HUSTLER Super Z XR-7 User manual

•••••••
Hustler Turf Equipment
•••••
P.O. Box 7000
•••
Hesston, Kansas
•
67062-2097
Hustler Z XR7
Parts Manual

IMPORTANT: This engine is not equipped with a spark arrester muffler. It is a violation of California Public ResourceCode
Section 4442 to use or operate this engine on any forest-covered, brush-covered, or grass-covered unimproved land. Other
states or federalareas 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.
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects or other reproductive harm.
WARNING:

106567 4/07 c-1
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Chapter 4
Battery Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Chapter 9
Tractor Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
66" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
60" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
54" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

c-2 106567 4/07
Chapter 10
Maintenance & Adjustment Safety . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Safe Maintenance & Adjustment Practices . . . . . . . . . . . . . . . . . . 10-4
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

106567 4/07 1-1
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
Service Literature
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 neces-
sary, without notification. If a change has been made to your machine which is not reflected in this parts manual, see
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
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

1-2 106567 4/07
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.
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.
NOTE:
Loctite® 592 to be used on all pipe threads.
Lubricate all grease zerks.
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
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 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

106567 4/07 2-1
Chapter 2 Contents
Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Footrest Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2-2 106567 4/07
Rivet Nut Installation
NOTES:
1. Seat support 547950 includes rivet nuts.
INDEX NO. SERVICE
PART NO. MFG. PART NO. QTY. DESCRIPTION
1 548032 107701 1 TRACTOR FRAME (54")
547760 106211 1 TRACTOR FRAME (60")
547752 106039 1 TRACTOR FRAME (66")
2 N/A 808493 15 3/8-16 THREAD RIVET NUT
3 N/A 600961 8 1/2-13 THREAD RIVET NUT
4 N/A 808477 2 1/4-20 THREAD RIVET NUT (KAW ONLY)
5 547950 106732 1 XR7 MMZ SEAT SUPPORT
1
2
2
2
2
3
3
4
5
1

106567 4/07 2-3
Footrest Assembly
NOTES:
1. Do not tighten, Item 2 (348276 Floor) must be able to pivot on these
bolts.
INDEX
NO. SERVICE PART NO. MFG. PART NO. QTY 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
1
2
1
3
45
5
6
7

2-4 106567 4/07

106567 4/07 3-1
Chapter 3 Contents
Hydraulic System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 106567 4/07
Hydraulic System Installation
822
FRONT
16 1
31
23
4
17
18
5
6
7
20
19
17
21
10
11
23 12
24
25
26
929
11
10
18
20
14
30
15
17
11
13
27
24
12
28

106567 4/07 3-3
Hydraulic System Installation
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)
ITEM
NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION
1 768515 768515 2 FW .281 X .625 X .051/.080 HD ZN/YL
2 055947 055947 2 CS .250-20 X .500 HX G5 ZN
3 032771 032771 1 STRAINER
4 032763 032763 1 BREATHER CAP
5 349860 349860 1 RESERVOIR
6 034272 034272 4 NT .312-18 HX G5 ZN
7 768523 768523 4 FW .343 X .687 X .051/.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 LEFT 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)

3-4 106567 4/07
HYDRAULIC SYSTEM CHARGING PROCEDURE
1. Set handles in the neutral position.
2. Start engine at idle.
3. Let run for a minimum of 30 seconds.
4. Stroke handles to forward position.
5. 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)

106567 4/07 4-1
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

4-2 106567 4/07
Battery Installation
1
TRACTOR
FRAME
11
12
99
10
8
4
1
3165
8
5
7
2
11

1065674/07 4-3
Battery Installation
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.
INDEX
NO. SERVICE PART NO. MFG. PART NO. QTY 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 .312-18 X 3.00 FUL ZN

4-4 106567 4/07
Deck Lift Assembly
1
TRACTOR
FRAME
1
1
1
4
1
3
2
5
5
5
5
5
4
45
6
8
8
4
4
4
4
14
13
9
710
10
4
10
11 12
8
10
6
9
9

1065674/07 4-5
Deck Lift Assembly
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).
ITEM
NO. SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION
1 348318 348318 1 STOP HANDLE
2 600437 600437 1 DECK HEIGHT 1/2" PIN W/A
348284 N/A 1 HEIGHT ADJUSTMENT STOP 3/8"
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
14 781831 781831 1 CS .437-14 X 1.750 FUL THD G5 ZN
2
{

4-6 106567 4/07
Steering and Park Brake Assembly
TRACTOR
FRAME
1
2
3
15
27
10 3
28 3
40 29
30
7
7
6
30
36
36
37
28
34
3
29
33
32
31
39
26
35
3
41
2
3
4
5
7
6
8
9
14 7616
15
3
3
17
18
722
23
6
4
24
38
7
7
533
21 21
30
11
1
10 3
11 12 13
19
20
25