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User manual HUSTLER 106575
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Manual abstract: user guide HUSTLER 106575
Detailed instructions for use are in the User's Guide. Hustler Super Z XR7 Parts Manual
·······
Hustler Turf Equipment
·····
P.O. Box 7000
···
Hesston, Kansas
·
67062-2097
106575 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 Frame Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Seat Support Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Chapter 3 Contents Hydraulic System InstallationÂAll Air Cooled Engines . . . . . . . . . . 3-2 Hydraulic System InstallationÂKawasaki 26HP Engine . . . . . . . . . 3-6 Chapter 4 Contents Battery Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering and Park Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . Pump Belt and Pulleys Installation . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 5 Contents Kawasaki 25 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . Kawasaki 26 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . Kawasaki 26 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . Honda 24 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Kohler 27 & 30 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . Kohler 28 HP EFI Engine Installation . . . . . . . . . . . . . . . . . . . . . . . Kohler 28 HP EFI Engine Installation . . . . . . . . . . . . . . . . . . . . . . . Fuel SystemÂAir Cooled W/Carburetor. . . . . . . . . . . . . . . . . . . . . . Fuel SystemÂLiquid Cooled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System ÂWith EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System ÂWith EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Panel AssemblyÂAir Cooled W/Carb. . . . . . . . . . . . . . . Instrument PanelÂLiquid Cooled . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument PanelÂLiquid Cooled . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Panel AssemblyÂWith EFI. . . . . . . . . . . . . . . . . . . . . . . Instrument Panel AssemblyÂWith EFI. . . . . . . . . . . . . . . . . . . . . . . Electrical Schematic - Common Air Cooled (799320). . . . . . . . . . . Electrical Schematic - Kawasaki LC (796599) . . . . . . . . . . . . . . . . Electrical Schematic - Kawasaki LC (799338) . . . . . . . . . . . . . . . . Electrical Schematic - Kohler EFI (789560) . . . . . . . . . . . . . . . . . . Electrical Schematic - Kohler EFI (799346) . . . . . . . . . . . . . . . . . . Chapter 6 Contents Front Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Wheel BreakdownÂ747782 . . . . . . . . . . . . . . . . . . . . . . . . . . Optional Semi-Pneumatic Tire/WheelÂ789537 . . . . . . . . . . . . . . . . Drive Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-Rollover Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 7 Contents
106575 7/06 c-1
4-2 4-4 4-6 4-10 5-2 5-6 5-10 5-14 5-18 5-22 5-26 5-30 5-32 5-34 5-36 5-38 5-40 5-42 5-44 5-46 5-48 5-49 5-50 5-51 5-52 6-2 6-4 6-5 6-6 6-7
72" Side Discharge Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . 72" Side Discharge Deck Pulley Assembly . . . . . . . . . . . . . . . . . . 66" Side Discharge Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . 66" Side Discharge Deck Pulley Assembly . . . . . . . . . . . . . . . . . . 60" Side Discharge Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . 60" Side Discharge Deck Pulley Assembly . . . . . . . . . . . . . . . . . . 54" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54" Side Discharge Deck Pulley Assembly . . . . . . . . . . . . . . . . . . 72" Rear Discharge Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . 72" Rear Discharge Deck Pulley Assembly . . . . . . . . . . . . . . . . . . 60" Rear Discharge Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . 60" Rear Discharge Deck Pulley Assembly . . . . . . . . . . . . . . . . . . Spindle AssemblyÂ796235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spindle AssemblyÂ796680 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 8 Contents Deck InstallationÂSide Discharge. . . . . . . . . . . . . . . . . . . . . . . . . . Deck InstallationÂRear Discharge . . . . . . . . . . . . . . . . . . . . . . . . . 72", 66", & 54" Deck Belt Routing and Tensioning . . . . . . . . . . . . . 60" Side Discharge Deck Belt Routing and Tensioning . . . . . . . . . 72" & 60" Rear Discharge Deck Belt Routing and Tensioning . . . . Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 9 Contents Tractor Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72", 66" & 60" Side Discharge Deck Decals. . . . . . . . . . . . . . . . . . 54" Side Discharge Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . 72" and 60" Rear Discharge Deck Decals . . . . . . . . . . . . . . . . . . .
7-2 7-4 7-6 7-8 7-10 7-12 7-14 7-16 7-18 7-20 7-22 7-24 7-26 7-27 8-2 8-4 8-6 8-7 8-8 8-10 9-2 9-4 9-5 9-6
Chapter 10 Contents Maintenance & Adjustments Safety Precautions . . . . . . . . . . . . . 10-3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1
c-2
106575 7/06
Chapter 1 General Information
This Manual covers Hustler XR7 Super Z models: 927467, 927624, 927673, 927681, 927848, 927855, 927871, 927889, 927897, 927913, 927921, 927939, 927947, 927970, 927988, 927996, 928002, 928010, 928028, 928036, 928044, 928051, 928069.
Frequently Ordered Parts
PART NO. 027912 027920 768341 781443 797696 794685 798496 798702 793794 795633 796839 796508 797928 797720 797936 784207 795781 797167 068478 785261 785279 772079 785634 747303 DESCRIPTON Lubrizol 7 oz. Bottle Lubrizol 10 oz. Bottle Hydraulic Oil Filter Pump Drive Belt Blade, F18.50"-H-F-CW Blade, F20.50"-H-F-CW (60" Deck) Blade, F22.50"-H-F-CW (66" Deck) Blade, F24.50"-H-F-CW(72" Deck) Blade, 20.50"-L-F-CW Blade 20.50"-L-F-CCW Blade, 23.86-L-F-CW Blade, 23.86-L-F-CCW Belt, B-Section (54" Deck) Belt, B-Section (60" Deck) Belt, B-Section (66" Deck) Belt, B-Section (72" Deck) 60" Rear Discharge Deck Belt 72" Rear Discharge Deck Belt 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 19Â25 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.
106575 7/06
1-1
Using this manual
Illustrations used were current at the time of printing, but subsequent production changes may cause your machine to vary slightly in detail. Excel Industries, Inc. reserves the right to redesign and change the machine as deemed necessary, without notification. If a change has been made to your machine which is not reflected in this parts manual, see your Hustler dealer for current information and parts.
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
106575 7/06
Chapter 2 Contents
Frame Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Seat Support Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
106575 7/06
2-1
Frame Rivet Nut Installation
1
2 2
INDEX NO. 1
SERVICE PART NO. 547992 547760 547752 547984 548016 548024
MFG. PART NO. 103531 352278 103952 107616 100412 101808 808493
QTY. 1 1 1 1 1 1 10
DESCRIPTION TRACTOR FRAME (54") TRACTOR FRAME (60") TRACTOR FRAME (66") TRACTOR FRAME (72") 60" RD TRACTOR FRAME 72" RD TRACTOR FRAME 3/8-16 THREAD RIVET NUT
2
N/A
NOTES:
2-2
106575 7/06
Seat Support Rivet Nut Installation
3 2 3 6 4 5
1
4 5
4
6
4
5
INDEX NO.
SERVICE PART NO. 547950 547968 N/A N/A N/A N/A N/A N/A
MFG. PART NO. 106732 348615 808485 808493 808493 600961 808477 808477
QTY. 1 1 4 5 5 8 2 3
DESCRIPTION XR7 MMZ SEAT SUPPORT 26HP KAWASAKI SEAT SUPPORT 5/16-18 THREAD RIVET NUT (KAWASAKI LIQUID COOLED ONLY) 3/8-16 THREAD RIVET NUT (FOR AIR COOLED) 3/8-16 THREAD RIVET NUT (FOR LIQUID COOLED) 1/2-13 THREAD RIVET NUT (PER EACH SUPPORT) 1/4-20 THREAD RIVET NUT (KAWASAKI AIR COOLED ONLY) 1/4-20 THREAD RIVET NUT (KAWASAKI LIQUID COOLED ONLY)
11 22
3 4 4 5 6 6
NOTES:
1. Used on all mowers with air cooled engines (service part includes rivet nuts). 2. Used only on mowers with liquid cooled engines (service part includes rivet nuts).
106575 7/06
2-3
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 (395533 Floor) must be able to pivot on these bolts.
2-4
106575 7/06
Chapter 3 Contents
Hydraulic System InstallationÂAll Air Cooled Engines. . . . . . . . . . . . 3-2 Hydraulic System InstallationÂKawasaki 26HP Engine . . . . . . . . . . . 3-6
106575 7/06
3-1
Hydraulic System InstallationÂAll Air Cooled Engines
1 2
SUPER Z HOOD
3 4 7 8 5 21 2 4 6 22 23 24 13 14 15 25 33 36 28 11 12 26 27 20 16 32 29 17 19 15 18 21 10 9 2 30 31 24 25 22
23 13
14 15
15 18 35 34
19
36
3-2
106575 7/06
Hydraulic System InstallationÂAll Air Cooled Engines
INDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 SERVICE PART NO. 705608 768515 713198 783704 033035 068551 032763 032771 055947 357616 034272 768523 788042 008193 767962 783928 783936 008573 782383 700484 784132 784124 784108 784082 781534 781658 784025 783993 788174 783985 784116 782870 782880 782458 782441 781526 N/A MFG. PART NO. 705608 768515 713198 783704 033035 068551 032763 032771 055947 357616 034272 768523 788042 008193 767962 783928 783936 008573 782383 700484 N/A N/A N/A N/A N/A ... |
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