Hustler Z Parts Manual ••••••• Hustler Turf Equipment ••••• P.O.
WARNING: The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. IMPORTANT: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate this engine on any forest-covered, brush-covered, or grass-covered unimproved land. Other states or federal areas may have similar laws. This spark ignition system complies with Canadian ICES-002.
Table of Contents Chapter 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Chapter 2 Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Chapter 3 Hydraulic System Installation—S/N 07120009 and higher . . . . . . . 3-2 Hydraulic System Installation—S/N prior to 07120009 . . . . . . . . . .
54" Rear Discharge Deck Assy—S/N 08010000—08100000 . . . . 54" Rear Discharge Deck Assy–S/N Prior to 08010000. . . . . . . . . 54" Rear Discharge Deck Pulley Assy—S/N 08100000 & Higher . 54" Rear Discharge Deck Pulley Assy—S/N Prior to 08100000 . . Spindle Assembly–796235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spindle Assembly–796680 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 7-22 7-24 7-26 7-28 7-29 Chapter 8 Deck Installation . . . . . . . . . . . . . . . .
Chapter 1 General Information This Manual covers Hustler Z models 927723A/B, 927749A/B, 927756A/B, 927772A/B, 927798A/ B, 927806A/B, 927814A/B, 928432, 928853A/B, and 928861A/B, with serial numbers higher than 07020000. Frequently Ordered Parts PART NO. 027912 027920 768341 781443 797696 794685 798496 601012 601013 797928 797720 797936 601015 068478 785261 785279 601652 601653 772079 785634 747303 DESCRIPTION Lubrizol 7 oz. Bottle Lubrizol 10 oz. Bottle Hydraulic Oil Filter Pump Drive Belt Blade, F18.
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. Options Available From Your Dealer PART NO.
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 .312 .375 .438 .500 .562 .625 .750 .875 1.00 8.2 17 30 48 73 105 145 260 420 625 11.1 23 40 65 99 143 200 350 565 850 M3 M4 M5 M6 M8 M10 M12 M14 M16 M20 M24 1 2.2 4.5 7.7 18.5 37 64 80 160 320 555 1.3 3 6.
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Chapter 2 Contents Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rivet Nut Installation FOR KAWASAKI 26 HP LIQUID COOLED ONLY 4 3 2 6 1 2 3 2 3 2 FOR ALL MOWERS EXCEPT 26 HP LIQUID COOLED 2 4 5 3 ITEM NO. SERVICE PART NO. MFG. PART NO. QTY.
Footrest Assembly 1 2 3 4 5 6 5 1 7 ITEM NO. SERVICE PART NO. MFG. PART NO. QTY 1 359547 359547 2 2 395533 395533 1 FLOOR 3 305615 305615 2 PLATFORM STEP TREAD 4 086660 086660 2 NT .375-16 HX LK NY DESCRIPTION STEP TREAD 5 767954 767954 4 FW .406 X .812 X .060 SAE HD ZN 6 781880 781880 2 RUBBER BUMPER 7 052860 052860 2 CS .375-16 X 1.250 HX G5 ZN NOTES: 1. Do not tighten, Item 2 (348276 Floor) must be able to pivot on these bolts.
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Chapter 3 Contents Hydraulic System Installation—S/N 07120009 and higher . . . . . . . . 3-2 Hydraulic System Installation—S/N prior to 07120009 . . . . . . . . . . .
Hydraulic System Installation—S/N 07120009 and higher 4 2 3 1 19 18 21 15 5 22 32 6 FRONT 19 20 8 7 14 10 23 17 11 16 24 12 25 22 31 9 27 10 19 30 11 20 26 29 16 17 11 28 12 13 25 3-2 108602 10/08
Hydraulic System Installation—S/N 07120009 and higher ITEM NO. SERVICE PART NO. MFG. PART NO. 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 548636 349860 1 RESERVOIR 6 034272 034272 4 NT .312-18 HX G5 ZN 7 768523 768523 4 FW .343 X .687 X .051/.
HYDRAULIC SYSTEM CHARGING PROCEDURE 1. 2. 3. 4. 5. Set handles in the neutral position. Start engine at idle. Let run for a minimum of 30 seconds. Stroke handles to forward position. If motors do not turn in 15 seconds return handles to neutral and repeat step 3 and 4 (one time). 6. If motors do not turn after second attempt, shut off the engine and check for oil at the pump. 7.
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Hydraulic System Installation—S/N prior to 07120009 4 2 3 17 1 16 19 18 15 20 5 31 17 8 6 10 FRONT 14 11 23 22 7 21 12 24 20 30 26 18 25 17 10 11 29 9 28 11 27 12 13 24 3-6 108602 10/08
Hydraulic System Installation—S/N prior to 07120009 ITEM NO. SERVICE PART NO. MFG. PART NO. 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 548636 349860 1 RESERVOIR 6 034272 034272 4 NT .312-18 HX G5 ZN 7 768523 768523 4 FW .343 X .687 X .051/.
HYDRAULIC SYSTEM CHARGING PROCEDURE 1. 2. 3. 4. 5. Set handles in the neutral position. Start engine at idle. Let run for a minimum of 30 seconds. Stroke handles to forward position. If motors do not turn in 15 seconds return handles to neutral and repeat step 3 and 4 (one time). 6. If motors do not turn after second attempt, shut off the engine and check for oil at the pump. 7.
Chapter 4 Contents Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Steering and Park Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Steering Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Pump Belt and Pulleys Installation . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Installation 5 6 5 7 8 8 4 9 1 10 9 2 9 3 1 1 TRACTOR FRAME 11 11 12 4-2 108602 10/08
Battery Installation ITEM NO. SERVICE PART NO. MFG. PART NO. QTY 1 024927 024927 2 2 771428 771428 1 RED BATTERY CABLE BOOT 3 796219 796219 1 36" NEGATIVE BATTERY CABLE DESCRIPTION NT .250-20 HX GR.5 ZN 4 744276 744276 1 POSITIVE BATTERY CABLE 5 768523 768523 3 FW .343 X .687 X .051/.080 HD ZN/YL 6 058776 058776 2 NT .312-18 HX NL ZN 7 348417 348417 1 BATTERY CLAMP STRAP 8 055939 055939 2 CS .250-20 X .750 HX G5 ZN 9 029868 029868 4 LW .
Deck Lift Assembly 2 1 4 6 5 TRACTOR FRAME 4 3 5 5 12 11 4 5 6 5 7 4 10 1 13 1 10 8 10 4 4 5 9 10 4 1 8 1 9 14 8 4 9 4-4 108602 10/08
Deck Lift Assembly ITEM NO. SERVICE PART NO. MFG. PART NO. QTY 1 348318 348318 1 STOP HANDLE 2 600437 600437 1 DECK HEIGHT 1/2" PIN W/A 3 783001 783001 1 DECK LIFT INDICATOR SUBASSEMBLY 4 704643 704643 8 NT .437-14 HX FLG ZN 5 781294 781294 7 CLIP E, 1.00 X .625 X .050 6 782995 782995 2 DECK LIFT SPRING SUBASSEMBLY 7 781229 781229 1 CE .750 X 2.25 X 1.75 HEADLESS 8 055749 055749 3 CS .437-14 X 1.
Steering and Park Brake Assembly 2 3 SEE STEERING SUB-ASSEMBLY page 4-9 1 6 4 5 9 10 8 6 6 11 7 13 16 14 6 7 10 5 17 6 22 18 12 6 14 15 5 19 20 5 21 4 6 27 5 25 28 23 5 6 22 28 6 7 25 26 5 24 6 35 31 34 1 5 4 32 23 6 33 2 22 TRACTOR FRAME 29 30 4-6 108602 10/08
Steering and Park Brake Assembly 8 7 ITEM NO. SERVICE PART NO. 1 348987 348987 1 STEERING CONTROL PANEL 2 781716 781716 2 SS .500-13 X 1.75 SH ZN 3 053199 053199 2 NT .500-13 HX JAM ZN 4 055822 055822 8 CS .375-16 X .750 HX G5 ZN 5 767954 767954 26 FW .406 X .812 X .060 SAE HD ZN 6 6 8 7 8 7 QTY DESCRIPTION 6 768523 768523 30 FW .343X .687 X .051/.080 HD ZN/YL 7 023655 023655 6 NT .
2. For units with serial number 07120009 and higher: Torque to 17 ft.-lbs. 3. For units with serial number 07120009 and higher: 600925 used on left wheel. 600924 used on right wheel. 4. For units with serial numbers prior to 07120009: Torque to 350-375 ft.lbs. Included with wheel motor. 5. For units with serial numbers prior to 07120009: Torque brake assembly mounting bolts to 100 ft.-lbs. 6. For units with serial numbers prior to 07120009: 781112 used on left wheel. 781351 used on right wheel. 7.
Steering Sub-Assembly 1 8 2 3 12 7 14 6 7 5 4 3 5 3 10 3 11 10 9 3 13 ITEM NO. SERVICE PART NO. MFG. PART NO. QTY. 1 781260 N/A 2 1 DESCRIPTION STEERING BAR GRIP 2 348755 348755 2 STEERING BAR 3 767954 767954 16 FW .406 X .812 X .060 SAE HD ZN 4 036244 036244 4 CS .375-16 X 1.000 HX G5 ZN 5 705178 705178 6 CS .375-16 X 1.750 HX G5 ZN 6 023655 023655 2 NT .312-24 HXZY NL 7 768523 768523 4 FW .343X .687 X .051/.
Pump Belt and Pulleys Installation 24 TRACTOR FRAME 25 26 2 6 8 7 2 6 8 1 5 7 23 7 2 6 7 13 2 10 9 11 27 10 12 10 3 13 14 4 1 5 18 19 16 3 15 17 20 21 22 4-10 108602 10/08
Pump Belt and Pulleys Installation ITEM NO.ITE M NO. SERVICE PART NO. MFG. PART NO. QTY 1 779876 779876 1 2 212076 212076 1 KEY 1/4 SQ X 1.50 LONG 3 601311 601311 1 WARNER CLUTCH 5 DESCRIPTION ENGINE SC SINGLE PULLEY 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 768705 768705 2 PULLEY 325308 325308 2 PULLEY & FAN NT .
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Chapter 5 Contents Kawasaki Engine Installation (Remote Air Cleaner) . . . . . . . . . . . . . 5-2 Kawasaki 25 HP Engine Installation (With HD Air Cleaner) . . . . . . . 5-6 Kawasaki 26 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Kawasaki 29 HP Engine Installation (With HD Air Cleaner) . . . . . . 5-10 Honda Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Kohler Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kawasaki Engine Installation (Remote Air Cleaner) TO ENGINE SENSOR 2 YELLOW PART OF ENGINE 1 6 5 16 BLK 9 STARTER 3 SOLENOID 22 GROUND 21 2 5 20 3 17 NEGATIVE BATTERY 18 CABLE 7 TO SPADE TERMINAL TO BULLET 2 TERMINALS 8 2 2 RED/BLK 19 4 23 3 7 6 17 24 7 10 6 3 25 20 11 17 2 12 6 13 14 POSITIVE BATTERY CABLE 3 RED 16 PUR 2 26 3 15 TRACTOR FRAME 27 28 3 24 3 33 39 3 15 34 29 32 30 38 3 37 PART OF COMMON WIRE HARNESS 7 35 1 31 36 40 5-2 108602 10/08
Kawasaki Engine Installation (Remote Air Cleaner) 108602 10/08 ITEM NO. SERVICE PART NO. MFG. PART NO. QTY 1 777656 777656 1 KAWASAKI 23 HP ENGINE 782318 782318 1 KAWASAKI 25 HP ENGINE (FH721V, 3600 RPM) 2 058776 058776 4 NT .312-18 HXZY NL 3 768523 768523 24 FW .343 X .687 X .051/.080 HD ZN/YL 4 029876 029876 1 LW .312 INT-EXT TOOTH ZN 5 792762 792762 1 BATTERY CABLE 6 768515 768515 5 FW .281 X .625 X .051/.080 HD ZN/YL 7 024927 024927 3 NT .250-20 HX GR.
NOTES: 1. 2. 3. 4. Includes mounting hardware. Part of Item 8 (799312 Wire Harness Adapter). Engine oil capacity: Refer to engine owner’s manual. Engine RPM to be set at 3600± 50. 5. Includes one (1) of Item 17 (057661 Hose Clamp). 6. When installing lower hose clamp on air cleaner hose, install as low as possible (against carburetor inlet). 7. This connector used for optional electrical equipment. 8.
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Kawasaki 25 HP Engine Installation (With HD Air Cleaner) 1 2 3 4 5 7 8 2 TO ENGINE 5 SENSOR YELLOW PART OF ENGINE 6 27 4 STARTER SOLENOID 5 GROUND TO SPADE TERMINAL 2 11 12 TO BULLET 2 TERMINALS 26 21 5 25 10 22 19 24 23 13 2 RED/BLK 23 5 18 20 14 23 29 31 15 PART OF COMMON WIRE HARNESS 5 24 16 33 30 24 1 28 24 9 32 2 PURPLE 17 5 34 6 5-6 108602 10/08
Kawasaki Engine Installation (With HD Air Cleaner) ITEM NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 601119 601119 1 KAWASAKI 25 HP ENGINE W/ H/D AIR 2 601257 601257 1 FITTING, 90 1/8NPT BRASS 3 788943 788943 1 AIR FILTER INDICATOR 4 058776 058776 4 NT .312-18 HXZY NL 5 768523 768523 12 FW .343 X .687 X .051/.080 HD ZN/YL 6 050161 050161 4 CS .312-18 X 1.75 HX G5 7 796524 796524 1 OIL DRAIN M20 X 2.
Kawasaki 26 HP Engine Installation 1 PART OF WIRE HARNESS 30 3 } 4 5 2 7 6 6 KAWASAKI ENGINE SCREEN { 1 7 8 PART OF ENGINE 11 9 12 12 PART OF ENGINE 13 16 11 14 15 12 17 18 12 19 10 8 20 22 21 23 26 NEGATIVE BATTERY CABLE 2 BLK 27 28 2 BLK POSITIVE BATTERY CABLE PUR 2 29 30 31 } 24 25 8 6 9 5-8 108602 10/08
Kawasaki 26 HP Engine Installation ITEM NO. 1 SERVICE PART NO. 795617 MFG. PART NO. 795617 QTY 1 KAWASAKI FD731V ENGINE 2 796748 796748 1 KAWASAKI 26HP EXHAUST MANIFOLD 3 780841 780841 2 KAW (23) MUFFLER GASKET 4 017004 017004 4 LW .312 MED SPRING ZN 5 782664 782664 4 NT M8-1.25 HX STAINLESS STEEL 6 796755 796755 1 KAWASAKI 26HP LC MUFFLER 7 785378 785378 1 1.50" MUFFLER CLAMP 8 767962 767962 14 FW .531 X 1.063 X .090 SAE HD ZN 9 016527 016527 10 CS .500-13 X 1.
Kawasaki 29 HP Engine Installation (With HD Air Cleaner) 1 2 PART OF COMMON WIRE HARNESS 7 4 3 4 { 10 { 7 8 9 5 29 11 1 6 11 12 13 14 15 16 18 17 15 22 23 19 21 4 YEL/BLK 20 25 3 28 PUR 3 TO SPADE TERMINAL ON RECT.
Kawasaki 29 HP Engine Installation (With HD Air Cleaner) ITEM NO. SERVICE PART NO. MFG. PART NO. QTY 1 2 601548 N/A 1 KAWASAKI 29 HP ENGINE 109743 109743 1 CABLES HEAT SHIELD DESCRIPTION 3 720516 720516 3 CS M8 X1.25 X 16 G10.9 HX 4 788018 788018 1 MUFFLER 5 785378 785378 1 1.50" MUFFLER CLAMP 6 601550 601550 1 MANIFOLD, 29/31 KAW 7 780841 780841 2 8 017004 017004 KAW MUFFLER GASKET LW .312 MED SPRING ZN 9 782664 782664 10 029751 029751 NT M8-1.
Honda Engine Installation PART OF ENGINE 1 2 YEL 8 2 3 ORG 10 3 6 12 2 BLK 11 BRN 3 4 5 7 NEGATIVE BATTERY CABLE 2 6 PUR GRA/PUR 3 POSITIVE 3 BATTERY CABLE 13 3 11 14 RED/BLK 15 3 16 25 26 13 3 3 9 17 11 PART OF COMMON WIRE HARNESS 9 2 27 3 28 18 29 36 19 TRACTOR FRAME 20 3 16 22 3 9 33 7 21 30 31 24 23 3 16 35 31 1 32 7 7 34 7 5-12 108602 10/08
Honda Engine Installation ITEM NO. SERVICE PART NO. MFG. PART NO. 1 785014 785014 1 HONDA 24HP ENGINE 2 058776 058776 4 NT .312-18 HXZY NL 3 768523 768523 23 FW .343 X .687 X .051/.080 HD ZN/YL 4 799320 799320 1 COMMON WIRE HARNESS 5 029876 029876 1 LW .312 INT-EXT TOOTH ZN 6 077545 N/A 1 NT M8-1.25 X 10 HX ZNYC 7 017004 N/A 5 LW .312 MED SPRING ZN 8 799304 799304 1 WIRE HARNESS ADAPTER 9 050161 050161 4 CS .312-18 X 1.
7. Supplied with engine. 8. When installing lower hose clamp on air cleaner hose, install as low as possible (against carburetor inlet). 9. This connector used for optional electrical equipment. 10.
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Kohler Engine Installation 1 7 2 3 5 12 8 4 POSITIVE BATTERY CABLE 5 6 BLK 2 NEGATIVE BATTERY CABLE 10 13 11 4 9 14 PUR (P/O ENGINE) 4 15 RED/BLK 2 8 4 16 13 8 4 3 6 4 17 TRACTOR FRAME 18 19 4 24 25 27 26 20 4 15 6 5 4 21 1 28 22 PART OF COMMON WIRE HARNESS 2 23 15 30 25 29 5-16 108602 10/08
Kohler Engine Installation ITEM NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 788216 788216 1 KOHLER 27HP ENGINE 2 799320 799320 1 COMMON WIRE HARNESS 3 058776 058776 4 NT .312-18 HXZY NL 4 768523 768523 29 FW .343 X .687 X .051/.080 HD ZN/YL 5 029876 029876 1 LW .312 INT-EXT TOOTH ZN 6 050161 050161 4 CS .312-18 X 1.
Fuel System Installation (Air Cooled Engines) 1 2 5 1 6 4 15 1 7 3 8 9 10 9 8 11 6 1 14 13 9 12 4 11 4 4 17 7 16 6 1 14 13 7 1 6 5-18 108602 10/08
Fuel System Installation (Air Cooled Engines) ITEM NO. SERVICE PART NO. MFG. PART NO. 1 779306 779306 2 3.5" FUEL CAP 2 793240 793240 1 LEFT SIDE FUEL TANK 3 793232 793232 1 RIGHT SIDE FUEL TANK 4 000323 000323 6 CLIP 5 106732 N/A 1 REAR SEAT SUPPORT 6 055822 055822 12 CS .375-16 X .750 HX G5 ZN QTY DESCRIPTION 7 712919 712919 11 FW .406 X 1.00 X .12 HRD ZN 8 036244 036244 2 CS .375-16 X 1.000 HX G5 ZN 9 767954 767954 3 FW .406 X .812 X .
Fuel System Installation (Liquid Cooled Engines) 1 2 6 1 4 7 5 20 17 1 11 16 6 19 3 7 15 9 11 8 12 10 6 14 6 6 5 1 5 13 10 1 7 7 18 14 13 7 6 5 1 5-20 108602 10/08
Fuel System Installation (Liquid Cooled Engines) ITEM NO. SERVICE PART NO. MFG. PART NO. 1 779306 779306 2 3.5" FUEL TANK CAP 2 793240 793240 1 LEFT SIDE Z FUEL TANK 3 793232 793232 1 RIGHT SIDE Z FUEL TANK 4 109678 N/A 1 REAR SEAT SUPPORT 5 055822 055822 12 CS .375-16 X .750 HX G5 ZN 6 712919 712919 14 FW .406X 1.00X.12 HRD Z 7 000323 000323 8 CLIP 8 068478 068478 1 IN-LINE FUEL FILTER 9 797035 797035 1 1.
Instrument Panel Assembly (Air Cooled) 1 2 4 8 RELAY ASSEMBLY 7 16 3 7 5 9 9 RELAYS 17 11 6 WIRE HARNESS 1 18 3 4 7 12 10 13 14 15 RIGHT SIDE FUEL TANK 14 13 FUSE SIZE AND LOCATION 10a 15a 15a 5-22 108602 10/08
Instrument Panel Assembly (Air Cooled) ITEM NO. SERVICE PART NO. MFG. PART NO. QTY 1 776476 776476 1 PTO SWITCH 2 785808 785808 1 KEY SET 3 045898 045898 1 KEY SWITCH 4 785030 785030 1 Z CHOKE CABLE (KAWASAKI) 786657 786657 1 Z CHOKE CABLE (HONDA & KOHLER) 712257 712257 1 RED INDICATOR LIGHT 5 DESCRIPTION 6 000430 000430 3 TIE STRAP 7 704932 704932 8 FW .219 X .500 X .048 ZN 8 714998 714998 3 MS #10-24 X .625 HX ZN 9 601098 601098 2 CB 10-24 X .
Instrument Panel Assembly (Liquid Cooled) 4 14 RELAY ASSEMBLY 7 15 1 2 RELAYS 7 8 5 6 3 16 11 10 9 1 3 WIRE HARNESS 10 12 7 13 8 17 18 19 RIGHT SIDE FUEL TANK 18 17 FUSE SIZE AND LOCATION 10a 15a 15a 5-24 108602 10/08
Instrument Panel Assembly (Liquid Cooled) ITEM NO. SERVICE PART NO. MFG. PART NO. QTY 1 776476 776476 1 PTO SWITCH 2 785808 785808 1 KEY SET 3 045898 045898 1 KEY SWITCH 4 785030 785030 1 Z CHOKE CABLE DESCRIPTION 5 712257 712257 3 RED INDICATOR LIGHT 6 601098 601098 2 CB 10-24 X .500 ZYNC 7 704932 704932 8 FW .219 X .500 X .048 ZN 8 059832 059832 5 NT #10-24 HX NL ZN 9 769166 769166 1 HOUR METER 10 794347 794347 1 ULTRA LOUD WARBLE ALARM RIVET .
Electrical Schematic (799320) 5-26 108602 10/08
Electrical Schematic—Kawasaki LC (799338) 108602 10/08 5-27
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Wheel Assembly 1 2 TRACTOR FRAME 3 3 4 1 2 3 3 4 5 3 4 6 7 8 5 9 9 3 2 4 10 6 7 9 9 11 8 1 11 6-2 1 108602 10/08
Front Wheel Assembly ITEM NO. SERVICE PART NO. MFG. PART NO. QTY 1 705954 705954 2 CS .500-13 X 1.25 HX G5 ZN 2 344267 344267 2 FW .510 X 2.15 X .187 SPL ZN 3 712976 712976 2 FW .531X 1.375X.125 ZNY 4 784223 784223 4 BEARING W/O COLLAR 5 387035 387035 2 SPACER, 1.07 X 1.312 X 2.793 6 045765 045765 2 FW 1.030 X 1.500 X.134 ZN 7 349266 349266 2 FORK 8 041475 041475 2 CS .750-10 X 9.50 HX ZN 9 025296 025296 4 FW .760 X 1.625 X .08 10 061101 061101 2 NT .
Front Wheel Breakdown—747782 1 2 1 3 4 1 5 6 ITEM NO. SERVICE PART NO. MFG. PART NO. QTY 1 039677 N/A 2 WHEEL BEARING 2 747741 N/A 1 13 X 6.50 TIRE 3 747832 N/A 1 6 X 4.5 WHEEL 4 782771 N/A 1 BEARING SPACER 5 019521 N/A 1 TIRE VALVE 6 015511 N/A 1 GREASE FITTING 45 DEG 1/4 DESCRIPTION NOTES: 1. Inflate tire to 8-12 psi.
Optional Semi-Pneumatic Tire/Wheel—789537 2 1 3 4 1 ITEM NO. SERVICE PART NO. MFG. PART NO.
Drive Wheel Assembly Installation 1 6 1 3 3 5 2 3 4 2 ITEM NO. SERVICE PART NO. PART NO. QTY 1 784058 784058 2 2 781245 N/A TIRE, 12 X 12 X 24 FOR 66" 3 784066 N/A WHEEL ASSEMBLY 12 X 8.50 FOR 66" 4 019521 N/A 5 061077 061077 10 WHEEL NUT (QTY PER TRACTOR) 6 770859 N/A 10 1/2" WHEEL LUG STUD 1 601238 601238 2 2 781245 N/A 3 796250 N/A WHEEL ASSEMBLY 12 X 8.
Anti-Rollover Wheel Assembly 1 3 3 4 1 2 3 TRACTOR FRAME 1 3 2 ITEM NO. SERVICE PART NO. MFG. PART NO. QTY 1 068239 068239 2 CS .500-13 X 4.500 HX G5 ZN 2 031997 031997 2 ANTI-SCALP WHEEL 3 767962 767962 4 FW .531 X 1.063 X .090 SAE HD ZN 4 781567 781567 2 NT .50-13 HX LK NY DESCRIPTION NOTES: 1. Do not torque, wheel must turn freely.
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Chapter 7 Contents 66" Side Discharge XR7 Deck Assembly . . . . . . . . . . . . . . . . . . . . . 7-2 66" Side Discharge XR7 Deck Pulley Assembly . . . . . . . . . . . . . . . . 7-4 60" Side Discharge XR7 Deck Assembly . . . . . . . . . . . . . . . . . . . . . 7-6 60" Side Discharge XR7 Deck Pulley Assembly . . . . . . . . . . . . . . . . 7-8 54" Side Discharge XR7 Deck Assembly . . . . . . . . . . . . . . . . . . . . 7-10 54" Side Discharge XR7 Deck Pulley Assembly . . . . . . . . . . . . . . .
66" Side Discharge XR7 Deck Assembly 7 2 5 8 4 10 4 1 14 9 12 4 3 14 11 4 3 13 5 6 9 12 1 12 7 11 8 10 11 10 9 9 7 15 8 9 11 11 10 8 12 9 7 4 10 8 7 5 8 7 16 7-2 108602 10/08
66" Side Discharge XR7 Deck Assembly 3 2 ITEM NO. SERVICE PART NO. MFG. PART NO. QTY 1 548446 108536 1 66" DECK W/A CRATED 2 798694 798694 1 RUBBER CHUTE ASSEMBLY 3 052860 052860 8 CS .375-16 X 1.250 HX G5 ZN 4 767954 767954 18 FW .406 X .812 .060 SAE HD ZN 5 086660 086660 10 NT .375-16 HXZY NL 6 103010 103010 1 DISCHARGE CHUTE MOUNT BRACKET 7 781708 N/A 6 CS .500-13 X 4.25 HX G5 ZN 8 767962 N/A 12 FW .531 X 1.063 X .
66" Side Discharge XR7 Deck Pulley Assembly 1 4 5 3 8 6 7 9 10 11 2 6 15 13 3 15 14 14 2 17 18 15 12 19 15 66" DECK ASSY 16 20 16 21 16 16 24 22 BELT GUIDE INDEXING 25 23 28 26 27 30 28 7-4 29 1 108602 10/08
66" Side Discharge XR7 Deck Pulley Assembly ITEM NO. SERVICE PART NO. MFG. PART NO. QTY 1 797936 797936 1 B-SECTION BELT 2 797910 797910 6 CS .312-18 X 1.50 FLT SH ZNYC 3 601434 601434 2 UHMW IDLER SLIDE 4 025007 025007 1 CS .625-11 X 1.75 HX G5 ZNYC 5 347443 347443 1 DECK BELT IDLER GUIDE 6 028118 028118 3 FW .62 X 1.00X.134 ZN 7 781856 781856 1 5.
60" Side Discharge XR7 Deck Assembly 2 4 5 4 6 3 4 8 1 14 4 7 4 13 11 9 15 16 5 3 4 16 10 7 14 8 12 4 1 12 5 4 12 9 10 11 11 7 13 8 4 14 18 10 12 9 8 11 4 11 8 4 10 5 14 8 11 9 10 9 7 7 9 7 17 7-6 108602 10/08
60" Side Discharge XR7 Deck Assembly ITEM NO. SERVICE PART NO. MFG. PART NO. QTY. 1 548438 108501 1 60" DECK W/A CRATED 2 798694 798694 1 RUBBER CHUTE ASSEMBLY 3 052860 052860 8 CS .375-16 X 1.25 HX G5 4 767954 767954 26 FW .406 X .812 X .060 SAE HD ZN 5 086660 086660 14 NT .375-16 HX LK NY 6 103010 103010 1 DISCHARGE CHUTE MOUNT BRACKET 7 781708 N/A 6 CS .500-13 X 4.25 HX G5 ZN 8 767962 N/A 12 FW .531 X 1.063 X .
60" Side Discharge XR7 Deck Pulley Assembly 1 4 5 6 3 7 8 9 2 10 6 3 11 13 15 14 14 13 16 15 15 14 17 2 12 18 19 60" DECK ASSY 15 16 21 20 16 27 16 BELT GUIDE INDEXING 24 22 23 28 25 26 30 27 1 7-8 29 108602 10/08
60" Side Discharge XR7 Deck Pulley Assembly ITEM NO. SERVICE PART NO. MFG. PART NO. QTY 1 797720 797720 1 B-SECTION BELT 2 797910 797910 6 CS .312-18 X 1.50 FLT SH ZNYC 3 601434 601434 2 UHMW IDLER SLIDE 4 025007 025007 1 CS .625-11 X 1.75 HX G5 ZNYC 5 347443 347443 1 DECK BELT IDLER GUIDE 6 028118 028118 3 FW .62 X 1.00X.134 ZN 7 781856 781856 1 5.
54" Side Discharge XR7 Deck Assembly 2 4 5 4 3 7 1 9 11 17 4 13 16 15 14 10 3 4 12 4 14 8 10 8 4 5 4 9 1 5 4 12 8 13 17 11 11 13 9 4 12 6 10 11 10 12 13 4 13 11 16 8 12 5 10 9 4 13 11 9 10 9 6 7-10 108602 10/08
54" Side Discharge XR7 Deck Assembly ITEM NO. 6 2 SERVICE PART NO. MFG. PART NO. QTY. DESCRIPTION 1 548420 108607 1 54" DECK W/A CRATED 2 798694 798694 1 54" DISCHARGE CHUTE 3 052860 052860 8 CS .375-16 X 1.25 HX G5 ZN 4 767954 767954 26 FW .406 X .812 X .060 SAE HD ZN 5 086660 086660 14 NT .375-16 HX LK NY 6 025395 025395 2 CB .375-16X 1.00 STD CD 7 103010 103010 1 DISCHARGE CHUTE MOUNT BRACKET 8 808485 808485 4 5/16-18 THREAD RIVET NUT 9 781708 N/A 6 CS .
54" Side Discharge XR7 Deck Pulley Assembly 1 3 9 3 12 10 13 4 7 11 8 2 5 6 5 14 2 16 6 15 17 30 18 54" DECK ASSY 19 20 30 30 25 30 21 24 BELT GUIDE POSITIONING 27 26 22 28 23 27 24 29 1 7-12 108602 10/08
54" Side Discharge XR7 Deck Pulley Assembly ITEM NO. SERVICE PART NO. MFG. PART NO. QTY. 1 797928 797928 1 B-SECTION BELT 2 016972 016972 2 NT .625-11 HX G5 ZNYC 3 025007 025007 1 CS .625-11 X 1.750 HX G5 4 028118 028118 3 FW .62 X 1.00 X .134 ZN 5 781385 781385 2 6.00" IDLER PULLEY 6 797449 797449 4 FW .650X1.125 X .18 ZNYCG5 7 797910 797910 6 CS .312-18 X 1.
Side Discharge Deck—"A" Adaptors 2 Deck Assembly 2 4 3 1 3 4 7-14 108602 10/08
Side Discharge Deck—"A" Adaptors ITEM NO. SERVICE PART NO. MFG. PART NO. QTY. 1 108531 108531 2 AIR FLOW FLOOR (66" DECKS) 108516 108516 2 AIR FLOW FLOOR (60" DECKS) DESCRIPTION 108619 108619 2 AIR FLOW FLOOR (54" DECKS) 2 025395 025395 4 CB .375-16X 1.00 STD CD 3 767954 767954 4 FW .406X .812 X.060 SAE 4 086660 086660 4 NT .
Side Discharge Deck—"B" Adaptors Deck Assembly 4 4 5 6 2 7 4 5 3 1 5 6 Assembled Detail 7-16 108602 10/08
Side Discharge Deck—"B" Adaptors ITEM NO. SERVICE PART NO. MFG. PART NO. QTY.
54" Rear Discharge Deck Assy—S/N 08100000 & Higher 27 3 27 5 10 23 25 8 18 3 25 24 8 4 5 27 3 19 20 9 21 27 2 22 7 3 17 29 6 7 19 26 1 12 13 11 29 26 4 7 14 5 30 15 31 20 16 21 12 5 22 10 13 7 16 15 16 13 6 15 12 14 14 13 16 13 31 13 12 10 5 DEFLECTOR DETAIL 28 7-18 108602 10/08
54" Rear Discharge Deck Assy—S/N 08100000 & Higher 3 1 2 ITEM NO. SERVICE PART NO. MFG. PART NO. 1 549733 110441 1 54" REAR DISCHARGE DECK W/A 2 109490 109490 1 DISCHARGE SHIELD 3 768523 768523 10 FW .343 X .687 X .051/.080 HD ZN 4 086660 086660 6 NT .375-16 HX LK NY 5 767954 767954 26 FW .406 X .812 X .060 SAE HD ZN 6 710194 710194 6 CB .375-16X 1.50 STD G5 7 601069 601069 4 CN .312-18X.200 MAX THK 8 015495 015495 2 STRAIGHT GREASE FITTING QTY.
54" Rear Discharge Deck Assy—S/N 08010000—08100000 18 27 3 8 3 4 5 27 5 10 23 25 27 3 25 24 19 8 20 27 17 21 2 7 1 13 19 29 6 12 3 9 22 7 26 11 14 26 7 29 16 4 5 20 30 31 12 10 15 21 22 13 5 7 6 16 16 13 15 15 14 12 14 13 13 16 13 12 31 10 5 DEFLECTOR DETAIL 28 7-20 108602 10/08
54" Rear Discharge Deck Assy—S/N 08010000—08100000 2 1 ITEM NO. SERVICE PART NO. MFG. PART NO. 1 548644 107933 1 54" REAR DISCHARGE DECK W/A 2 109490 109490 1 DISCHARGE SHIELD 3 768523 768523 10 FW .343 X .687 X .051/.080 HD ZN 4 086660 086660 6 NT .375-16 HX LK NY 5 767954 767954 26 FW .406 X .812 X .060 SAE HD ZN 6 710194 710194 6 CB .375-16X 1.50 STD G5 7 601069 601069 4 CN .312-18X.200 MAX THK 8 015495 015495 2 STRAIGHT GREASE FITTING QTY.
54" Rear Discharge Deck Assy–S/N Prior to 08010000 3 26 23 17 4 26 18 26 3 3 5 20 24 19 21 24 2 22 8 25 9 7 6 19 23 5 10 8 7 12 4 1 13 25 11 14 7 25 5 20 28 16 12 21 15 22 10 13 7 5 16 13 6 16 15 15 12 14 14 13 16 13 13 12 28 DEFLECTOR DETAIL 10 5 27 7-22 108602 10/08
54" Rear Discharge Deck Assy–S/N Prior to 08010000 ITEM NO. 2 1 SERVICE PART NO. MFG. PART NO. QTY. DESCRIPTION 1 548644 107933 1 54" REAR DISCHARGE DECK W/A 2 108066 108066 1 RD DECK GUARD 3 768523 768523 12 FW .343 X .687 X .051/.080 HD ZN 4 086660 086660 6 NT .375-16 HX LK NY 5 767954 767954 26 FW .406 X .812 X .060 SAE HD ZN 6 025395 025395 12 CB .375-16 X 1.00 STD CD 7 601069 601069 4 CN .312-18X.
54" Rear Discharge Deck Pulley Assy—S/N 08100000 & Higher 1 9 4 5 10 11 3 14 13 6 12 7 2 8 18 11 16 15 2 19 17 5 20 18 5 21 6 5 6 19 10 19 2 22 5 3 20 21 19 10 22 22 23 24 22 23 25 31 32 26 24 28 27 27 29 23 1 30 1 7-24 33 23 108602 10/08
54" Rear Discharge Deck Pulley Assy—S/N 08100000 & Higher 4 5 ITEM NO. SERVICE PART NO. MFG. PART NO. QTY. 1 601015 601015 1 54" REAR DISCHARGE DECK BELT 2 110449 110449 1 RIGHT 54" REAR DISCHARGE PULLEY COVER DESCRIPTION 3 110448 110448 1 LEFT 54" REAR DISCHARGE PULLEY COVER 4 794446 794446 1 CS .625-11 X 1.500 HX G5 5 028118 028118 7 FW .62 X 1.00 X .
54" Rear Discharge Deck Pulley Assy—S/N Prior to 08100000 1 6 2 5 7 10 5 3 9 8 12 2 11 14 15 16 4 4 4 5 7 5 5 7 7 5 14 13 3 14 2 15 16 17 14 13 17 13 23 13 27 23 18 25 19 20 26 22 20 23 1 21 27 1 24 23 28 7-26 108602 10/08
54" Rear Discharge Deck Pulley Assy—S/N Prior to 08100000 4 5 ITEM NO. SERVICE PART NO. MFG. PART NO. QTY. 1 601015 601015 1 54" REAR DISCHARGE DECK BELT 2 107945 107945 1 RIGHT 54" REAR DISCHARGE PULLEY COVER 3 107946 107946 1 LEFT 54" REAR DISCHARGE PULLEY COVER 4 016972 016972 4 NT .625-11 HX G5 ZNYC DESCRIPTION 5 028118 028118 7 FW .62 X 1.00 X .134 ZN 6 794446 794446 1 CS .625-11 X 1.
Spindle Assembly–796235 1 1 2 3 4 1 2 5 6 ITEM NO. SERVICE PART NO. MFG. PART NO. QTY. 1 077123 N/A 2 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 DESCRIPTION BEARING W/O COLLAR NOTES: 1. Install upper bearing with extended inner race up. 2. Install lower bearing with extended inner race down. 3. Apply grease to zerk.
Spindle Assembly–796680 1 1 2 3 4 2 1 5 6 ITEM NO. SERVICE PART NO. MFG. PART NO. QTY. 1 077123 N/A 2 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 796698 N/A 1 SPINDLE SHAFT DESCRIPTION BEARING W/O COLLAR NOTES: 1. Install upper bearing with extended inner race up. 2. Install lower bearing with extended inner race down. 3. Apply grease to zerk.
7-30 108602 10/08
Chapter 8 Contents Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 66" & 54" Side Discharge Deck Belt Routing and Tensioning . . . . . . 8-4 60" Side Discharge Deck Belt Routing and Tensioning. . . . . . . . . . . 8-5 54" Rear Discharge Deck Belt Routing and Tensioning . . . . . . . . . . 8-6 Seat Installation—S/N 08010000 & Higher . . . . . . . . . . . . . . . . . . . . 8-8 Seat Installation—S/N Prior to 08010000 . . . . . . . . . . . . . . . . . . . .
Deck Installation TRACTOR ASSEMBLY 1 4 2 3 5 DECK ASSEMBLY 5 8-2 108602 10/08
Deck Installation ITEM NO. SERVICE PART NO. MFG. PART NO. 1 055749 055749 4 CS .437-14 X 1.750 HX G5 ZN 2 061101 061101 2 NT .750-10 HX NL ZN 3 025296 025296 4 FW .760 X 1.625 X.08 ZN 4 051169 051169 2 CS .750-10 X 3.000 HX G5 ZN 5 704643 704643 8 NT .437-14 HX FLG ZN QTY DESCRIPTION NOTES: 1. 66" Deck installation is shown, 60" and 54" Side Discharge Decks, and 54" Rear Discharge Decks are similar.
66" & 54" Side Discharge Deck Belt Routing and Tensioning 1 DECK ASSEMBLY NOTES: 1. Spring length after tensioning belt. Measure spring from outside of hook to outside of hook. 2. Route belt as shown.
60" Side Discharge Deck Belt Routing and Tensioning 1 DECK ASSEMBLY NOTES: 1. Spring length after tensioning belt. Measure spring from outside of hook to outside of hook. 2. Route belt as shown.
54" Rear Discharge Deck Belt Routing and Tensioning 1 DECK ASSEMBLY NOTES: 1. Spring length after tensioning belt. Measure spring from outside of hook to outside of hook. 2. Route belt as shown.
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Seat Installation—S/N 08010000 & Higher 17 16 14 LATCH W/A DETAIL 1 19 20 22 19 21 18 21 21 20 21 25 10 24 2 3 4 2 5 6 1 4 15 1 14 10 7 4 8 23 10 5 11 5 4 13 12 9 5 8-8 108602 10/08
Seat Installation—S/N 08010000 & Higher 3 ITEM NO. SERVICES PART NO. MFG. PART NO. 1 793661 793661 1 MICHIGAN SEAT 2 109307 109307 1 SEAT PAN 3 000331 000331 3 BLACK CABLE TIE 4 086660 086660 6 NT .375-16 HX LK NY 5 767954 767954 6 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 1 CS .375-16 X 1.000 HX G5 ZN QTY DESCRIPTION 9 052860 052860 2 CS .375-16 X1.
Seat Installation—S/N Prior to 08010000 17 16 8 5 14 15 1 3 3 4 5 2 1 1 6 7 8 10 11 5 13 4 12 9 5 8-10 108602 10/08
Seat Installation—S/N Prior to 08010000 ITEM NO. SERVICES PART NO. MFG. PART NO. 1 793661 793661 1 MICHIGAN SEAT 2 350041 350041 1 SEAT PAN 3 000331 000331 3 BLACK CABLE TIE 4 086660 086660 3 NT .375-16 HX LK NY 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 QTY DESCRIPTION 9 052860 052860 2 CS .375-16 X1.250 HX G5 ZN 10 768523 768523 4 FW .
ROPS Installation 2 1 3 5 4 3 7 6 6 2 8 1 7 9 10 9 5 11 8-12 108602 10/08
ROPS Installation ITEM NO. SERVICES PART NO. MFG. PART NO. 1 601440 N/A 1 ROPS 2 601471 N/A 2 LYNCH PIN W/ LANYARD 3 601470 N/A 2 KNOB 4 601560 N/A 1 ROPS WARNING DECAL 5 061812 N/A 5 CS .500-13X3.500 HX G5 6 601472 N/A 1 ROPS STOP 7 023317 N/A 6 NT .500-13 UNT LK G5 ZN 8 077859 N/A 1 CS .500-13X3.250 HX G5 9 767962 N/A 4 FW .531X 1.063X.090 SAE 10 601473 N/A 2 SPACER WASHER 11 349704 N/A 1 ENGINE CAGE MOUNT PLATE QTY DESCRIPTION NOTES: 3.
8-14 108602 10/08
Chapter 9 Contents Tractor Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 66" Side Discharge XR7 Deck Decals. . . . . . . . . . . . . . . . . . . . . . . . 9-4 60" Side Discharge XR7 Deck Decals. . . . . . . . . . . . . . . . . . . . . . . . 9-5 54" Side Discharge XR7 Deck Decals. . . . . . . . . . . . . . . . . . . . . . . . 9-6 54" Rear Discharge Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tractor Decals A B 17 B 6 8 2 1 5 3 A 1 4 TOP OF SEAT PAN 7 9 VIEW B-B 10 BOTTOM OF SEAT PAN 11 12 13 14 18 15 2 7 9-2 108602 10/08
Tractor Decals 16 ITEM NO. SERVICE PART NO. MFG. PART NO. QTY.
66" Side Discharge XR7 Deck Decals 8 1 10 2 9 3 7 4 8 6 5 6 ITEM NO. SERVICE PART NO. MFG. PART NO. QTY. 1 799189 799189 1 2 760637 760637 1 MOWER DECK QUICK REFERENCE DECAL 3 727420 727420 1 DEFLECTOR SHIELD DECAL 4 727172 727172 1 "MADE IN U.S.A." DECAL 5 727453 727453 2 BELT & PULLEY DECAL 6 727438 727438 2 WHIRLING BLADES DECAL 7 781419 781419 1 BELT ROUTING DECAL 8 799353 799353 2 DECK XR7 ID DECAL 9 359547 359547 1 5.00 X 9.
60" Side Discharge XR7 Deck Decals 8 1 10 2 9 7 3 4 8 6 5 6 ITEM NO. SERVICE PART NO. MFG. PART NO. QTY. 1 786277 786277 1 2 760637 760637 1 MOWER DECK QUICK REFERENCE DECAL 3 727420 727420 1 DEFLECTOR SHIELD DECAL 4 727172 727172 1 "MADE IN U.S.A." DECAL 5 727453 727453 2 BELT & PULLEY DECAL 6 727438 727438 2 WHIRLING BLADES DECAL 7 799395 799395 1 BELT ROUTING DECAL 8 799353 799353 2 DECK XR7 ID DECAL 9 359547 359547 1 5.00 X 9.
54" Side Discharge XR7 Deck Decals 8 1 2 10 6 9 3 7 5 8 5 6 4 ITEM NO. SERVICE PART NO. MFG. PART NO. QTY. 1 799171 799171 1 2 760637 760637 1 MOWER DECK QUICK REFERENCE DECAL 3 727420 727420 1 DEFLECTOR SHIELD DECAL 4 727172 727172 1 "MADE IN U.S.A." DECAL 5 727453 727453 2 BELT & PULLEY DECAL 6 727438 727438 2 WHIRLING BLADES DECAL 7 781419 781419 1 BELT ROUTING DECAL 8 799353 799353 2 DECK XR7 ID DECAL 9 359547 359547 1 5.00 X 9.
54" Rear Discharge Deck Decals 2 1 3 4 5 8 7 3 6 4 3 4 4 3 ITEM NO. SERVICE PART NO. MFG. PART NO. QTY. 1 799171 799171 1 54" REAR DISCHARGE DECK ID DECAL 2 760637 760637 1 DECAL MOWER DECK QUICK REFERENCE 3 727438 727438 4 DECAL WHIRLING BLADES 4 727453 727453 4 DECAL BELT & PULLEY 5 727172 727172 1 DECAL 'MADE IN U.S.A.
9-8 108602 10/08
Chapter 10 Contents Assembly Pictures and Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 General information for all models: . . . . . . . . . . . . . . . . . . . . 10-3 Hustler Z’s with Kawasaki engines: . . . . . . . . . . . . . . . . . . . 10-4 Hustler Zs with Kawasaki 29 HP engines: . . . . . . . . . . . . . . 10-6 Hustler Z’s with Kawasaki 26 HP engines: . . . . . . . . . . . . . . 10-7 Hustler Z’s with Honda engines: . . . . . . . . . . . . . . . . . . . . . .
Recommended service procedure . . . . . . . . . . . . . . . . . . . 10-29 Air restriction indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29 General engine maintenance . . . . . . . . . . . . . . . . . . . . . . . 10-30 Belt replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30 Mower blade maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 10-31 Mower blade removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31 Adjustment . . . . .
Assembly Pictures and Aids General information for all models: PTO clutch wire routing "FIG. 1". TIE STRAP CLUTCH PIGTAIL WIRE FIG. 1 PTO clutch switch installation (Instrument Panel) "FIG. 2" & "FIG. 3". PTO SWITCH TIE STRAP FIG. 2 FIG.
Hustler Z’s with Kawasaki engines: Does not include machines with 29 HP or 26 HP engines. Throttle cable routing "FIG. 4". TIE STRAP THROTTLE CABLE ROUTED THROUGH TUBE HYDRAULIC RESERVOIR FIG. 4 Choke cable routing, front and rear tie straps "FIG. 5" & "FIG. 6". POS. & NEG. BATTERY CABLES OIL SENSOR WIRE TIE STRAP CHOKE CABLE TIE STRAP TIE STRAP CHOKE CABLE TIE STRAP FIG. 5 FIG.
Fuel line routing "FIG. 7" & "FIG. 8". TIE STRAP WIRE HARNESS NEG. BATTERY CABLE FUEL LINE TIE STRAP POS. BATTERY TIE STRAP CABLE FUEL LINE FIG. 7 LEFT FUEL TANK WIRE HARNESS RIGHT FUEL TANK TO ENGINE THROTTLE CABLE FIG.
Hustler Zs with Kawasaki 29 HP engines: Routings "FIG. 9". POSITIVE BATTERY CABLE WIRE HARNESS TIE STRAP NEGATIVE BATTERY CABLE FIG. 9 Route fuel lines, battery cables, and choke and throttle cables and tie as shown, "FIG. 10". Tie fuel lines to seat support as shown in "FIG. 11" (right side shown, left side similar). WIRE HARNESS TIE STRAP CHOKE CABLE POS. & NEG. BATTERY CABLES FUEL LINES THROTTLE CABLE TIE STRAP FIG. 10 FIG. 11 Choke and throttle cable routed around engine, see "FIG. 12".
Choke and throttle cable connections to engine, see "FIG. 13". CABLE CLAMP CHOKE CABLE STOP SCREW CHOKE CABLE “C” CLAMP THROTTLE THROTTLE PLATE CABLE THROTTLE CABLE FIG. 13 CABLE CLAMP FIG. 14 THROTTLE AND CHOKE CABLE INSTALLATION TO ENGINE (SEE "FIG. 13" & "FIG. 14"). 1. 2. 3. 4. 5. 6. 7. Clamp Instrument Panel to side of seat support in installed orientation Make sure throttle lever is in the full throttle détente position. Install Throttle Cable and leave cable clamp screw loose.
Throttle and choke cable connections to engine: "FIG. 17" and "FIG. 18". CHOKE CABLE CHOKE CABLE THROTTLE CABLE TIE STRAP THROTTLE CABLE FIG. 17 FIG. 18 Hustler Z’s with Honda engines: Choke/Throttle cable routing "FIG. 19". Tie throttle and choke cables to hydro hose as shown.Fuel line routing "FIG. 20" & "FIG. 21". TIE STRAP WIRE HARNESS TIE STRAP POSITIVE BAT. CABLE TIE STRAP NEGATIVE BAT. CABLE CHOKE CABLE THROTTLE CABLE FIG.
FUEL VALVE RIGHT FUEL LINE LEFT FUEL LINE WIRE HARNESS TIE STRAP WIRE HARNESS TO ENGINE FUEL LINE FIG. 20 FIG. 21 Choke/Throttle cable routing "FIG. 22". Tie choke and throttle cables together. CHOKE AND THROTTLE CABLE TIE STRAP LEFT PUMP FIG.
Honda carburetor drain/vent hose routing "FIG. 23". TO CLUTCH VENT/DRAIN HOSES FIG. 23 Hustler Z’s with Kohler engines: Wire harness and cable routing "FIG. 24", "FIG. 25", and "FIG. 26". POSITIVE BATTERY CABLE NEGATIVE BATTERY CABLE FIG.
TIE STRAP WIRE HARNESS WIRE HARNESS TIE STRAP NEGATIVE BATTERY CABLE BATTERY CABLES FUEL LINES & WIRE HARNESS FIG. 25 FIG. 26 Choke and throttle cable routing "FIG. 27". TIE STRAP CHOKE CABLE ROUTE THROTTLE CABLE BELOW HYDRAULIC HOSE FIG.
Fuel line routing "FIG. 28". FUEL LINE TIE STRAP FIG.
Maintenance & 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.
Safe Maintenance & Adjustment Practices ▲ This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death. ▲ Unless specifically required, DO NOT have engine running when servicing or making adjustments to tractor. Place control levers in the park brake position, disengage deck clutch, remove ignition switch key and disconnect the negative battery cable.
off and remove ignition switch key for maximum safety. 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.
Safety and Instruction Decals ▲ Specific safety warning decals are located on the equipment near the immediate areas of potential hazards. These decals should not be removed or obliterated. Replace them if they become nonreadable. The following illustrations show the various safety decals that are located on the machine. A brief explanation, for those requiring one, is shown to help the operator understand the meanings of these decals. Do not smoke while refueling.
Keep shields or covers in place while machine is in operation. Keep hands away from rotating pulleys and belts. Do not remove or modify stabilizer wheels or rear engine guard or injury can result. Part Number 727453 Part Number 771436 Part Number 788968 Part Number 727008 Keep engine and pump compart-ment(s) clean (especially in exhaust area) to prevent fire and provide maximum engine and hydraulic cooling. Hydraulic fluid escaping under pressure can penetrate skin.
Maintenance Maintenance Locator Chart 6 11 2a 7 5 12 9 3 2b 10 4 1a 6 1a. 1b. 2a. 2b. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Maintenance Locator Chart 54" & 66" XR7 deck 3 1 4 2 3 60" XR7 deck 3 1 3 1 4 4 2 3 1. 2. 3. 4. 3 1 Deck Pusher Arm Zerks (2) Deck Belt Spindle Housing Zerk (3) Blades 4 54" Rear Discharge deck 3 1 4 3 2 4 1 3 FIG.
SERVICE AT INTERVALS INDICATED Verify safety start interlock system Visually inspect unit for loose hardware and/or damaged parts Visually inspect tires Check oil level, engine (1) Clean air intake screen (5) Check fuel level Blades - sharpen & securely fastened Discharge chute - securely in place & in lowest position Clean engine and pump compartment Replace air cleaner paper element (5) Grease deck idler Grease deck pusher arms Grease pump idler Grease deck height pivots Grease gauge wheel bearings Change
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.
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. WARNING: Explosive separation of a tire and rim can cause serious injury or death.
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. Otherwise, follow battery manufacturer’s maintenance, safety, storing and charging specifications. The battery is located under the seat platform "FIG. 32". BATTERY FIG.
WARNING: Incorrect battery cable routing could cause damage to the tractor and battery cables. 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.
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 20W50 SG, SF/CC, CD service motor oil. Change hydraulic system filter element ("FIG. 34") after first 50 hours of tractor operation, then replace filter and oil in reservoir every 500 hours thereafter.
Fuel system 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.
The fuel filter ("FIG. 36") is installed in the fuel line between fuel tanks and engine fuel pump. Replace filter 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. 37").
Engine air filter Perform engine air filter maintenance per the scheduled maintenance chart. See “SERVICE AT INTERVALS INDICATED” on page 10-20. 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. 39". PRE-CLEANER ENGINE AIR FILTER Kawasaki Engine Shown FIG. 39 RECOMMENDED SERVICE PROCEDURE 1. 2. 3. 4. 5. Many engine failures can be attributed to improper air cleaner servicing.
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.
A restriction indicator takes the guesswork out of air cleaner servicing and allows you to safely benefit from the filter’s optimum performance. RESET BUTTON INDICATOR FIG. 40 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.
4 5 2 5 5 4 2 5 2 2 2 3 5 Deck Belt Drive Layout 1 1. Spindle drive belt 2. Deck blade spindle pulley 3. Spindle belt tension idler 4. Spindle belt tension idler spring (9.0" at operation) 5. Deck belt idler 6. Idler arm 2 3 6 Deck Belt Drive Layout 1. Spindle drive belt 2. Deck blade spindle pulley 1 3. Spindle belt tension idler 4. Spindle belt tension idler spring (9.0" at operation) 5. Deck belt idler 60" XR7 DECK FIG. 43 5 5 54" RD DECK FIG.
Sharpen the blades on a grinder following pattern as shown "FIG. 45". 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 slowly, blade should not wobble. If blade is out of balance, true it up before reinstalling.
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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 some adjustments to change. Remain alert for unusual noises, they could be signaling a problem. Visually inspect the machine for any abnormal wear or damage. A good time to detect potential problems is while performing scheduled maintenance service.
JAM NUT JAM NUT CONTROL PANEL PUMP LINKAGE ROD STOP PUMP ARM CONTROL LEVER FIG. 49 FIG. 50 If the tractor creeps in the neutral position the control linkage may be adjusted as follows: 1. 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.
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.
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 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.
CONTROL LEVER PARK BRAKE SLOT JAM NUTS 1/8" BREAK LINKAGE OUTSIDE EDGE FIG. 55 TURNBUCKLE FIG. 56 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 slot "FIG. 55". The tire should not rotate when the control lever is in the park brake position. 10.
Deck drive belt adjustment The spindle belt tension remains constant by means of a tension idler and spring "FIG. 58". 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. 58". Installed spring length should be 9.0" ± .3" (22.8 cm ± .
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. 60". This will set the cutting height at 3-1/2 ". NOTE: Back of deck will automatically be set ¼" higher. 4.
5/16" BOLT ADJUSTER JAM NUT HARDWARE FIG. 64 7. Loosen the two nuts on the front of height indicator so that the foot pedal is free "FIG. 65". 8. Start the leveling process on the left front of the tractor. 9. Set the amount of threads protruding on the deck lift rod from the lift block at approximately 1" "FIG. 66". 10. Jam both nuts against the block. 11.
height indicator. FOOT PEDAL LIFT BLOCK 1" 1" DECK LIFT ROD NUTS FIG. 65 FIG.
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