Hustler Super Z Parts Manual ······· Hustler Turf Equipment ····· P.O. Box 7000 ··· Hesston, Kansas · 67062-2097 355750 Rev. 12/02 Table of Contents Chapter 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Chapter 2 Contents Nutsert 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 25 HP 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 Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 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 Chapter 10 Contents Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 355750 12/02 Chapter 11 Contents 72" and 60" Mulch Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52" Mulch Kit - 344929 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Valve Kit - 353748 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2 11-3 11-4 i-1 355750 12/02 Chapter 1 General Information This Manual covers Hustler Super Z models 926360, 926378, 926436, 926444, 926485, 926493. Frequently Ordered Parts PART NO. 027912 027920 783936 781443 784207 781310 782292 068478 780171 780155 772079 783977 782516 781898 DESCRIPTION LUBRIZOL 7 OZ. BOTTLE LUBRIZOL 10 OZ. BOTTLE FILTER ELEMENT 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 24" OFFSET FLAT BLADE 21" CW BLADE 18" CW BLADE 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. 355750 12/02 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 355750 12/02 Chapter 2 Contents Nutsert Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Foot Rest Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 355750 12/02 2-1 Nutsert Installation 1 2 INDEX NO. 1 SERVICE PART NO. 545756 545731 545749 MFG. PART NO. 348029 353482 359158 808493 QTY. 1 1 1 4 DESCRIPTION SUPER Z 72" FRAME SUPER Z 60" FRAME SUPER Z 52" FRAME 3/8-16 THREAD NUTSERT 2 N/A NOTES: 2-2 355750 12/02 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 .406X .812 X .060 SAE HD ZN RUBBER BUMPER CS .375-16 X 1.25 HX G5 ZNYC NOTES: 1. Do not tighten, Floor must be able to pivot on these bolts. 355750 12/02 2-3 2-4 355750 12/02 Chapter 3 Contents Hydraulic System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 355750 12/02 3-1 Hydraulic System Installation 1 2 SUPER Z HOOD 3 4 7 8 23 26 22 2 22 10 11 23 24 25 14 15 16 26 35 38 12 27 29 28 31 30 18 20 21 17 34 16 19 9 2 32 33 25 24 13 5 15 16 4 6 16 19 37 36 20 38 3-2 355750 12/02 Hydraulic System 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 32 33 34 35 36 37 38 SERVICE PART NO. 705608 768515 713198 783704 033035 068551 032763 032771 055939 357616 034272 768523 783779 783019 008193 767962 783928 783936 008573 782383 700484 784132 784124 784108 784082 781534 781658 784025 783993 764126 784074 783985 784116 782870 782880 782458 782441 781526 N/A MFG. PART NO. 705608 768515 713198 783704 033035 068551 032763 032771 055939 357616 034272 768523 783779 783019 008193 767962 783928 783936 008573 782383 700484 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 N/A 783720 QTY 4 10 2 2 2 4 1 1 2 1 4 4 1 1 4 12 1 1 8 2 2 2 2 2 2 4 1 1 1 1 1 1 1 1 1 1 1 4 1 DESCRIPTION CS .250-20 X 2.25 HX G5 ZNYC FW .281 X .625 X .051/.080 HD ZNYC SEAL 3/8 X 3/4 X 7.25" LONG OIL COOLER WEATHERSTRIP 1/8 X 3/4 X 5.88" LONG NT .250-20 HX NL ZNYC BREATHER CAP STRAINER CS .250-20 X .750 HX G5 ZNYC SUPER Z RESERVOIR NT .312-18 HX G5 ZNYC FW .343 X .687 X .051/.080 HD ZNYC PUMP, HYDRO-GEAR BDP-21L-409 PUMP, HYDRO-GEAR BDP-21L-408 NT .500-13 HX G5 ZNYC FW .531 X 1.063 X .090 SAE HD ZN ZAF SERIES FILTER HEAD FILTER ELEMENT CS .500-13 X 2.50 HX G5 ZNYC WHITE MOTOR CE782383-18 HOSE CLAMP RETURN HOSE ASSY, #6 16.5" LONG RETURN HOSE, #6 16.5" LONG FITTING, #6 BEADED TUBE-ORB 45° FITTING, #8 BEADED TUBE-ORB 90° FITTING, STR-8MORB/-8MSL HEX PLUG FITTING, STR-8MORB SUCTION HOSE ASSY, FILTER-PUMP SUCTION HOSE, TANK-FILTER FITTING, T -8MJIC/8MJIC/8MORIN ADAPTER, -12-8 FITTING, 10 FX05-S SUCTION HOSE, #12 16" LONG TUBE, HYDRAULIC LINE TUBE, HYDRAULIC LINE TUBE, HYDRAULIC LINE TUBE, HYDRAULIC LINE FITTING, 90-10MORB/-8MSL HYDRO KIT (INCLUDES ITEMS 22-38) 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). 355750 12/02 3-3 HYDRAULIC SYSTEM CHARGING PROCEDURE 1. Set handles in the neutral position. 2. Start engine at idle. 3. Let run for a minimum of 30 seconds. 4. Stroke handles to forward position. 5. 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. 3-4 355750 12/02 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 355750 12/02 4-1 Battery Installation BLACK WIRE, PART OF WIRE HARNESS 2 1 4 RED WIRE, PART OF WIRE HARNESS 1 1 3 5 6 5 7 8 9 9 10 5 8 3 14 12 TRACTOR FRAME 2 11 11 2 13 4-2 355750 12/02 Battery Installation ITEM 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 ZNYC 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 .132-18 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 11 (NT .312-18 HX G5 ZN) to be tightened against frame to lock Items 13 (CB .132-18 x 3.00 FUL ZN) to frame. 355750 12/02 4-3 Deck Lift Assembly 1 2 4 3 5 6 2 TRACTOR FRAME 3 4 5 10 7 1 5 5 2 11 12 13 4 7 5 1 4 5 6 4 8 4 7 8 1 4 8 14 9 4 7 1 9 4-4 355750 12/02 Deck Lift Assembly INDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 SERVICE PART NO. 348318 348284 783001 704643 781294 782995 015495 055749 348391 756270 034272 348458 781229 781831 MFG. PART NO. 348318 348284 783001 704643 781294 782995 015495 055749 348391 756270 034272 348458 781229 781831 QTY 1 1 1 8 7 2 4 3 4 1 1 1 1 1 STOP HANDLE HEIGHT ADJUSTMENT STOP DECK LIFT INDICATOR NT .437-14 HX FLG ZN CLIP E, 1.00 X.625X .050 DECK LIFT SPRING ASSEMBLY STRAIGHT GREASE FITTING CS .437-14X1.750 HX G5 ZNYC DECK LIFT CHAIN CS .312-18 X 1.50 FLTHR GR5 ZNYC NT .312-18 HX G5 ZNYC DECK LEVELER YOKE W/A CE .750X2.25 X1.75 HEADLESS CS .437-14 X 1.750 FULTH G5 ZNYC DESCRIPTION NOTES: 1. Apply grease to zerks (see owners manual). 2. See "Deck Lift Spring 782995" on page 4-12 for breakdown. 3. See "Deck Lift Indicator 783001" on page 4-13 for breakdown. 355750 12/02 4-5 Steering and Park Brake Assembly 1 6 7 8 5 17 3 19 11 18 20 21 10 25 16 3 24 4 2 2 3 4 9 10 11 13 3 14 15 6 26 27 8 4 11 12 10 11 19 22 21 23 27 28 29 7 2 3 5 11 10 31 34 24 37 9 2 30 3 32 11 33 3 41 42 39 40 36 38 15 34 3 3 35 33 11 24 1 43 4-6 355750 ...