Hydro WalkBehind Parts Manual ······· Hustler Turf Equipment ····· P.O. Box 7000 ··· Hesston, Kansas · 67062-2097 778837 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 Frame Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upper H-Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lower H-Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-Bar Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2-4 2-6 2-8 2-10 Chapter 3 Contents Hydraulic Installation--37" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Hydraulic Installation--48" & 54" . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Hydraulic Hose Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Chapter 4 Contents Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Chapter 5 Contents Pump Drive Assembly--15 & 17 HP. . . . . . . . . . . . . . . . . . . . . . . . 5-2 Pump Drive Assembly (23 & 25HP) . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Chapter 6 Contents Console Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Chapter 7 Contents Engine Installation--Electric Start. . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Engine Installation--23 & 25 HP. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Battery Installation--Electric Start. . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Chapter 8 Contents Electrical Schematic--Recoil Start--778498 . . . . . . . . . . . . . . . . . 8-2 Electrical Schematic--Electric Start--779991 . . . . . . . . . . . . . . . . 8-4 Chapter 9 Contents Deck Carrier Frame Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Chapter 10 Contents Deck Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37" Deck Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48" Deck Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54" Deck Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 10-4 10-6 10-8 10-10 10-12 10-14 10-16 10-17 10-18 Chapter 11 Contents Tractor Decal Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2 925651 6/06 c-1 37" Deck Decal Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4 48" Deck Decal Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6 54" Deck Decal Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8 Chapter 12 Contents Drive Wheel Assembly--48" & 54". . . . . . . . . . . . . . . . . . . . . . . . . Drive Wheel Assembly--37" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spindle Housing Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2 12-3 12-4 12-5 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1 c-2 925651 6/06 Chapter 1 General Information This Manual covers Hydro Walk Behind mowers models: 925651, 17HP Pull Start 48" Deck; 925669, 15HP Pull Start 48" Deck; 925644, 17 HP Pull Start 54" Deck; 925677, 15HP Pull Start 37" Deck; 926238, 17HP Electric Start 48" Deck; 926246, 17HP Electric Start 54" Deck; 927129, 23HP Electric Start 48" Deck; & 927137, 25HP Electric Start 54" Deck. Frequently Ordered Parts PART NO. 027912 768341 776435 779694 776724 777185 068478 772111 772103 785261 772079 770339 767111 DESCRIPTION Lubrizol 7 oz. Bottle Hydraulic Oil Filter Pump Drive Belt 37" WB DECK DRIVE BELT 48" WB Deck Drive Belt 54" WB Deck Drive Belt Fuel Filter Precleaner Air Filter Paper Element Air Filter Main Air Filter Element - Remote Engine Oil Filter 19" Clockwise Rotation Blade 17" Clockwise Rotation Blade Service Literature PART NO. 778845 771501 778423 DESCRIPTION Walk Behind Owner's Manual Kawasaki 15 & 17 HP Engine Manual Kawasaki 19 thru 23 HP 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. 778837 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 FW HX LW MB MS NT SC SB SS DESCRIPTION Carriage Bolt Clevis Pin Cotter Pin Cap Screw Cup Washer Flat Washer Hex Head Lock Washer Machine Bushing Machine Screw Nut Self Tapping Cap Screw Shoulder Bolt Set Screw Standard Torques The following chart is 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 nest 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: Loctite 592 to be used on all pipe threads. Lubricate all grease zerks. 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 1-2 778837 6/06 Chapter 2 Contents Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Upper H-Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Lower H-Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 H-Bar Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 778837 6/06 2-1 Frame Rivet Nut Installation 2 1 3 2 4 2 5 5 6 7 5 5 8 3 2-2 778837 6/06 Frame Rivet Nut Installation INDEX NO 1 2 3 4 5 6 7 8 SERVICE PART NO. N/A N/A N/A 330498 N/A 340182 340174 341693 MFG. PART NO. 335273 808493 808485 330498 808477 340182 340174 341693 QTY 1 14 6 1 6 1 1 1 DESCRIPTION HYDRO WALK BEHIND FRAME NUTSERT, 3/8-16 NUTSERT, 5/16-18 STEERING PIVOT NUTSERT, 1/4-20 LOWER CONSOLE PANEL CONSOLE SUPPORT NEUTRAL LOCK NOTES: 778837 6/06 2-3 Pump Installation 4 1 6 2 3 11 12 14 12 9 7 8 10 13 15 8 13 10 6 15 2 3 9 7 12 5 11 4 14 12 1 TRACTOR FRAME 3 3 16 16 2-4 778837 6/06 Pump Installation INDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 SERVICE PART NO. 768226 041707 704742 075994 778514 068551 341289 778621 715599 059832 041152 768523 341487 034272 712919 705186 MFG. PART NO. 768226 041707 704742 075994 778514 068551 341289 778621 715599 059832 041152 768523 341487 034272 712919 705186 QTY. 2 4 8 2 2 2 2 2 2 2 2 6 2 4 8 4 DESCRIPTION HYDRO GEAR PUMP BDP10L137P NT .437-14 HX G5 ZN FW .453X .812X.060 ZN CS .250-20X3.250 ZN PUMP ROD ASSEMBLY NT .250-20 HX NL ZN PUMP ARM TORSION PUMP SPRING CS 10-24X1.000 HX G5 ZN NT #10-24 HX NL ZN NT .312-24 HX ZN FW .343X.687X.051X.080 HD ZN/YL NEUTRAL ADJUSTER PLATE NT .312-18 HX G5 ZN FW .406X 1.00X.12 HRD ZN CS .437-14X1.375 HX G5 ZN NOTES: 778837 6/06 2-5 Upper H-Bar Assembly 4 3 1 5 12 1 2 9 10 5 8 10 9 2 11 12 1 12 1 2 16 14 15 10 13 10 11 6 3 7 4 17 18 14 2-6 778837 6/06 Upper H-Bar Assembly ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 SERVICE PART NO. 341446 333047 773556 771139 779157 068551 772483 077842 058776 768523 341826 769299 342378 778506 779165 039693 341149 794412 MFG PART NO. 341446 333047 773556 771139 779157 068551 772483 077842 058776 768523 341826 769299 342378 778506 779165 039693 341149 N/A QTY 1 1 2 2 2 1 1 4 2 6 2 6 2 1 4 2 1 1 DESCRIPTION STEERING PIVOT TUBE STEERING BAR STEERING BEARING GRIP, .875 X 4.562 BLACK CB .312-18X 1.750 ZN G5 NT .250-20 HX NL ZN SB .312X .750 SH .250-20TD ZN/YL MS # 6-32 X1.000 RD SL ZN NT .312-18 HX NL ZN FW .343X.687X.051/.080 HD ZN/YL OPC ARM SC #10 X.750 PHILLIPS TYPE AB ZN SWITCH SPACER OPERATOR PRESENCE WIRE HARNESS RP .078X .50 LONG ZN WN #6-32 X 1.00 TP 1116 SPEED BAR HBAR MICRO SWITCH LEVER NOTES: 1. Screw will be self tapped into steering handle bearing. 2. Must be tight but must not be so tight as to cause binding of item 2 (333047 Steering Bar) within item 3 (773556 Steering Bearing). Items 11 (341826 OPC Arm) must move freely. 778837 6/06 2-7 Lower H-Bar Assembly 1 3 4 STEERING PIVOT 2 6 8 4 10 SPEED 11 12 BAR 14 9 15 22 13 23 8 9 13 26 16 24 PUMP ROD ASSEMBLIES 25 23 22 7 5 13 17 13 18 19 20 NEUTRAL LOCK 21 2-8 778837 6/06 Lower H-Bar Assembly INDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 SERVICE PART NO. 332072 038828 754317 728584 341651 768499 778522 779173 034272 778530 342857 034280 768523 341743 004416 765339 726711 023002 18 19 20 21 22 23 24 25 26 049346 726778 017251 341503 041152 754358 341156 772483 068551 MFG. PART NO. 332072 038828 754317 728584 341651 768499 778522 779173 034272 778530 342857 034280 768523 341743 004416 765339 726711 023002 049346 726778 017251 341503 041152 754358 341156 772483 068551 QTY 1 1 1 2 1 1 2 4 4 1 1 2 6 1 1 2 1 1 1 1 2 1 2 2 1 1 1 DESCRIPTION LOCK COLLAR CS .312-18X2.250 HX G5 ZN NT .312-18 LOW CROWN ACORN ZN PIVOT TUBE BUSHING NEUTRAL LOCK HANDLE KNOB, 1.00 RDX.312-18 FE BLACK SB .375X1.000 SH.312-18TD ZN FW .312X .562X .06 SPL HD ZN/YL NT .312-18 HX G5 ZN TORSION SPRING STEERING SPACER CS .312-18X .750 HX G5 ZN FW .343X.687X.051/.080 HD ZN/YL STEERING SUPPORT RP .375 X 2.25 ZN BUSHING, INGUS#MFI-0608_05 SWITCH DOUBLE POLE SWITCH FW .375X .870X.078 ZN SWITCH BOOT CP .156DX1.000 LG HML ZN NEUTRAL LOCK ROD NT .312-24 HX ZN SB .375X.375 SH .312-18 SPEED CONTROL YOKE SB .312X.750 SH .250-20TD ZN/YL NT .250-20 HX NL ZN 2 3 17 NOTES: 1. For H-Bar in lower position, install Item 1 (Lock Collar) and item 14 (Steering Support) in upper holes in (Upper H-Bar Assembly). Install Speed Bar) using upper hole of the two lower holes in Speed Bar). 2. Used on pull start models only. 3. Used on electric start models only. 778837 6/06 2-9 H-Bar Installation H-BAR ASSEMBLY 5 CONSOLE SUPPORT 2 TRACTOR FRAME 4 6 1 2 3 2 1 2-10 778837 6/06 H-Bar Installation ITEM NO. 1 2 3 4 5 6 SERVICE PART NO. 036244 767954 778738 054502 052860 080655 MFG. PART NO. 036244 767954 778738 054502 052860 080655 QTY 9 13 1 1 2 1 DESCRIPTION CS .375-16X1.000 HX G5 ZN FW .406X .812 X.060 SAE HD ZN WIRING CLAMP NT .375-16 HX GRD 5 ZN CS .375-16X1.250 HX G5 ZN CS .375-16X1.500 HX G5 ZN NOTES: 778837 6/06 2-11 2-12 778837 6/06 Chapter 3 Contents Hydraulic Installation--37". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Hydraulic Installation--48" & 54" . ...