Hustler Turf Z XR7 manual Safe Maintenance & Adjustment Practices

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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. 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 operator’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.

Never put hands or feet under any part of the machine while it is running.

Except when changing or checking belt, always keep belt covers on mower for safety as well as 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 gasoline 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

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106567 4/07

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Contents Hustler Z XR7 Parts Manual This spark ignition system complies with Canadian ICES-002 Table of Contents Chapter General Information Service LiteratureFrequently Ordered Parts Hardware Description Codes & Abbreviations Contents Thread Rivet NUT Rivet Nut InstallationTractor Frame Thread Rivet NUT KAW onlyFloor Footrest AssemblyStep Tread Platform Step Tread106567 4/07 Contents Hydraulic System Installation Reservoir StrainerBreather CAP HYDRO-GEAR PUMP, BDP-10A-300Hydraulic System Charging Procedure Contents Battery Installation Positive Battery Cable RED Battery Cable BootNegative Battery Cable Battery Clamp StrapDeck Lift Assembly Deck Lift Spring Subassembly Height Adjustment Stop 3/8Deck Lift Indicator Subassembly Stop HandleSteering and Park Brake Assembly Pump ROD Adjuster Assembly Brake ROD AssemblyPush Button Switch Adjustable Pivot106567 4/07 This page intentionally left blank Pump Belt and Pulleys Installation KEY 5MM X 30MM Radius Ends Engine SC Single PulleyWarner Clutch Pulley & FAN106567 4/07 106657 4/07 Part Kawasaki Engine InstallationEngine Common Wire Harness Battery CableWire Harness Adapter Starter Relay Ground WireMain AIR Filter Element Vacuator Valve This page intentionally left blank Part Engine YEL BLK Negative Battery Cable RED/BLK Honda Engine InstallationORG BRN GRA/PUR Positive Battery Cable Honda OIL Drain Valve Remote AIR Cleaner Mount BracketHonda 24HP Engine LOW Pressure HOSE, 3.00 LongMain AIR Filter Element Vacuator Valve This page intentionally left blank Kohler Engine Installation OIL Drain Valve Kohler 27HP EngineRemote AIR Filter Hose Straight LOW Pressure HoseFuel System Installation Right Side Fuel Tank Fuel CAPLeft Side Fuel Tank ClipInstrument Panel Assembly RED Indicator Light PTO SwitchKEY Switch Delay Module not ShownElectrical Schematic Contents Front Wheel Assembly Fork Optional SEMI-PNEUMATIC WHEEL/TIRE AssemblyBearing W/O Collar Wheel & Tire AssyBearing Spacer Front Wheel Breakdown-747782Wheel Bearing Tire ValveTIRE/WHEEL Assembly Optional Semi-Pneumatic Tire/Wheel-789537Drive Wheel Assembly Installation Anti-Rollover Wheel Assembly ANTI-SCALP Wheel106567 4/07 Contents Deck Assembly Deck Crated Rubber Chute AssemblyANTI-SCALP Wheel Assembly Discharge Chute Mount BracketDeck Pulley Assembly Deck Belt Idler Guide Spindle Housing AssemblySection Belt RS Uhmw Idler SlideSide Discharge Deck Assembly Rear ANTI-SCALP Bracket Deck Deck Drive Pulley RS 60 XR7 Pulley CoverLS 60 XR7 Pulley Cover Optional BLADE, 20.50 GAT-F-CWDeck Assembly Discharge Chute AIR Flow BaffleDeck Assy Belt Guide Positioning Deck Belt Idler TOP Guide Idler Slide Uhmw RSIdler Slide Uhmw LS Uhmw .03 ThickSpindle Assembly-796235 Contents Deck Installation 055749 CS .437-14 X 1.750 HX G5 ZN Deck Belt Routing and Tensioning 106567 4/07 Seat Installation Seat PAN Seat SwitchMichigan Seat Black Cable TIE106567 4/07 Contents Tractor Decals Service Decal Deck Height Indicator DecalFuel Indicator Decal Battery DecalDeck Decals 786277 799171 106567 4/07 10-1 10-2 1065674/07 Maintenance & Adjustment Safety Safe Maintenance & Adjustment Practices Using a ramp Safety and Instruction Decals Whirling blades! Keep hands and feet awayHot surface 10-7 106567 4/07 Maintenance Maintenance Locator ChartMaintenance Locator Chart References Torque values IntroductionHour meter TiresLubrication Battery Electrical systemAccess to engine and hydraulic pumps Hydraulic systemHydraulic Reservoir Hydraulic Filter Fuel system Fuel Tank Fuel FilterEngine oil and filter Recommended Service Procedure Engine air filterOverservicing Improper installation of an air filter elementIncorrect air cleaner element Damaged filter, seals or canisterAir restriction indicator Recommended service procedureGeneral engine maintenance Belt replacement Viewed from Bottom of UnitMower blade maintenance Mower blade removal10-23 106567 4/07 This page intentionally left blank Introduction AdjustmentControl Lever Neutral Adjustment Steering linkageStop Control Lever Control lever stopsControl lever adjustment Steering dampenerPark brake adjustment Front Brake Link Right Side Bypass ValveHydraulic pump belt adjustment Deck drive belt adjustmentDeck leveling and height adjustment Engine RPM settingDeck level adjustments Deck Lift Foot Pedal Nuts Lift Block Deck Lift ROD Numerical Index Part Part Part