Hustler Z Parts Manual ······· Hustler Turf Equipment ····· P.O. Box 7000 ··· Hesston, Kansas · 67062-2097 350165 Rev. 5/02 Table of Contents Chapter 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Chapter 2 Contents Nutserts Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Chapter 3 Contents Hydraulic System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Chapter 4 Contents Battery Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering and Park Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . Pump Belt and Pulleys Installation . . . . . . . . . . . . . . . . . . . . . . . . . Deck Lift Spring 782995 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deck Lift Indicator 783001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 5 Contents Kawasaki Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Panel Assembly/Installation . . . . . . . . . . . . . . . . . . . . . Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 6 Contents Front Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Wheel Breakdown - 747782 . . . . . . . . . . . . . . . . . . . . . . . . . Drive Wheel Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . Anti-Rollover Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 7 Contents 72" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60" Deck (with Blade Saddles) Pulley Assembly . . . . . . . . . . . . . . 60" Deck (No Blade Saddles) Pulley Assembly . . . . . . . . . . . . . . . 52" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spindle Housing Assembly - 520627 . . . . . . . . . . . . . . . . . . . . . . . Spindle Assembly - 350595 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4-4 4-6 4-10 4-12 4-13 5-2 5-4 5-6 5-8 6-2 6-4 6-5 6-6 7-2 7-4 7-6 7-8 7-10 7-12 7-14 7-16 7-17 Chapter 8 Contents Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Deck Belt Routing and Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Chapter 9 Contents Tractor Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 72" and 60" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 52" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 926253 5/02 c-1 Chapter 10 Contents Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 Chapter 11 Contents 72" and 60" Mulch Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52" Mulch Kit - 344929 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Valve Kit - 353748 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2-3 2-4 i-1 c-2 926253 5/02 Chapter 1 General Information This Manual covers Hustler Z models 926253, 926295, 926311, 926345, 926451,926469, 926550, and 926568. Frequently Ordered Parts PART NO. 027912 027920 768341 781443 784207 781310 782292 068478 780171 780155 772079 777391 781898 782516 783977 DESCRIPTION LUBRIZOL 7 OZ. BOTTLE LUBRIZOL 10 OZ. BOTTLE HYDRAULIC OIL FILTER PUMP DRIVE BELT B-SECTION BELT, 72" DECK B-SECTION BELT, 60" DECK B-SECTION BELT, 52" DECK FUEL FILTER AIR FILTER ELEMENT ASSEMBLY PRECLEANER AIR FILTER ENGINE OIL FILTER 21" HIGH SAIL CW BLADE 18" CW BLADE FOR SADDLESS 21" CW BLADE FOR SADDLESS 24" OFFSET FLATBLADE Service Literature PART NO. 350157 778423 DESCRIPTION HUSTLER Z OWNER'S MANUAL 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. 350165 5/02 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 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 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 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 NOTE: Loctite 592 to be used on all pipe threads. Lubricate all grease zerks. 1-2 350165 5/02 Chapter 2 Contents Nutsert Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Foot Rest Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 350165 5/02 2-1 Nutserts Installation 1 2 INDEX NO. 1 SERVICE PART NO. 545285 545350 545806 MFG. PART NO. 349605 347534 362657 808493 QTY 1 1 1 4 DESCRIPTION TRACTOR FRAME (60") TRACTOR FRAME (52") TRACTOR FRAME (72") 3/8-16 THREAD NUTSERT 2 N/A NOTES: 2-2 350165 5/02 Footrest Assembly 1 2 3 4 5 6 5 7 1 INDEX NO. 1 2 3 4 5 6 7 SERVICE PART NO. 359547 348276 305615 086660 767954 781880 052860 MFG. PART NO. 359547 348276 305615 086660 767954 781880 052860 QTY 2 1 2 2 4 2 2 STEP TREAD FLOOR DESCRIPTION PLATFORM STEP TREAD NT .375-16 HX LK NY FW .406 X .812 X .060 SAE HD ZN RUBBER BUMPER 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. 350165 5/02 2-3 2-4 350165 5/02 Chapter 3 Contents Hydraulic System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 350165 5/02 3-1 Hydraulic System Installation 4 2 1 16 15 31 5 20 17 3 3 17 19 18 6 8 FRONT 14 23 10 7 22 11 21 12 24 20 30 18 3 26 25 17 10 11 9 28 29 11 27 12 13 24 3-2 350165 5/02 Hydraulic System Installation ITEM 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. 768515 055947 032771 032763 349860 034272 768523 781062 781047 041707 704742 781054 705186 768341 768333 781575 763946 778985 781591 779132 781559 781542 781658 781526 781500 781492 781484 781476 781534 781518 763953 N/A MFG. PART NO. 768515 055947 032771 032763 349860 034272 768523 781062 781047 041707 704742 781054 705186 768341 768333 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 781469 QTY 2 2 1 1 1 4 4 1 1 4 8 2 4 1 1 1 3 2 1 2 1 1 1 4 1 1 1 1 2 1 1 1 DESCRIPTION FW .281 X .625 X .051/.080 HD ZN/YL CS .250-20 X .500 HX G5 ZN STRAINER BREATHER CAP RESERVOIR NT .312-18 HX G5 ZN FW .343 X .687 X .051/.080 HD ZN/YL HYDRO-GEAR PUMP, BDP-10A-300 HYDRO-GEAR PUMP BDP-10A-400 NT .437-14 HX G5 ZN FW .453 X .812 X .060 ZN ROSS/PARKER WHEEL MOTOR, MB-15 CS .437-14 X 1.375 HX G5 ZN FILTER ELEMENT FILTER HEAD -6STR -6 90°, PUSHLOC HOSE 4.75" 90°, -6 O-RING/-6 JIC FITTING -6STR -6 90°, PUSHLOC HOSE, 13.00" -6STR -6 90°, PUSHLOC HOSE, 15.00" STR-6MORB/-6JIC FITTING 45°, -8MORB/-8MSL FITTING 90°,-8MORB/-8MSL FITTING STR-8-MORB/HEX PLUG 90°, -10MORB/-8MSL FITTING RIGHT LOOP/RP-BM HYDRO TUBE RIGHT LOOP/LP-TM HYDRO TUBE LEFT LOOP/RP-BM HYDRO TUBE LEFT LOOP/LP-TM HYDRO TUBE STR-8MORB/-8MSL FITTING -6STR -6STR PUSHLOC HOSE, 9.00" -6 O-RING/-6JIC/6JIC T FITTING MMZ HYDRAULIC KIT (INCLUDES 16-31) NOTES: 1. Add 3.5 oz. Lubrizol (027912) to new system or 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) 3. Two of Items 17 (763946 90°, -6 O-Ring/-6 JIC Fitting) must be installed to pumps prior to installing pumps in tractor. 350165 5/02 3-3 HYDRAULIC SYSTEM CHARGING PROCEDURE 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. Increase throttle to half speed and work handles through forward and reverse position until the motor operates smoothly throughout the entire speed range. 1. 2. 3. 4. 5. 3-4 350165 5/02 Chapter 4 Contents Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Steering and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Pump Belt and Pulley Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Deck Lift Spring 782995 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Deck Lift Indicator 783001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 350165 5/02 4-1 Battery Installation BLACK WIRE, PART OF WIRE HARNESS 3 2 1 1 5 6 5 7 8 9 4 RED WIRE, PART OF WIRE HARNESS 8 10 9 TRACTOR FRAME 1 2 3 11 14 12 11 5 2 13 4-2 350165 5/02 Battery Installation INDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 SERVICE PART NO. 024927 771428 768820 744276 768523 058776 348417 055939 029868 740696 034272 034280 779850 029876 MFG. PART NO. 024927 771428 768820 744276 768523 058776 348417 055939 029868 740696 034272 034280 779850 029876 QTY 2 1 1 1 3 2 1 2 4 1 2 1 2 1 DESCRIPTION NT .250-20 HX GR.5 ZN RED BATTERY CABLE BOOT BATTERY GROUND CABLE POSITIVE BATTERY CABLE FW .343 X .687 X .051/.080 HD ZN/YL NT .312-18 HX NL ZN BATTERY CLAMP STRAP CS .250-20 X .750 HX G5 ZN LW .250 INT-EXT TOOTH ZN BATTERY NT .312-18 HX G5 ZN CS .312-18 X .750 HX G5 ZN CB .312-18 X 3.00 FUL ZN LW .312 INT-EXT TOOTH ZN NOTES: 1. Battery ground cable and black wire of harness should not be connected to battery until engine is ready to be started. See Owners Manual. 2. Items 12 (034272 NT .312-18 HX G5 ZN) to be tightened against frame to lock Items 14 (779850 CB .312-18 X 3.00 FUL ZN) to frame. 350165 5/02 4-3 Deck Lift Assembly 1 2 4 6 5 TRACTOR FRAME 5 3 4 5 12 11 4 6 5 5 10 1 4 5 10 13 10 1 8 4 4 1 10 1 7 9 8 4 14 8 4 9 9 4-4 350165 5/02 Deck Lift Assembly ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 SERVICE PART NO. 348318 348284 783001 704643 781294 782995 781229 055749 348391 015495 034272 756270 348458 781831 MFG. PART NO. 348318 348284 783001 704643 781294 782995 781229 055749 348391 015495 034272 756270 348458 781831 QTY 1 1 1 8 7 2 1 3 4 4 1 1 1 1 STOP HANDLE HEIGHT ADJ STOP DECK LIFT INDICATOR SUBASSEMBLY NT .437-14 HX FLG ZN CLIP E, 1.00 X .625 X .050 DECK LIFT SPRING SUBASSEMBLY CE .750 X 2.25 X 1.75 HEADLESS CS .437-14 X 1.750 HX G5 ZN DECK LIFT CHAIN STRAIGHT GREASE FITTING NT .312-18 HX G5 ZN CS .312-18 X 1.50 FUL THR GR5 ZN DECK LEVELER YOKE CS .437-14 X 1.750 FUL THD G5 ZN DESCRIPTION NOTES: 1. Apply grease to zerks on new assemblies. 350165 5/02 4-5 Steering and Park Brake Assembly 1 11 12 13 10 8 2 3 6 3 6 23 22 24 14 4 5 5 3 3 3 9 15 47 10 5 7 6 24 25 7 6 16 3 20 3 17 7 18 33 7 26 7 9 27 28 21 43 4 19 30 29 3 3 3 10 39 38 31 3 32 3 40 3 41 45 42 31 39 6 7 3 33 7 34 37 3 33 46 32 3 1 44 36 15 4 TRACTOR FRAME 35 2 4-6 350165 5/02 ...