media becomes too clogged to allow air to pass
67. oth sides When completed all chains will be tight and deck cutting height will be set to the deck height indicator FOOT PEDA E PALIFT BLOCK memi cO lim FIG 37 10 32 e DECK LIFI ROD 106567 4 07 Numerical Index Part No Index Part Numbers 000323 000331 000430 005116 008193 012005 015495 015511 015818 016527 016899 016972 017004 017038 018846 019521 024927 025007 025296 025395 026237 027912 027920 028118 029751 029868 029876 029934 030817 031997 032763 032771 034272 034843 036236 036244 039677 041152 041475 041707 044255 045088 045765 045898 050161 051169 106567 4 07 Page Part No 5 13 5 13 8 7 5 15 4 7 7 7 7 11 4 11 7 14 4 5 4 11 7 3 7 7 7 11 6 4 6 5 5 13 4 11 5 3 5 7 5 11 5 13 7 5 7 9 7 13 5 11 7 5 7 9 7 13 5 3 5 7 5 7 4 5 6 4 6 6 4 3 5 3 5 7 7 5 7 9 7 13 4 11 6 3 8 3 7 3 7 11 5 15 1 1 3 3 1 1 4 11 7 5 7 9 7 13 5 11 4 3 5 3 5 7 5 11 7 5 7 9 7 13 5 3 6 7 7 3 7 7 7 11 3 3 3 3 3 3 4 3 4 5 4 7 4 11 5 3 5 7 5 11 8 7 7 14 4 7 4 11 5 3 5 7 5 11 4 7 5 13 8 7 6 4 6 5 4 7 6 3 3 3 5 3 5 13 6 3 5 15 5 3 5 7 5 11 8 3 Page 2 3 7 3 7 7 7 11 8 7 4 7 7 3 7 7 7 11 4 7 4 5 8 3 4 7 5 13 4 3 3 3 5 3 5 15 5 7 5 3 5 7 5 11 4 3 5 3 5 7 5 11 7 5 7 9 7 13 4 7 5 15
68. pump If wheel s are rotating in reverse then loosen the jam nuts on the pump linkage rods and rotate the rod to shorten the steering control linkage until the wheel s come to a stop FIG 20 Repeat for the opposite side if necessary NOTE The left linkage controls the left hydraulic pump and the right linkage controls the right hydraulic pump When both wheels remain in neutral tighten the jam nuts to lock the turnbuckle in place Test again by moving the control levers forward and backward before returning them to the neutral position If the tires are in neutral the unit is now ready for operation After adjusting for neutral it may be necessary to re adjust the control lever stop FIG 21 Control lever stops The control lever stops FIG 21 are designed to do two things First and most important they must keep the pumps from bottoming out internally Secondly the stops may be adjusted to help drive straight when the control levers are pushed forward against the stops To keep the pumps from bottoming out internally use the following procedure 1 2 To make the first adjustment the tractor engine must NOT be running Check to make sure the control levers are against the stops before the pumps are bottomed out internally To do this gently and slowly move the control levers forward and feel if there is some resistance on the pump lever before the control levers hit the stops Check one side at a time If you sense that t
69. r annually or after every 500 hours of operation whichever occurs first When replacing the fuel filter check the fuel line hoses and fuel shut off valve grommet for any cracks or leaks Replace as needed Hustler Z tractors are equipped with a fuel shutoff valve located on the right fuel tank mount FIG 9 Rotate the valve to the middle position shown to prevent fuel flow to the fuel pump The forward position allows fuel to flow from the right fuel tank to the fuel pump The rear position allows fuel to flow from the left fuel tank to the fuel pump Close this valve to prevent fuel flow to the engine when servicing the fuel system or when transporting the unit on a trailer or truck RIGHT TANK POSITION TEM EFT TANK 3 SEE FUEL SHUT OFF Nay VALVE CLOSED NA POSITION SHOWN D P4 FIG 9 Engine oil and filter Check engine oil daily and after every 4 hours of operation Crankcase dipstick and oil filler tube are located at the rear of the machine FIG 10 Tractor must be sitting level when checking oil Refer to engine manual and maintenance schedule for oil recommendation and capacities Change the engine oil and filter after the first 5 hours of operation per the engine manufacturer s recommendations after that If tractor is being operated in extremely dirty conditions then it is recommended oil be changed more frequently 10 17 106567 4 07 The oil drain and oil filter are located at the rear of the engine FIG 1
70. rts water and one part baking soda when they become corroded WARNING Shorts caused by battery terminals or metal tools touching metal tractor components can cause sparks Sparks can cause a battery gas explosion which will result in personal injury Prevent the battery terminals from touching any metal tractor parts when removing or installing the battery Do not allow metal tools to short between the battery terminals and metal tractor parts 10 13 106567 4 07 This can cause sparks which can cause a battery gas explosion which will result in personal injury Always disconnect the negative black battery cable before disconnecting the positive red cable Always connect the positive red battery cable before connecting the negative black cable WARNING Incorrect battery cable routing could cause damage to the tractor and battery cables Common circuit failures are usually caused by shorting corroded or dirty terminals loose connections defective wire insulation or broken wires Switches solenoids and ignition components may also fail causing a shorted or open circuit Before attempting any failure diagnosis of the electrical system use a test light or voltmeter to check the battery voltage Ifthe battery voltage is satisfactory check the cleanliness and tightness of the terminals and ground connections A general understanding of electrical servicing and use of basic test equipment is necessary for troubleshooting and repair
71. 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 neces sary without notification If a change has been made to your machine which is not reflected in this parts manual see 106567 4 07 1 1 your Hustler dealer for current information and parts Hardware Description Codes amp Abbreviations The following codes are used throughout this parts manual Refer to this list when ordering parts ABBREVIATION DESCRIPTION CB Carriage Bolt CE Clevis Pin CP Cotter Pin CS Cap Screw CW Cup Washer FDRW Fender Washer FW Flat Washer HX Hex Head LW Lock Washer MB Machine Bushing MS Machine Screw NT Nut SC Self Tapping Cap Screw SH Socket Head SB Shoulder Bolt SS Set Screw OD Outside Diameter ID Inside Diameter Standard Torques The following chart lists the standard torque values for the threaded fasteners found in this manual Torque all cap screws nuts and set screws to these values unless a different torque is shown in the Notes section next to the fastener SIZE FT LBS NM SIZE FT LBS NM 250 8 2 11 1 M3 1 1 3 312 17 23 M4 2 2 3 375 30 40 M5
72. sure in the system before disconnecting or working on hydraulic lines To relieve pressure lower all attachments and shut off engine The 1 0 U S gallon 3 79 liter hydraulic reservoir is located in front of the engine and under the operator s platform FIG 6 10 14 106567 4 07 Check oil level in hydraulic system after every 50 hours of operation or weekly whichever occurs first Check more often if system appears to be leaking or otherwise malfunctioning Fluid level should be 1 from top of reservoir Use only SAE 10W40 SG SF CC CD service motor oil Change hydraulic system filter element FIG 6 after first 50 hours of tractor operation then replace filter and oil in reservoir every 500 hours thereafter When changing hydraulic oil use 1 2 unit approximately 3 5 oz of Lubrizol additive Hustler P N 027912 This additive available from your Hustler dealer will increase the performance life of the hydraulic 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 Fill the filter element with clean system oil Smear a light coating of oil on upper surface of rubber seal Install the filter element on base Tighten the oil filter by hand until the f
73. t whenever the restriction indicator shows reaches the change filter red line Check the indicator daily and replace element as needed or annually whichever occurs first Reset the indicator by pushing in on the yellow button after each element change FIG 12 A restriction indicator takes the guesswork out of air cleaner servicing and allows you to safely benefit from the filter s optimum performance General engine maintenance Detailed instructions and recommendations for break in and regular maintenance are specified in the Engine Owner s manual Please refer to this manual for engine servicing lubricating oil levels with quality and viscosity recommendations bolt torques etc The engine warranty is backed by the manufacturer Special attention should be paid to applicable data which will not be duplicated here Belt replacement FIG 13 FIG 14 amp FIG 15 show diagrams and descriptions of the unit s belt drive systems Inspect these belts frequently for wear and serviceability Replace a belt that shows signs of severe cuts tears separation weather checking and cracking or burns caused by slipping Slight raveling of belt covering does not indicate failure trim ravelings with a sharp knife 10 20 106567 4 07 VIEWED FROM f BOTTOM OF UNIT H Pump belt N Engine pulley Pump idler pulley Pump idler arm Pump pulley Electric deck clutch Pump idler spring
74. tor Decals nor aue ca ea na alab a pan NG dia ila ge 9 2 66 Deck Decals na hah ahah hha AMAYA Ana BA kn de 9 4 60 Deck Deoalea a aani et ig tct ele Ma S teu e hd a ok 9 5 547 Deck Decanos dix ets e ER ae dote Ge poi 9 6 106567 4 07 c 1 Chapter 10 Maintenance amp Adjustment Safety 10 3 Safe Maintenance Adjustment Practices 10 4 EN ne EE EE 10 8 ARISMENDI a e ar 10 25 1 1 c 2 106567 4 07 Chapter 1 General Information This Manual covers Hustler XR7 Z models 927723 927731 927749 927756 927772 927798 927806 927814 with serial numbers prior to 07020000 Frequently Ordered Parts PART NO DESCRIPTION 027912 Lubrizol 7 oz Bottle 027920 Lubrizol 10 oz Bottle 768341 Hydraulic Oil Filter 781443 Pump Drive Belt 797696 Blade F18 50 H F CW 54 Deck 794685 Blade F20 50 H F CW 60 Deck 798496 Blade F22 50 H F CW 66 Deck 797928 Belt B Section 54 Deck 797720 Belt B Section 60 Deck 797936 Belt B Section 66 Deck 068478 Fuel Filter 785261 Main Air Filter Element 785279 Safety Air Filter Element 772079 Kawasaki Engine Oil Filter 785634 Honda Engine Oil Filter 747303 Kohler Engine Oil Filter Service Literature PART NO DESCRIPTION 600876 Owner s Manual 785642 Honda 18 20 24 Engine Owner s Manual 778423 Kawasaki 19 25 hp Engine Owner s Manual 742684 Kohler Engine Owner s Manual Note When ordering parts you must use the part number as
75. udes items 7 8 9 and 10 3 Service part deck includes decals see 60 Deck Decals in on page 5 for listing of decals 4 For optional anti scalp wheels order SERVICE INDEX NO PARTNO EP 788166 22 781567 106567 4 07 MFG PART NO 788166 781567 QTY 2 2 DESCRIPTION ANTI SCALP WHEEL ASSEMBLY NT 500 13 H8ZY NL 7 7 60 Deck Pulley Assembly L B ES NN NN BELT GUIDE INDEXING 7 8 106567 4 07 60 Deck Pulley Assembly ITEM NO ON OO Od BR Go N D N N ND N N N N gt AA GD NO dl G ND O O Om ND o 28 29 30 NES SERVICE PART NO 797720 025007 347443 028118 781856 797910 600189 600171 373191 781302 350884 786335 103192 103200 016972 781385 792002 016527 752386 770842 705954 767962 768523 058776 212472 796235 794685 794230 794214 782474 029934 783738 Torque to 118 ft lbs Torque to 65 75 ft lbs Apply grease to zerk see owner s manual See Deck Belt Routing and Tensioning in on page 4 for belt tensioning MFG PART NO 797720 025007 347443 028118 781856 797910 600189 600171 059961 781302 350884 786335 103192 103200 016972 781385 792002 016527 752386 770842 705954 767962 768523 058776 212472 796235 794685 N A N A 782474 029934 783738 QTY Q CO CQ d Q D a a aa 2 2 2 3 O1 da ak Kr N N DH GO 0 CO G DA O WI O DESCRIPTION B SEC
76. wly blade should not wobble If blade is out of balance true it up before reinstalling Lay the blade on a flat surface and check for distortion FIG 17 and FIG 18 Replace any distorted blade Do not re use spindle bolts which have stripped worn or undercut threads Torque bolts to 118 foot pounds when reinstalling blades WARNING When mounting blades rotate them after installation to ensure blade tips do not touch each other or sides of the mower WARNING Failure to correctly torque the bolt may result in the loss of the blade which can cause serious injury WARNING Mower blades are sharp and can cut Wrap the blade s or wear gloves and use extra caution when servicing them PPP 10 22 106567 4 07 Straight Blade Replace Comparison of Warped and Straight Blades 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 Twisted Blade Edge replace Cutting Plane Cutting edge Straight Blade Edge End view of blades comparing twisted and straightened blades FIG 18 Original edge FIG 16 10 23 106567 4 07 This page intentionally left blank 10 24 106567 4 07 Adjustment Introduction 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 s

Hustler Turf Z XR7 User's Manual

Contents

Download Pdf Manuals

Related Search

Related Contents