Hustler Z Parts Manual ······· Hustler Turf Equipment ····· P.O. Box 7000 ··· Hesston, Kansas · 67062-2097 375535 Rev. 6/06 WARNING: The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. IMPORTANT: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate this engine on any forest-covered, brush-covered, or grass-covered unimproved land. Other states or federal areas may have similar laws. This spark ignition system complies with Canadian ICES-002. The enclosed Engine Owner's Manual is supplied for information regarding the U.S. Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance and warranty. Keep this Engine Owner's Manual with your unit. Should the Engine Owner's Manual become damaged or illegible, replace immediately. Replacements may be ordered per the information found in the Product Information section of this manual. Table of Contents Chapter 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Chapter 2 Contents Rivet Nut 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 (Centering Damper) . . . . . . . . Pump Belt and Pulleys Installation . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 5 Contents Kawasaki Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Honda Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kohler Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Schematic - Kawasaki (783894) . . . . . . . . . . . . . . . . . . . Electrical Schematic - Honda (787200). . . . . . . . . . . . . . . . . . . . . . Electrical Schematic - Kohler (788000). . . . . . . . . . . . . . . . . . . . . . Chapter 6 Contents Front Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Wheel Breakdown--747782 . . . . . . . . . . . . . . . . . . . . . . . . . Optional Semi-Pneumatic Tire/Wheel--789537 . . . . . . . . . . . . . . . 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 - 350595K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spindle Assembly - 796235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4-4 4-6 4-14 5-2 5-6 5-10 5-14 5-16 5-18 5-20 5-22 5-24 6-2 6-4 6-5 6-6 6-7 7-2 7-4 7-8 7-10 7-14 7-16 7-19 7-20 Chapter 8 Contents Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Deck Belt Routing and Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Seat Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Chapter 9 Contents 375535 6/06 c-1 Tractor Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 72" and 60" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 52" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Chapter 10 Contents 72" and 60" Mulch Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 72" Mulch Kit­352419 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 60" Mulch Kit­352427 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 52" Mulch Kit­344929 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 52" Mulch Kit­352435 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 Chapter 11 Contents Maintenance & Adjustments Safety Precautions . . . . . . . . . . . . . . 11-3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1 c-2 375565 6/06 Chapter 1 General Information This Manual covers Hustler Z models 926667 24/60, 926675 24/60, 926881 23/52, 926915 23/60, 926923 23/60, 926931 25/60, 926949 25/60, 926964 25/72, 927111 27/60, 927160 27/72, and 927475 27/52. Frequently Ordered Parts PART NO. 027912 027920 768341 781443 784207 781310 782292 068478 785261 785279 772079 785634 747303 795526 795252 795260 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 MAIN AIR FILTER ELEMENT SAFETY AIR FILTER ELEMENT KAWASAKI ENGINE OIL FILTER HONDA ENGINE OIL FILTER KOHLER ENGINE OIL FILTER 17.86"-H-F-CW BLADE 20.95"-H-F-CW BLADE 23.86"-H-F-CW BLADE Service Literature PART NO. 375527 742684 778423 785642 DESCRIPTION HUSTLER Z OWNER'S MANUAL KOHLER ENGINE MANUAL KAWASAKI 19/23HP OWNERS MANUAL HONDA 18/20/24 OWNERS 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. 375535 6/06 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 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 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 375535 6/06 Chapter 2 Contents Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Foot Rest Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 375535 6/06 2-1 Rivet Nut 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 RIVET NUT 2 N/A NOTES: 2-2 375535 6/06 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 395533 305615 086660 767954 781880 052860 MFG. PART NO. 359547 348276 395533 305615 086660 767954 781880 052860 QTY 2 1 1 2 2 4 2 2 STEP TREAD FLOOR FLOOR DESCRIPTION 2 3 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 (348276/395533 Floor) must be able to pivot on these bolts. 2. Used on mowers with serial number prior to 03082000. 3. Used on mowers with serial number 03082000 and higher. 375535 6/06 2-3 2-4 375535 6/06 Chapter 3 Contents Hydraulic System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 375535 6/06 3-1 Hydraulic System Installation 4 2 1 16 15 31 3 17 19 5 6 20 18 17 8 FRONT 14 23 10 7 22 11 21 12 24 20 30 18 17 10 11 9 28 29 26 25 27 12 24 11 13 3-2 375535 6/06 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) 375535 6/06 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. Note: Seal Kit for hydraulic pump; 727756 (BDP10 Overhaul Seal Kit) 1. 2. 3. 4. 5. 3-4 375535 6/06 Chapter 4 Contents Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Steering and Brake Assembly (Centering Damper). . . . . . . . . . . . . . 4-6 Steering and Park Brake Assembly (With Anti Reverse) . . . . . . . . . 4-10 Pump Belt and Pulley Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 375535 6/06 4-1 Battery Installation 1 BLACK WIRE, PART OF WIRE HARNESS 2 1 3 1 5 6 5 7 8 9 4 9 10 RED WIRE, PART OF WIRE HARNESS 8 TRACTOR FRAME 1 3 11 14 12 11 5 13 4-2 375535 6/06 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 ...