Hustler Super Z Diesel Parts Manual ····· P.O. Box 7000 ··· Hesston, Kansas · 67062-2097 350702 Rev. 4/05 Table of Contents Chapter 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Chapter 2 Contents Tractor Frame Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . Seat Latch & Belt Guard Rivet Nut Installation . . . . . . . . . . . . . . . . Seat Support Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . Cooling System Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . Foot Rest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2-3 2-4 2-5 2-6 Chapter 3 Contents Hydraulic Component Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Hydraulic Component Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Hydraulic Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Chapter 4 Contents Battery Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Steering and Park Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Chapter 5 Contents Engine Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cleaner Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat Support Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Muffler Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Tank Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Schematic--795336 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Schematic--795831 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 6 Contents Front Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Wheel Breakdown--791897 . . . . . . . . . . . . . . . . . . . . . . . . . Drive Wheel Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . Anti-Rollover Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 7 Contents 72" Side Discharge Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . 72" Side Discharge Deck Pulley Assembly. . . . . . . . . . . . . . . . . . . Side Discharge Deck Hydraulic Motor Installation . . . . . . . . . . . . . 60" Side Discharge Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . 60" Side Discharge Deck Pulley Assembly. . . . . . . . . . . . . . . . . . . 72" Rear Discharge Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . 72" Rear Discharge Deck Pulley Assembly . . . . . . . . . . . . . . . . . . Rear Discharge Deck Hydraulic Motor Installation . . . . . . . . . . . . . 350702 4/05 c-1 5-2 5-3 5-4 5-6 5-7 5-8 5-10 5-12 5-14 5-16 5-18 5-20 6-2 6-4 6-5 6-6 7-2 7-4 7-6 7-8 7-10 7-12 7-14 7-16 60" Rear Discharge Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . 60" Rear Discharge Deck Pulley Assembly . . . . . . . . . . . . . . . . . . Spindle Assembly--796235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spindle Assembly--796680 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 8 Contents Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Side Discharge Deck Belt Routing and Tensioning . . . . . . . . . . . . Deck Belt Routing and Tensioning­Rear Discharge . . . . . . . . . . . ROPS Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 9 Contents Tractor Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Side Discharge Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Discharge Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18 7-20 7-22 7-23 8-2 8-4 8-5 8-7 8-8 9-2 9-4 9-5 1-1 c-2 350702 4/05 Chapter 1 General Information This Manual covers Hustler Super Z Diesel model 927327 34/60, Hustler Super Z Diesel model 927335 34/72, Hustler Super Z Diesel Rear Discharge model 927608 34/72, & Hustler Super Z Diesel Rear Discharge model 927616 34/60,. Frequently Ordered Parts PART NO. 027912 027920 783936 792267 791970 791988 797159 795773 795815 785261 795799 DESCRIPTION Lubrizol 7 oz. Bottle Lubrizol 10 oz. Bottle Hydraulic Oil Filter Pump Drive Belt B-Section 60" Diesel Z Belt B-Section 72" Diesel Z Belt 72" Diesel Z Rear Discharge Deck Belt 60" Diesel Z Rear Discharge Deck Belt Fuel Filter Air Filter Engine Oil Filter Service Literature PART NO. 351254 795807 DESCRIPTION Super Diesel Z Owner's Manual Caterpillar 3013 User's Handbook 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. 350702 4/05 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 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 350702 4/05 Chapter 2 Contents Tractor Frame Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Seat Latch Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Seat Latch & Belt Guard Rivet Nut Installation . . . . . . . . . . . . . . . . . 2-4 Cooling System Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Foot Rest Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 350702 4/05 2-1 Tractor Frame Rivet Nut Installation 1 2 2 2 2 2 2 2 2 2 2 2 INDEX NO. 1 2 SERVICE PART NO. 547067 N/A MFG. PART NO. 382010 808493 QTY. 1 44 DESCRIPTION DIESEL Z TRACTOR FRAME 3/8-16 THREAD RIVET NUT NOTES: 2-2 350702 4/05 Seat Latch & Belt Guard Rivet Nut Installation 1 3 2 2 INDEX NO. 1 2 3 SERVICE PART NO. 334060 808493 352476 MFG. PART NO. 334060 808493 352476 QTY. 1 6 1 SEAT CATCH DESCRIPTION 3/8-16 THREAD RIVET NUT FAN END BELT COVER NOTES: 350702 4/05 2-3 Seat Support Rivet Nut Installation 2 2 2 1 2 INDEX NO. 1 2 SERVICE PART NO. 333492 808493 MFG. PART NO. 333492 808493 QTY. 1 6 SEAT SUPPORT DESCRIPTION 3/8-16 THREAD RIVET NUT 2-4 350702 4/05 Cooling System Rivet Nut Installation 1 3 2 3 3 INDEX NO. SERVICE PART NO. 101402 338996 N/A MFG. PART NO. 791939 338996 808493 QTY. 1 1 12 DESCRIPTION COOLER PACKAGE OVERFLOW BOTTLE MOUNT 3/8-16 THREAD RIVET NUT 1 1 2 3 NOTES: 1. Service part includes rivet nuts. 350702 4/05 2-5 Foot Rest Assembly 1 2 3 5 6 7 8 5 10 9 11 4 5 12 INDEX NO. 1 2 3 4 5 6 7 8 9 10 11 SERVICE PART NO. 795104 795088 314633 056069 767954 314716 058776 713685 796276 086660 781880 063297 MFG. PART NO. 795104 795088 314633 056069 767954 314716 058776 713685 796276 086660 781880 063297 QTY. 1 1 1 3 7 1 2 2 3 3 2 2 DESCRIPTION FOOTPAN HORIZONTAL SOUNDMAT FOOTPAN VERTICAL SOUNDMAT FLOORPLATE CS .375-16 X .625 HX G5 ZN FW .406 X .812 X .060 SAE HD ZN PIVOTING SUPPORT NT .312-18 HX NL ZNYC FW .312 X .75 X .06 ZNYC 3/8 M/F ROUND VIBRATION MOUNT NT .375-16 HX LK NY BUMPER SB .375 X .500 SH .312-18 TD ZN NOTES: 2-6 350702 4/05 Chapter 3 Contents Hydraulic Component Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Hydraulic Component Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Hydraulic Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 350702 4/05 3-1 Hydraulic Component Fittings 2 1 3 7 4 5 21 12 6 13 14 8 9 13 10 11 13 16 15 17 18 19 18 20 4 3-2 350702 4/05 Hydraulic Component Fittings INDEX NO. 1 2 SERVICE PART NO. 792069 794743 795922 781542 793877 793752 795401 796144 795930 796110 796128 796284 779132 796706 771311 792200 795914 781534 771303 796060 796292 MFG. PART NO. 792069 794743 N/A N/A 793877 793752 795401 N/A N/A N/A N/A N/A N/A N/A N/A 792200 N/A N/A N/A N/A N/A QTY. 1 1 2 6 1 1 1 1 2 1 1 1 5 1 1 1 1 2 2 1 1 DESCRIPTION WHEEL MOTOR, PDM RH PORTS WHEEL MOTOR, PDM LH PORTS FITTING, 90-6MORB/-6MJIC FITTING, 90-8MORB/-8MSL PERMCO PUMP VALVE ASSEMBLY-DIESEL FITTING, T 20MORB.12MJIC.6MJIC FITTING, 45-12MORB/-12MJIC FITTING, STR - 12MORB/-12MJIC FITTING,QC-12FORB/-12F FITTING,QC-12FORB/-12M CASE DRAIN MANIFOLD FITTING, STR-6MORB/-6JIC FITTING, STR-6MORB/-8MORB FITTING, 90-8MORB/-8MJIC HYDRO-GEAR TANDOM PUMP FITTING, STR-6MJIC/-8MORB FITTING, STR-8MORB/-8MSL FITTING, STR-4MORB/-6MJIC HOSE,LP PUMP TO PUMP CASE DRAIN MANIFOLD 1 1 3 4 5 6 7 1 1 1 1 2 2 2 1 1 1 1 1 1 8 9 10 11 12 13 14 15 16 17 18 19 20 21 NOTES: 1. Included in 794727 Hydraulic Kit. 2. Included in Item 21 (796292 Case Drain Manifold) 350702 4/05 3-3 Hydraulic Component Mounting 1 2 4 3 TRANSPORT PUMPS 89 10 1 4 6 5 7 11 21 23 25 22 23 24 12 32 11 20 23 17 24 11 14 1 22 21 6 12 11 11 15 1 26 LEFT SIDE 6 WHEEL MOTOR 27 DECK PUMP 28 29 30 19 18 2 11 13 12 11 14 1 LEFT SIDE WHEEL MOTOR 1 11 15 16 31 26 6 MANIFOLD 3-4 350702 4/05 Hydraulic Component Mounting 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 32 SERVICE PART NO. 032763 032771 791939 050161 056036 767954 712372 794263 028118 021634 767962 781567 074252 721910 795153 794958 794438 016147 795492 795518 029868 782029 712927 058776 795567 029751 350850 086660 015719 783928 783936 796367 MFG. PART NO. 032763 032771 791939 050161 056036 767954 712372 794263 028118 021634 767962 781567 074252 721910 795153 794958 794438 016147 795492 795518 029868 782029 712927 058776 795567 029751 350850 086660 015719 783928 783936 796367 QTY. 1 1 1 6 2 8 1 1 1 1 16 6 2 4 4 2 1 4 1 1 2 2 12 6 3 4 1 2 1 1 1 1 BREATHER CAP STRAINER COOLER PACKAGE CS .312-18 X 1.75 HX G5 ZNYC CS .375-16 X 2.25 HX G5 ZNYC FW .406 X .812 X .060 SAE HD ZN 1/4 SQ X 0.66 LONG KEY 8 GROOVE MIRCO V PULLEY FW .625 X 1.00 X .134 ZNYC NT .625-18 HX PN FW .531 X 1.063 X .090 SAE HD ZN NT .50-13 HX LK NY ZNYC CS .500-13 X 1.50 HX G5 ZNYC CS .500-13 X 2.75 HX G5 ZNYC NT .50-13 SERRATED HX FLANGE AT,1/2-13 X 42.00" B7 ZINC DECK PUMP CLUTCH CS .250-20 X .750 HXFLK ZNYC FW .32 X .875 X .187 CS .312-24 X 1.50 HX W/ LK PATCH CS .250-20 X .625 HXFLK ZNYC LW .250 INT-EXT TOOTH Z FW .344 X 1.00 X .12 HRD ZNYC NT .312-18 HX NL ZNYC DIESEL Z FUEL TANK FOAM CS .375-16 X 1.00 HXFLK ZNYC FILTER GUARD NT .375-16 HX LK NY WOODRUFF .156X.625 SAE# 6 FILTER HEAD ZAF SERIES FILTER ELEMENT 1.625 X 2.00 X .188 RUBBER GROMMET DESCRIPTION NOTES: 1. Torque to 75 ft. lbs. 2. Torque to 25-28 ft. Lbs. 3. Hydraulic system capacity: Fill reservoir to 3.5" below top of fill neck--12 Qts. 4. Electric clutch burnishing procedure: With engine at half throttle-- approximately 2400 RPM--engage clutch for 15 se ...