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User manual HUSTLER 103234
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Manual abstract: user guide HUSTLER 103234
Detailed instructions for use are in the User's Guide. Hustler TrimStar Hydro Walkbehind Parts Manual
·····
P.O. Box 7000
···
Hesston, Kansas
·
67062-2097
103234 Rev. 8/06
Table of Contents
Chapter 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Chapter 2 Contents 36" Deck Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48" Deck Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Caster Wheel AssemblyÂ788064 . . . . . . . . . . . . . . . . . . . . . . . . . . Spindle AssemblyÂ350595K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 3 Contents Tractor Frame Rivet Nut Assembly . . . . . . . . . . . . . . . . . . . . . . . . . Hydro Transmission Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Lower Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-Bar Steering Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 4 Contents Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Schematic--792838 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 5 Contents Drive Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36" Belt Routing and Tensioning. . . . . . . . . . . . . . . . . . . . . . . . . . . 48" Deck Belt Routing and Tensioning . . . . . . . . . . . . . . . . . . . . . . Tractor Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2-4 2-6 2-8 2-10 2-12 2-14 2-15 3-2 3-4 3-6 3-8 4-2 4-4 4-6 4-8 5-2 5-3 5-4 5-6 5-8 5-9 i-1
103234 8/06
c-1
c-2
103234 8/06
Chapter 1 General Information
This Manual covers TrimStar (15/36) model 927400 & TrimStar (17/48) model 927426.
Frequently Ordered Parts
PART NO. 788711 788729 788745 797514 788737 068478 797852 797860 772079 DESCRIPTION Pump Drive Belt TS 48" Deck Drive Belt, B-Section (65.29 EL) TS 48" Deck Belt, B-Section (86.0 EL) TS 36" Deck Drive Belt, A-Section (66.0 EL) TS 36" Deck Belt, A-Section (49.8 EL) Fuel Filter Kawasaki KAI Air Filter Precleaner Kawasaki KAI Air Filter Cartridge Engine Oil Filter
Service Literature
PART NO. 104893 797787 797795 DESCRIPTION TrimStar Owner's Manual Kawasaki KAI 15HP Engine Manual Kawasaki KAI 17/19HP Engine 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 your Hustler dealer for current information and parts.
103234 8/06
1-1
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 M16 M20 M24
FT-LBS 1 2.2 4.5 7.7 18.5 37 64 160 320 555
NM 1.3 3 6.1 10.4 25 50 87 215 435 750
Loctite® 592 to be used on all pipe threads. Lubricate all grease zerks.
1-2
103234 8/06
Chapter 2 Contents
36" Deck Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 36" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 36" Deck Pulley Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 48" Deck Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 48" Deck Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 48" Deck Pulley Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Caster Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Spindle AssemblyÂ350595K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
103234 8/06
2-1
36" Deck Carrier Assembly
2 1
3 4 3 4 6 7 8 9 7 8 10
1 1
6 5 3 4 3 4 11 13 14 10 9 11 13 14 13 12
1
1
9
9
12
13
15 16 17
15
19 18 23 24 20 21 23
16 17
22 18
24 23 19 20 21 23 22
36" DECK
25 25 2-2 103234 8/06
36" Deck Carrier Assembly
INDEX NO. SERVICE PART NO. 547596 100883 778399 778373 792002 705954 344267 712976 784223 784603 339689 042630 767962 781567 788604 306969 025593 102343 102350 706176 778431 054502 767954 005116 758631 MFG. PART NO. 381137 100883 778399 778373 792002 705954 344267 712976 784223 784603 339689 042630 767962 781567 788604 306969 025593 102343 102350 706176 778431 054502 767954 005116 758631 QTY. 1 1 8 4 4 2 2 2 4 2 2 2 4 2 2 2 4 2 2 2 2 2 4 2 2 DESCRIPTION TRIMSTAR 36 FRAME DECK MAIN COVER FW .781 X 1.375 X .250 ZNY .875 X 1 PLASTIC BUSHING 5/16-18 X 3/4" MALE KNOB CS .500-13 X 1.25 HX G5 ZN FW .510 X 2.15 X .187 SPL FW .531 X 1.375 X .125 ZNY BEARING FASTRAK SPACER CASTER FORK CS .500-13 X 6.50 HX G5 ZNY FW .531 X 1.063 X .090 SAE NT .50-13 HXZY NL WHEEL/TIRE ASSY 11 X 4-5 GAGE WHEEL SPACER HP .177 X 3.25 WW# 206 ZN FRONT DECK HEIGHT PIN REAR DECK HEIGHT PIN NT .375-24 HX JAM G5 ZN .375-24 SPHERICAL ROD END NT .375-16 HX GRD 5 ZNY FW .406 X .812 X .060 SAE CS .375-16X1.375 HX G5 RP .250X 1.375 HEAVY SPIRAL
2
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
NOTES:
1. Assemble with extended inner race down. 2. Service part frame includes rivet nuts and decals see"Tractor Frame Rivet Nut Assembly" on page 3-2 and "Tractor Decals" on page 5-6.
103234 8/06
2-3
36" Deck Assembly
3
1
2
3
4
5 3 6 8
5 3
10
7 10
11 3 9
2-4
103234 8/06
36" Deck Assembly
INDEX NO. 1 2 3 4 5 6 7 SERVICE PART NO. 798918 058776 767954 063297 054502 102335 011320 547612 036244 808485 102996 MFG. PART NO. 798918 058776 767954 063297 054502 102335 011320 100552 036244 808485 102996 QTY. 1 2 10 2 4 1 2 1 2 2 1 DESCRIPTION RUBBER DISCHARGE CHUTE NT .312-18 HXZY NL FW .406 X .812 X .060 SAE SB .375 X .500 SH .312-18 TD ZN NT .375-16 HX GRD 5 ZNY DISCHARGE CHUTE MOUNT CB .375-16 X .750 STD ZN 36" TRIMSTAR DECK CS .375-16 X 1.00 HX G5 5/16-18 THREAD RIVET NUT ANTI-BLOWOUT BAFFLE
1
8 9 10 11
NOTES:
1. Service part frame includes rivet nuts and decals, see "36" Deck Decals" on page 5-8.
103234 8/06
2-5
36" Deck Pulley Assembly
1
2
3 4 5 9 7 12 13
1
6 7 8 3 15 4 11 5 8 12 14
10
16 17
10
19 24
21 16 7
18 16 1 22 23 16 7 24 20
24 7 25 28 26 27 30 30
2
24
26 27
29
31
31 2
2-6
103234 8/06
36" Deck Pulley Assembly
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 SERVICE PART NO. 797514 788737 781872 028118 788364 023317 767962 781153 008193 770867 382101 036384 340885 259812 340158 016527 108059 372730 100875 103002 796946 078386 797043 792002 077859 350595 212472 793794 793802 782474 029934 705954 MFG. PART NO. 797514 788737 781872 028118 788364 023317 767962 781153 008193 770867 382101 036384 059931 059931 340158 016527 108059 372730 100875 103002 796946 078386 797043 792002 077859 350595 212472 793794 793802 782474 029934 705954 QTY. 1 1 2 2 2 1 11 2 1 2 1 2 1 1 1 9 1 1 1 1 1 1 1 4 1 2 2 1 1 2 2 1 DESCRIPTION BELT, A-SEC 66.0 EL BELT, A-SECT 49.8 EL CS .625-11 X 1.25 HX G5 ZN FW .625 X 1.00 X .134 ZNYC 4.288" IDLER PULLEY NT .500-13 UNT LK G5 ZN FW .531 X 1.063 X .090 SAE UHMW BUSHING NT .500-13 HX G5 ZNYC PLASTIC .75 X 1 BUSHING IDLER ARM SPRING 1/4 COIL PL 1.23 CHAIN (24 LINKS) CHAIN (13 LINKS) IDLER PIVOT BUSHING CS .500-13 X 1.00 HX G5 Z FW .515X1.500X.250 ZY SLIDE IDLER RIGHT PULLEY COVER LEFT PULLEY COVER 5.75 OD JACKSHAFT PULLEY FW .510 X 1.750 X .18 ZNYC 3.50 EOD DECK PULLEY 5/16-18 X 3/4" MALE KNOB CS .500-13 X 3.25 HX G5 SPINDLE ASSEMBLY KEY 1/4 SQ X 1.00 LONG 20.50"-L-F-CW BLADE 13.75"-L-F-CW BLADE CW .631 2.250 X .187 PNT CS .625-11 X 3.00 HX G5 CS .500-13X1.25 HX G5 Z
4
26 27 28 29 30 31 32
NOTES
1. Torque to 65-75 ft.-lbs. 2. Torque to 118 ft.-lbs. 3. See "36" Belt Routing and Tensioning" on page 5-3. 4. See "Spindle AssemblyÂ350595K" on page 2-15.
103234 8/06
2-7
48" Deck Carrier Assembly
2 1
3
6 7 8
1 1
3
4 5 3 3 6 11 9 8 9 10
1
9 10 9
1
4 4
12 13
13
9
11
14 15 16 17 18 22
13
13 12
15 17 23
19 20 21 23 22 23 18 17
19 20 21 23 24
25
24
48" DECK
25
2-8
103234 8/06
48" Deck Carrier Assembly
INDEX NO. SERVICE PART NO. 547604 381491 778399 778373 792002 705954 344267 712976 784223 784603 339689 042630 767962 781567 788604 306969 025593 381582 381616 706176 778431 054502 767954 005116 758631 MFG. PART NO. 351353 381491 778399 778373 792002 705954 344267 712976 784223 784603 339689 042630 767962 781567 788604 306969 025593 381582 381616 706176 778431 054502 767954 005116 758631 QTY. 1 1 8 4 4 2 2 2 4 2 2 2 4 2 2 2 4 2 2 2 2 2 4 2 2 DESCRIPTION TRIMSTAR 48 FRAME DECK MAIN COVER FW .781 X 1.375 X .250 ZNY .875 X 1 PLASTIC BUSHING 5/16-18 X 3/4" MALE KNOB CS .500-13 X 1.25 HX G5 ZN FW .510 X 2.15 X .187 SPL FW .531 X 1.375 X .125 ZNY BEARING FASTRAK SPACER CASTER FORK CS .500-13 X 6.50 HX G5 ZNY FW .531 X 1.063 X .090 SAE NT .50-13 HXZY NL WHEEL/TIRE ASSY 11 X 4-5 GAGE WHEEL SPACER HP .177 X 3.25 WW# 206 ZN FRONT DECK HEIGHT PIN REAR DECK HEIGHT PIN NT .375-24 HX JAM G5 ZN .375-24 SPHERICAL ROD END NT .375-16 HX GRD 5 ZNY FW .406 X .812 X .060 SAE CS .375-16X1.375 HX G5 RP .250X 1.375 HEAVY SPIRAL
2
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
NOTES:
1. Assemble with extended inner race down. 2. Service part frame includes rivet nuts and decals see"Tractor Frame Rivet Nut Assembly" on page 3-2 and "Tractor Decals" on page 5-6.
103234 8/06
2-9
48" Deck Assembly
1 2 3
4 5 3 6 7 8
9 14 7
10 11 10 14 12 12 13
10 11 10 9 14 7
15 5
5
2-10
103234 8/06
48" Deck Assembly
INDEX NO. 1 2 3 4 5 6 7 SERVICE PART NO. 798918 058776 767954 063297 054502 102335 808485 547620 781708 767962 031997 053199 781567 011320 352328 788166 MFG. PART NO. 798918 058776 767954 063297 054502 102335 808485 349993 N/A N/A N/A N/A 781567 011320 352328 788166 QTY. 1 2 6 2 6 1 3 1 2 2 2 2 2 6 2 2 DESCRIPTION RUBBER DISCHARGE CHUTE NT .312-18 HXZY NL FW .406 X .812 X .060 SAE SB .375 X .500 SH .312-18 NT .375-16 HX GRD 5 ZNY DISCHARGE CHUTE MOUNT BRACKET RIVET NUT, 5/16-18 THREAD 48" TRIMSTAR DECK CS .500-13 X 4.25 HX G5 ZNY FW .531 X 1.063 X .090 SAE ANTI-SCALP WHEEL NT .500-13 HX JAM ZNYC NT .50-13 HXZY NL CB .375-16 X .750 STD ZN AIRFLOW ANGLE ANTI SCALP WHEEL ASSY
2
8 9 10 11 12 13 14 15
1
16
NOTES:
1. Includes items 9 through 12. 2. Service part frame includes rivet nuts and decals, see "48" Deck Decals" on page 5-9.
103234 8/06
2-11
48" Deck Pulley Assembly
1
2
4 9 6 7
33 1 5
8
6 11 12 13 7 16 17 12 13 18 19 18 7 20 8 3
1
15
14
10
21 21
22 23 3 12 21
24 25 12 24 21 25 27 28
2
26 29 30
31 27 32
2-12
103234 8/06
48" Deck Pulley Assembly
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 SERVICE PART NO. 788729 788745 016527 108059 796482 781872 028118 781856 368985 368993 008193 767962 770867 340158 372730 788364 023317 781153 382101 016972 792002 078386 796474 036384 340885 077859 782474 783738 212472 350595 795757 029934 705954 MFG. PART NO. 788729 788745 016527 108059 796482 781872 028118 781856 368985 368993 008 ... |
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