Hustler Z XR7 Parts Manual ······· Hustler Turf Equipment ····· P.O. Box 7000 ··· Hesston, Kansas · 67062-2097 106567 Rev. 7/06 WARNING: The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. IMPORTANT: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate this engine on any forest-covered, brush-covered, or grass-covered unimproved land. Other states or federal areas may have similar laws. This spark ignition system complies with Canadian ICES-002. 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, replace 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Chapter 2 Contents Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Chapter 3 Contents Hydraulic System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Chapter 4 Contents Battery Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering and Park Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . Pump Belt and Pulleys Installation . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 5 Contents Kawasaki Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Honda Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kohler Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Schematic (799320) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 6 Contents Front Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Wheel Breakdown--747782 . . . . . . . . . . . . . . . . . . . . . . . . . Optional Semi-Pneumatic Tire/Wheel--789537 . . . . . . . . . . . . . . . Drive Wheel Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . Anti-Rollover Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 7 Contents 66" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spindle Assembly­796235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4-4 4-6 4-10 5-2 5-6 5-10 5-12 5-14 5-16 6-2 6-4 6-5 6-6 6-7 7-2 7-4 7-6 7-8 7-10 7-12 7-14 Chapter 8 Contents Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Deck Belt Routing and Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Seat Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Chapter 9 Contents Tractor Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106567 7/06 c-1 9-2 9-4 9-5 9-6 Chapter 10 Maintenance & Adjustments Safety Precautions . . . . . . . . . . . . .10-3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-7 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-15 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1 c-2 106567 7/06 Chapter 1 General Information This Manual covers Hustler XR7 Z models 927723, 927731, 927749, 927756, 927772, 927798, 927806, 927814. Frequently Ordered Parts PART NO. 027912 027920 768341 781443 797696 794685 798496 797928 797720 797936 068478 785261 785279 772079 785634 747303 DESCRIPTION Lubrizol 7 oz. Bottle Lubrizol 10 oz. Bottle Hydraulic Oil Filter Pump Drive Belt Blade, F18.50"-H-F-CW (54" Deck) Blade, F20.50"-H-F-CW (60" Deck) Blade, F22.50"-H-F-CW (66" Deck) Belt, B-Section (54" Deck) Belt, B-Section (60" Deck) Belt, B-Section (66" Deck) Fuel Filter Main Air Filter Element Safety Air Filter Element Kawasaki Engine Oil Filter Honda Engine Oil Filter Kohler Engine Oil Filter Service Literature PART NO. 375527 785642 778423 742684 DESCRIPTION Owner's Manual Honda 18/20/24 Engine Owner's Manual Kawasaki 19­25 hp Engine Owner's Manual Kohler Engine Owner's Manual Note: When ordering parts, you must use the part number as shown for each part, not the index number. Always give the model and serial number to your parts and service representative. Note: Items sold in bulk such as seals and hoses are sold by the foot. Using this manual Illustrations used were current at the time of printing, but subsequent production changes may cause your machine to vary slightly in detail. Excel Industries, Inc. reserves the right to redesign and change the machine as deemed necessary, without notification. If a change has been made to your machine which is not reflected in this parts manual, see 106567 7/06 1-1 your Hustler dealer for current information and parts. Hardware Description Codes & Abbreviations The following codes are used throughout this parts manual. Refer to this list when ordering parts. ABBREVIATION CB CE CP CS CW FDRW FW HX LW MB MS NT SC SH SB SS OD ID DESCRIPTION Carriage Bolt Clevis Pin Cotter Pin Cap Screw Cup Washer Fender Washer Flat Washer Hex Head Lock Washer Machine Bushing Machine Screw Nut Self Tapping Cap Screw Socket Head Shoulder Bolt Set Screw Outside Diameter Inside Diameter Standard Torques The following chart lists the standard torque values for the threaded fasteners found in this manual. Torque all cap screws, nuts and set screws to these values unless a different torque is shown in the Notes section next to the fastener. SIZE .250 .312 .375 .438 .500 .562 .625 .750 .875 1.00 FT-LBS 8.2 17 30 48 73 105 145 260 420 625 NM 11.1 23 40 65 99 143 200 350 565 850 NOTE: SIZE M3 M4 M5 M6 M8 M10 M12 M14 M16 M20 M24 FT-LBS 1 2.2 4.5 7.7 18.5 37 64 80 160 320 555 NM 1.3 3 6.1 10.4 25 50 87 108.5 215 435 750 Loctite® 592 to be used on all pipe threads. Lubricate all grease zerks. 1-2 106567 7/06 106567 7/06 1-3 1-4 106567 7/06 Chapter 2 Contents Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 106567 7/06 2-1 Rivet Nut Installation 1 2 2 2 3 5 2 4 3 INDEX NO. 1 SERVICE PART NO. 548032 547760 547752 MFG. PART NO. 107701 106211 106039 808493 600961 808477 106732 QTY. 1 1 1 15 8 2 1 DESCRIPTION TRACTOR FRAME (54") TRACTOR FRAME (60") TRACTOR FRAME (66") 3/8-16 THREAD RIVET NUT 1/2-13 THREAD RIVET NUT 1/4-20 THREAD RIVET NUT (KAW ONLY) XR7 MMZ SEAT SUPPORT 2 3 4 N/A N/A N/A 547950 3 5 NOTES: 1. Seat support 547950 includes rivet nuts. 2-2 106567 7/06 Footrest Assembly 1 2 3 4 5 6 5 7 1 INDEX NO. 1 2 3 4 5 6 7 SERVICE PART NO. 359547 395533 305615 086660 767954 781880 052860 MFG. PART NO. 359547 395533 305615 086660 767954 781880 052860 QTY 2 1 2 2 4 2 2 STEP TREAD FLOOR DESCRIPTION PLATFORM STEP TREAD NT .375-16 HX LK NY FW .406 X .812 X .060 SAE HD ZN RUBBER BUMPER CS .375-16 X 1.250 HX G5 ZN NOTES: 1. Do not tighten, Item 2 (348276 Floor) must be able to pivot on these bolts. 106567 7/06 2-3 2-4 106567 7/06 Chapter 3 Contents Hydraulic System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 106567 7/06 3-1 Hydraulic System Installation 4 2 1 16 15 31 3 17 19 5 6 20 18 17 8 FRONT 14 23 10 7 22 11 21 12 24 20 30 18 17 10 11 9 28 29 26 25 27 12 24 11 13 3-2 106567 7/06 Hydraulic System Installation ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 SERVICE PART NO. 768515 055947 032771 032763 349860 034272 768523 781062 781047 041707 704742 781054 705186 768341 768333 781575 763946 778985 781591 779132 781559 781542 781658 781526 781500 781492 781484 781476 781534 781518 763953 N/A MFG. PART NO. 768515 055947 032771 032763 349860 034272 768523 781062 781047 041707 704742 781054 705186 768341 768333 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 781469 QTY 2 2 1 1 1 4 4 1 1 4 8 2 4 1 1 1 3 2 1 2 1 1 1 4 1 1 1 1 2 1 1 1 DESCRIPTION FW .281 X .625 X .051/.080 HD ZN/YL CS .250-20 X .500 HX G5 ZN STRAINER BREATHER CAP RESERVOIR NT .312-18 HX G5 ZN FW .343 X .687 X .051/.080 HD ZN/YL HYDRO-GEAR PUMP, BDP-10A-300 HYDRO-GEAR PUMP BDP-10A-400 NT .437-14 HX G5 ZN FW .453 X .812 X .060 ZN ROSS/PARKER WHEEL MOTOR, MB-15 CS .437-14 X 1.375 HX G5 ZN FILTER ELEMENT FILTER HEAD -6STR -6 90°, PUSHLOC HOSE 4.75" 90°, -6 O-RING/-6 JIC FITTING -6STR -6 90°, PUSHLOC HOSE, 13.00" -6STR -6 90°, PUSHLOC HOSE, 15.00" STR-6MORB/-6JIC FITTING 45°, -8MORB/-8MSL FITTING 90°,-8MORB/-8MSL FITTING STR-8-MORB/HEX PLUG 90°, -10MORB/-8MSL FITTING RIGHT LOOP/RP-BM HYDRO TUBE RIGHT LOOP/LP-TM HYDRO TUBE LEFT LOOP/RP-BM HYDRO TUBE LEFT LOOP/LP-TM HYDRO TUBE STR-8MORB/-8MSL FITTING -6STR -6STR PUSHLOC HOSE, 9.00" -6 O-RING/-6JIC/6JIC T FITTING 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 7/06 3-3 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). 6. If motors do not turn after second attempt, shut off the engine and check for oil at the pump. 7. Increase throttle to half speed and work handles through forward and reverse position until the motor operates smoothly throughout the entire speed range. Note: Seal Kit for hydraulic pump; 727756 (BDP10 Overhaul Seal Kit) 1. 2. 3. 4. 5. 3-4 106567 7/06 Chapter 4 Contents Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Steering and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Pump Belt and Pulley Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 106567 7/06 4-1 Battery Installation 2 1 1 3 5 1 6 5 7 8 9 4 8 9 10 TRACTOR FRAME 11 11 12 4-2 106567 7/06 Battery Installation INDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 SERVICE PART NO. 024927 771428 796219 744276 768523 058776 348417 055939 029868 740696 034272 779850 MFG. PART NO. 024927 771428 796219 744276 768523 058776 348417 055939 029868 740696 034272 779850 QTY 2 1 1 1 3 2 1 2 4 1 2 2 DESCRIPTION NT .250-20 HX GR.5 ZN RED BATTERY CABLE BOOT 36" NEGATIVE BATTERY CABLE POSITIVE BATTERY CABLE FW .343 X .687 X .051/.080 HD ZN/YL NT .312-18 HX NL ZN BATTERY CLAMP STRAP CS .250-20 X .750 HX G5 ZN LW .250 INT-EXT TOOTH ZN BATTERY NT .312-18 HX G5 ZN CB .312-18 X 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. 106567 7/06 4-3 Deck Lift Assembly 1 2 4 5 6 TRACTOR FRAME 5 3 4 5 11 12 4 6 5 5 10 1 4 5 10 13 10 1 7 8 4 4 1 10 1 9 8 9 4 14 8 4 9 4-4 106567 7/06 ...