Hustler Super Z Parts Manual ······· Hustler Turf Equipment ····· P.O. Box 7000 ··· Hesston, Kansas · 67062-2097 375543 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 Engine Owner's Manual provides information regarding the U.S. Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance and warranty. Keep 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 the owner's 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 Installation­All Air Cooled Engines . . . . . . . . . . 3-2 Hydraulic System Installation­Kawasaki 26HP Engine . . . . . . . . . 3-6 Chapter 4 Contents Battery Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering and Park Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . Pump Belt and Pulleys Installation . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 5 Contents Kawasaki 25 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . Kawasaki 26 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . Honda 24 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Kohler 27 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Kohler 28 HP EFI Engine Installation . . . . . . . . . . . . . . . . . . . . . . . Fuel System ­Air Cooled Engines With Carburetor . . . . . . . . . . . . Fuel System­Air Cooled Engines With Carburetor . . . . . . . . . . . . . Fuel System­Liquid Cooled Engines With Carburetor . . . . . . . . . . Fuel System­With EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System ­With EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Panel Assembly­Air Cooled Engines . . . . . . . . . . . . . . Electrical Schematic - Kawasaki (783894) . . . . . . . . . . . . . . . . . . . Electrical Schematic - Kawasaki (796599) . . . . . . . . . . . . . . . . . . . Electrical Schematic - Honda (787200). . . . . . . . . . . . . . . . . . . . . . Electrical Schematic - Kohler (788000). . . . . . . . . . . . . . . . . . . . . . Electrical Schematic - Kohler EFI (789560) . . . . . . . . . . . . . . . . . . Chapter 6 Contents Front Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Wheel Breakdown­747782 . . . . . . . . . . . . . . . . . . . . . . . . . . Optional Semi-Pneumatic Tire/Wheel­789537 . . . . . . . . . . . . . . . . Drive Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-Rollover Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 7 Contents 72" Side Discharge Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . 72" Side Discharge Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . 60" Side Discharge Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . 60" Side Discharge Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . 52" Side Discharge Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . 52" Side Discharge Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . 375543 6/06 c-1 4-2 4-4 4-6 4-10 5-2 5-6 5-8 5-12 5-16 5-20 5-22 5-24 5-26 5-28 5-30 5-34 5-36 5-38 5-40 5-42 6-2 6-4 6-5 6-6 6-7 7-2 7-4 7-6 7-8 7-10 7-12 60" Rear Discharge Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . 60" Rear Discharge Deck Pulley Assembly . . . . . . . . . . . . . . . . . . 72" Rear Discharge Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . 72" Rear Discharge Deck Pulley Assembly . . . . . . . . . . . . . . . . . . Spindle Assembly­350595K. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spindle Assembly­796235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spindle Assembly­796680 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 7-16 7-18 7-20 7-22 7-23 7-24 Chapter 8 Contents Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Deck Belt Routing and Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Chapter 9 Contents Tractor Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72" and 60" Side Discharge Deck Decals . . . . . . . . . . . . . . . . . . . 52" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Discharge Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9-4 9-5 9-6 9-8 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 & Adjustment Safety Precautions . . . . . . . . . . . . . . . 11-3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1 c-2 375543 6/06 Chapter 1 General Information This Manual covers Hustler Super Z models 926725 24/52, 926741 24/60, 926766 24/72, 926972 25/72, 926980 25/60, 926998 25/72, 927038 27/60, 927046 27/72, 927053 28/60, 927061 28/72, 927319 27/52, 927558 26/60, 927566 26/72, 927467 27/60RD 927624 27/72RD, 927673 25/ 60RD, 927681 25/72RD. Frequently Ordered Parts PART NO. 027912 027920 783936 781443 784207 781310 782292 795781 797167 068478 789628 785261 785279 772079 785634 747303 795260 794867 793398 795252 793380 794859 795526 794198 785436 DESCRIPTION LUBRIZOL 7 OZ. BOTTLE LUBRIZOL 10 OZ. BOTTLE HYDRAULIC FILTER ELEMENT PUMP DRIVE BELT B-SECTION BELT, 72" DECK B-SECTION BELT, 60" DECK B-SECTION BELT, 52" DECK RD DECK BELT, 60" DECK RD DECK BELT, 72" DECK FUEL FILTER KOHLER EFI FUEL FILTER MAIN AIR FILTER ELEMENT SAFETY AIR FILTER ELEMENT KAWASAKI ENGINE OIL FILTER HONDA ENGINE OIL FILTER KOHLER ENGINE OIL FILTER BLADE, F23.86"-H-F-CW, 72" DECK BLADE, 23.86"-GAT-F-CW, 72" DECK BLADE, 23.86"-MUL-F-CW, 72" DECK BLADE, F20.95"-H-F-CW, 60" DECK BLADE, 20.95"-MUL-F-CW, 60" DECK BLADE, 20.95"-GAT-F-CW, 60" DECK BLADE, F17.86"-H-F-CW, 54" DECK BLADE,17.86"-MUL-F-CW, 54" DECK BLADE,17.86"-GAT-F-CW, 54" DECK Service Literature PART NO. 375527 778423 796805 785642 742684 DESCRIPTION HUSTLER SUPER Z OWNER'S MANUAL KAWASAKI 19/23/25 HP ENGINE MANUAL KAWASAKI FD731V ENGINE MANUAL HONDA 18/20/24 HP ENGINE MANUAL KOHLER CV740 ENGINE MANUAL Note: When ordering parts, you must use the part number as shown for each part, not the index number. Always give 375543 6/06 1-1 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. 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 375543 6/06 Chapter 2 Contents Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Foot Rest Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 375543 6/06 2-1 Rivet Nut Installation 1 2 INDEX NO. 1 SERVICE PART NO. 545756 545731 545749 100412 MFG. PART NO. 348029 353482 359158 100412 808493 QTY. 1 1 1 1 4 DESCRIPTION SUPER Z 72" FRAME SUPER Z 60" FRAME SUPER Z 52" FRAME SUPER Z RD 60" FRAME 3/8-16 THREAD NUTSERT 2 N/A NOTES: 2-2 375543 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 .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. 2. Used on mowers with serial number prior to 03082000. 3. Used on mowers with serial number 03082000 and higher. 375543 6/06 2-3 2-4 375543 6/06 Chapter 3 Contents Hydraulic System Installation­All Air Cooled Engines. . . . . . . . . . . . 3-2 Hydraulic System Installation­Kawasaki 26HP Engine . . . . . . . . . . . 3-6 375543 6/06 3-1 Hydraulic System Installation­All Air Cooled Engines 1 2 SUPER Z HOOD 3 4 7 8 5 21 2 4 6 22 23 24 13 14 15 25 33 36 28 11 12 26 27 20 16 32 29 17 19 15 18 21 10 9 2 30 31 24 25 22 23 13 14 15 15 18 35 34 19 36 3-2 375543 6/06 Hydraulic System Installation­All Air Cooled Engines 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 SERVICE PART NO. 705608 768515 713198 783704 033035 068551 032763 032771 055947 357616 034272 768523 788042 008193 767962 783928 783936 008573 782383 700484 784132 784124 784108 784082 781534 781658 784025 783993 788174 783985 784116 782870 782880 782458 782441 781526 N/A MFG. PART NO. 705608 768515 713198 783704 033035 068551 032763 032771 055947 357616 034272 768523 788042 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 783720 QTY 4 10 2 2 2 4 1 1 2 1 4 4 2 4 12 1 1 8 2 2 2 2 2 2 4 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 .50 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-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 17.375" 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 FITTING, 10 FX05-S SUCTION HOSE, #12 16" LONG TUBE, HYDRAULIC LINE TUBE, HYDRAULIC LINE TUBE, HYDRAULIC LINE TUBE, HYDRAULIC LINE FITTING, 90-1 ...