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User manual HUSTLER 107652
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Manual abstract: user guide HUSTLER 107652
Detailed instructions for use are in the User's Guide. Hustler Mini Z 36/42 Parts Manual
·······
Hustler Turf Equipment
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P.O. Box 7000
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Hesston, Kansas
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67062-2097
107652 Rev. 8/06
Table of Contents
Chapter 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Chapter 2 Contents Frame Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Anti-Rollover Bracket Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Chapter 3 Battery Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydro Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering and Brake Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3-4 3-6 3-8
Chapter 4 Contents Kawasaki Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Fuel System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Instrument Panel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Chapter 5 Contents Front Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Front Wheel BreakdownÂ786061 . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Drive Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Chapter 6 Contents Deck AssemblyÂ36" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deck Pulley AssemblyÂ36" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deck AssemblyÂ42" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deck Pulley AssemblyÂ42" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spindle AssemblyÂ783506 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6-4 6-6 6-8 6-10
Chapter 7 Contents Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Deck Belt Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Seat Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Chapter 8 Contents Tractor Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 36" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 42" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1
107652 8/06
c-1
c-2
107652 8/06
Chapter 1 General Information
This Manual covers Hustler Mini Z 17/36 model 928192 and Hustler Mini Z 19/42 928200,
Frequently Ordered Parts
PART NO. 788794 600726 600734 068478 797852 761726 600976 772079 DESCRIPTION Pump Drive Belt Deck Drive Belt, 36" Deck Drive Belt, 42" Fuel Filter Air Filter Precleaner Air Filter Element ZT 2800 Oil Filter Engine Oil Filter
Service Literature
PART NO. 107708 797795 DESCRIPTION Owner's Manual Kawasaki 17/19 HP Kai 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.
107652 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
SIZE M3 M4 M5 M6 M8 M10 M12 M14 M16 M20 M24 NOTE:
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
107652 8/06
Chapter 2 Contents
Tractor Frame Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Anti-Rollover Bracket Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
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2-1
Frame Rivet Nut Installation
2
1
INDEX NO.
SERVICE PART NO. 547851 547869 N/A
MFG. PART NO. 107300 107318 808493
QTY. 1 1 4 MINI Z 36" FRAME MINI Z 42" FRAME
DESCRIPTION
1
1 2
3/8-16 THREAD RIVET NUT
NOTES:
1. Service part frames include decals, see "Tractor Decals" on page 8-2.
2-2
107652 8/06
Anti-Rollover Bracket Assemblies
TRACTOR FRAME 2 4 8
1 3 5 6 7 8 6 5 3 4 2
INDEX NO. 1 2 3 4 5 6 7 8
SERVICE PART NO. 320580 781708 767962 031997 053199 344267 781567 N/A 788166
MFG. PART NO. 320580 N/A N/A N/A N/A 344267 781567 808493 788166
QTY. 2 2 4 2 2 4 2 6 2
DESCRIPTION ANTI ROLLOVER BRACKET CS .500-13 X 4.25 HX G5 FW .531 X 1.063 X .090 SAE ANTI-SCALP WHEEL NT .500-13 HX JAM ZNYC FW .510 X 2.15 X .187 SPL NT .500-13 HX GR8 ZNYC NL 3/8-16 THREAD RIVET NUT ANTI SCALP WHEEL ASSEMBLY
1
NOTES:
1. Includes items 2 through 5.
107652 8/06
2-3
Footrest Assembly
1
2 3 4 5 TRACTOR FRAME 9 4
6
4 7
8
INDEX NO. 1 2 3 4 5 6 7 8 9
SERVICE PART NO. 785493 785485 054502 767954 107637 107011 781880 052860 025395 086660
MFG. PART NO. 785493 785485 054502 767954 107637 107011 781880 052860 025395 086660
QTY. 1 2 2 6 1 1 2 2 2 2
DESCRIPTION LOWER STEP TREAD UPPER STEP TREAD NT .375-16 HX GRD 5 ZNYC FW .406 X .812 X .060 SAE 36" MINI Z FLOORPAN 42" MINI Z FLOORPAN .500 X 1.00 X .31 BUMPER CS .375-16 X 1.250 HX G5 CB .375-16 X 1.00 STD CD NT .375-16 HXZY NL
NOTES:
2-4
107652 8/06
Chapter 3 Contents
Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Hydro Transmission Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Steering and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
107652 8/06
3-1
Battery Installation
1 4 2 3 3 4 5 2 TRACTOR FRAME 6 4 2
8 9
7
10
INDEX NO. 1 2 3 4 5 6 7 8 9 10
SERVICE PART NO. 107631 024927 055939 029868 771428 786632 786640 740696 784918 793489
MFG. PART NO. 107631 024927 055939 029868 771428 786632 786640 740696 784918 793489
QTY. 1 3 2 4 1 1 1 1 1 1
DESCRIPTION MINI Z BATTERY STRAP NT .250-20 HX GR.5 ZNYC CS .250-20 X .750 HX G5 LW .250 INT-EXT TOOTH ZNYC RED BATTERY CABLE BOOT POSITIVE BATTERY CABLE NEGATIVE BATTERY CABLE BATTERY VU1LH-8 RUBBER BUMPER BATTERY CLAMP ROD
NOTES:
3-2
107652 8/06
This page intentionally left blank.
107652 8/06
3-3
Deck Lift Assembly
1
2
3 6 7 5 4 9 8 8 9 11
10
1
9
1
14 11 8 15 8 7 9 5 12 7 13 7 7 16 12 17 7
1
11
3-4
107652 8/06
Deck Lift Assembly
INDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 SERVICE PART NO. 348318 348284 797969 782995 055749 334045 704643 025296 781294 781229 015495 360131 767962 756270 034272 348458 781831 MFG. PART NO. 348318 348284 797969 782995 055749 334045 704643 025296 781294 781229 015495 360131 767962 756270 034272 348458 781831 QTY. 1 1 1 1 2 1 6 4 5 1 3 2 2 1 1 1 1 STOP HANDLE HEIGHT ADJUSTOR STOP DECK HEIGHT INDICATOR ASSEMBLY DECK LIFT SPRING ASSEMBLY CS .437-14 X 1.75 HX G5 DECK LIFT LINK NT .437-14 HX FLG ZNYC FW .760 X 1.625 X .08 ZNYC 1.00 X .625 X .05 E CLIP CE .750 X 2.25 X 1.75 HEADLESS STRAIGHT GREASE FITTING DECK LIFT CHAIN FW .531 X 1.063 X .090 SAE CS .312-18 X 1.50 FLTHR GR 5 NT .312-18 HX G5 ZNYC DECK LEVELER YOKE CS .437-14 X 1.75 FULTH DESCRIPTION
NOTES:
1. Apply grease to Zerks.
107652 8/06
3-5
Hydro Transmission Installation
2 1 1
2 21 20 22 23 26 27 23 30 29 28 4 3 5
3 2
24 25 26 30 31 3 5 3 6 9 8 7 10 7
11
12
13
14 15 2 2 19 2 17
1
16
17
1
18
3-6
107652 8/06
Hydro Transmission Installation
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 SERVICE PART NO. 710087 768523 028118 794404 025007 786848 025296 781153 324046 061101 036384 364315 788794 797225 797233 600965 034272 107633 054502 767954 036244 055939 768515 107632 600759 778381 107645 107644 024927 600880 600881 MFG. PART NO. 710087 768523 028118 794404 025007 786848 025296 781153 324046 061101 036384 364315 788794 797225 797233 600965 034272 107633 054502 767954 036244 055939 768515 107632 600759 778381 107645 107644 024927 600880 600881 QTY. 8 12 4 1 2 1 2 2 1 1 1 1 1 1 1 1 8 1 1 2 2 2 4 1 1 4 1 1 2 2 1 DESCRIPTION CS .312-18 X 2.50 HX G5 FW .343 X .687 X .051/.080 HD ZNYC FW .625 X 1.00 X .134 ZNYC STATIONARY IDLER PULLEY CS .625-11 X 1.75 HX G5 IDLER PULLEY FW .760 X 1.625 X .08 ZNYC UHMW BUSHING HYDRO IDLER ARM NT .750-10 HXZY NL SPRING 1/4 COIL PL 1.23 SPRING CHAIN PUMP BELT LEFT ZT-2800 RIGHT ZT-2800 CS .375-16 X 8.50 G5 HX ZN NT .312-18 HX G5 ZNYC TRANSMISSION SPACER NT .375-16 HX GRD 5 ZNYC FW .406 X .812 X .060 SAE CS .375-16 X 1.000 HX G5 CS .250-20 X .75 HX G5 FW .281 X .625 X .051/.080 HD ZNYC OVERFLOW TANK BRACKET OVERFLOW TANK ASSEMBLY HOSE CLAMP OVERFLOW HOSE 6" LONG OVERFLOW HOSE 4.25" LONG NT .250-20 HX GR.5 ZNYC 45° HYD FITTING HYDRAULIC BUSHING
NOTES:
1. Torque to 17 ft.-lbs. 2. Spring length is 5.0".
107652 8/06
3-7
Steering and Brake Assembly
1 2 3 12 21 20 19 15 11 18 13 15 18 22 21 12 15 18 14 12 9 24 12 10 12 11 15 16 23 17 8 5 3 3 4 3 7 7 6 3 4
25
26
18
32
37
STEERING LINK ROD 12 29 12 28 18 12 30 28 29 31 18 33 34 32 35 11 36
3-8
107652 8/06
Steering and Brake Assembly
INDEX NO. SERVICE PART NO. 781260 360487 767954 086660 705178 797753 797779 005108 079186 600896 600895 11 12 13 14 15 16 17 18 19 20 21 22 034272 768523 718288 325464 768259 054502 600878 041152 794396 793646 781922 600221 783696 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 793059 793612 781567 795625 796615 024927 600884 600882 795229 797837 048553 034280 600894 107651 016766 600957 MFG. PART NO. N/A 360487 767954 086660 705178 797753 797779 005108 079186 600896 600895 034272 768523 718288 325464 768259 054502 600878 041152 794396 793646 781922 600221 783696 793059 793612 781567 795625 796615 024927 600884 600882 795229 797837 048553 034280 600894 107651 016766 600957 QTY. 2 2 12 6 4 2 8 2 2 1 1 6 24 2 2 8 2 2 12 2 2 4 2 2 2 2 2 2 2 4 1 1 2 2 4 2 2 2 2 2 DESCRIPTION STEERING BAR GRIP STEERING BAR FW .406 X .812 X .060 SAE NT .375-16 HX ZNYC NL CS .375-16 X 1.75 HX G5 STEERING ARM IGUS BUSHING CS .375-16 X 3.50 HX G5 ZNYC CS .312-18 X 1.25 HX G5 LH STEERING BLOCK RH STEERING BLOCK NT .312-18 HX G5 ZNYC FW .343 X .687 X .051/.080 HD ZNYC FW .516 X .875 X .09 ZNYC STEERING CONTROL ARM IGUS BUSHING NT .375-16 HX GRD 5 ZNYC CS .375-16 X 1.75 G5 FULTD NT .312-24 HX ZNYC STEERING LINK ROD ASSEMBLY PUMP ROD ADJUSTER ASSEMBLY DAMPER BALL STUD CENTERING DAMPENER CENTERING DAMPENER E CLIP (1/2") .80 X .396 X .042 STEERING DRIVE ARM NT .500-13 HX G8 ZNYC NL SNAP MOUNT PLUNGER SWITCH BALL JOINT LINK NT .250-20 HX GR.5 ZNYC LH BRAKE ACTUATOR RH BRAKE ACTUATOR INLINE BALL JOINT BRAKE ROD ACTUATOR CP .062D X 1.00 LG HML ZNYC CS .312-18 X .750 HX G5 CS 8-32 X .75 PHIL PH BRAKE LEVER ADAPTOR NT # 8-32 HX ZN TOWLINK ROD
1
1 2 3 4 5 6 7 8 9 10
2
NOTES:
1. Included with Item 2 (360487 Steering Bar). 2. Use 783696 on mowers with serial numbers prior to 06080000.
107652 8/06
3-9
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107652 8/06
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