hustler fastrak super duty ce parts manual - motec€¦ · hustler fastrak super duty ce parts...
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•••••••Hustler Turf Equipment
•••••P.O. Box 7000
•••Hesston, Kansas
•67062-2097
Hustler FasTrak Super Duty CEParts Manual
t-2 109188CE 06/08
109188CE 06/08 c-1
Table of Contents
Chapter 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Chapter 2 Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Chapter 3 Battery Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Hydraulic System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Steering Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8Steering Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Park Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Chapter 4 Kawasaki 23 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . 4-2Fuel System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6Instrument Panel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8Electrical Schematic - Kawasaki (601341) . . . . . . . . . . . . . . . . . . . 4-10
Chapter 5 Front Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2Front Wheel Breakdown - 786061 . . . . . . . . . . . . . . . . . . . . . . . . . 5-4Drive Wheel Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . 5-5Engine Guard & Anti-Rollover Wheel Assembly . . . . . . . . . . . . . . . 5-6
Chapter 6 54" Side Discharge Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . 6-254" Side Discharge Deck Pulley Assembly. . . . . . . . . . . . . . . . . . . 6-4Spindle Assembly–783506 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Chapter 7 Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-454" Deck Belt Routing and Tensioning . . . . . . . . . . . . . . . . . . . . . . 7-6
Chapter 8 Tractor Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-254" Side Discharge Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1
c-2 109188CE 06/08
109188CE 06/08 1-1
Chapter 1
General Information
This Manual covers Hustler Fastrak Super Duty model 928382CE.
Frequently Ordered Parts
Service Literature
Note: When ordering parts, you must use the part number as shown for each part, not the item 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 neces-sary, 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.
PART NO. DESCRIPTION PART NO. DESCRIPTION600979 Pump Drive Belt 068478 Fuel Filter Kawasaki791335 Deck Belt 48" 772079 Engine Oil Filter Kawasaki789388 Deck Belt 54" 600976 Oil Filter ZT 2800782292 Deck Belt 60" 794685 F20.50"-L-F-CW Blade785261 Main Air Filter Element 797696 F18.50"-L-F-CW Blade785279 Air Filter Element 795757 F16.50"-L-F-CW Blade
PART NO. DESCRIPTION
601457 FST Owner’s Manual778423 Kawasaki Engine Manual
1-2 109188CE 06/08
Hardware Description Codes & Abbreviations
The following codes are used throughout this parts manual. Refer to this list when ordering parts.
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
NOTE:
Loctite 592 to be used on all pipe threads.Lubricate all grease zerks.
ABBREVIATION DESCRIPTION ABBREVIATION DESCRIPTIONCB Carriage Bolt MB Machine BushingCE Clevis Pin MS Machine ScrewCP Cotter Pin NT NutCN Clip Nut SC Self Tapping Cap ScrewCS Cap Screw SH Socket HeadCW Cup Washer SB Shoulder Bolt
FDRW Fender Washer SS Set ScrewFW Flat Washer OD Outside DiameterHX Hex Head ID Inside DiameterLW Lock Washer
SIZE FT-LBS NM SIZE FT-LBS NM
.250 8.2 11.1 M3 1 1.3
.312 17 23 M4 2.2 3
.375 30 40 M5 4.5 6.1
.438 48 65 M6 7.7 10.4
.500 73 99 M8 18.5 25
.562 105 143 M10 37 50
.625 145 200 M12 64 87
.750 260 350 M16 160 215
.875 420 565 M20 320 4351.00 625 850 M24 555 750
109188CE 06/08 2-1
Chapter 2 Contents
Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2-2 109188CE 06/08
Rivet Nut Installation
NOTES:
1. Service part includes items 2, 3, 4 and “Tractor Decals” on page 8-2.
ITEM NO.
SERVICE PART NO.
MFG. PART NO. QTY. DESCRIPTION
1 548743 108821 1 54" SUPER DUTY FASTRAK FRAME2 808493 808493 8 RIVET NUT, 3/8-16 THREAD3 600994 600994 2 HEX RIVET NUT, 3/8-16 THREAD4 808485 808485 1 RIVET NUT, 5/16-18 THREAD5 601324 601324 2 TUBE PLUG
4
2
1
2
5
23
1
109188CE 06/08 2-3
Footrest Assembly
NOTES:
1. Service part includes items 2 and 3.
ITEM NO.
SERVICE PART NO.
MFG. PART NO. QTY. DESCRIPTION
1 548768 108840 1 FLOOR PAN, 48/54 FSD2 785493 785493 2 STEP TREAD3 785485 785485 2 STEP TREAD4 011320 011320 2 CB .375-16X .750 STD ZN5 767954 767954 4 FW .406 X .812 X .060 SAE HD ZN6 054502 054502 2 NT .375-16 HX GRD 5 ZNY7 025395 025395 2 CB .375-16X 1.00 STD CD8 086660 086660 2 NT .375-16 HXZY NL
21
3
4
5
8
6
75
1
2-4 109188CE 06/08
109188CE 06/08 3-1
Chapter 3 Contents
Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Hydraulic System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Steering Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Steering Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Park Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3-2 109188CE 06/08
Battery Installation
1
TRACTORFRAME
7
3
4
5
6
1
78
7
13
11
2
7
6
11
12
109
109188CE 06/08 3-3
Battery Installation
NOTES:
1. When performing service on mower, disconnect battery ground cable and black wire of harness and do not reconnect to battery until engine is ready to be started. See Owners Manual.
2. Battery is not installed in export models. Hardware used for fastening battery cables to battery to be installed and tightened to battery cables. Battery clamp strap and associated hardware to be installed as shown with capscrews (Items 1) bottomed out on threads of clip nuts (Items 11).
ITEM NO.
SERVICE PART NO.
MFG. PART NO. QTY DESCRIPTION
1 714618 714618 2 CS .312-18X4.000 HX G52 768523 768523 2 FW .343 X .687 X .051/.080 HD ZNYC3 348417 348417 1 BATTERY CLAMP STRAP4 601312 601312 1 POSITIVE BATTERY CABLE5 796219 796219 1 NEGATIVE BATTERY CABLE6 024927 024927 2 NT .312-18 HX NL ZN7 029868 029868 4 LW .250 INT-EXT TOOTH ZN8 055939 055939 2 CS .250-20 X .750 HX G5 ZN9 771428 771428 1 BATTERY CBL BOOT-RED
10 740696 740696 1 BATTERY11 601069 601069 2 CN .312-18X.200 MAX THK12 794644 794644 2 GM 1.50 X 2.12 X 1.7513 000331 000331 1 WIRE TIE, SMALL/SHORT
12
3-4 109188CE 06/08
Deck Lift Assembly
TRACTORFRAME
1
2
46
5
3
16
10
6
5
7
5
9
4
5
4
12
7
8
8
16
8
14
6
4
5
4
6
10
5
15
16
6
6
10
106
16
13
11
109188CE 06/08 3-5
Deck Lift Assembly
NOTES:
1. Apply grease to zerks (see owners manual).
ITEM NO.
SERVICE PART NO.
MFG. PART NO. QTY DESCRIPTION
1 348318 348318 1 STOP HANDLE2 348284 348284 1 HEIGHT ADJUSTMENT STOP3 784488 784488 1 DECK LIFT INDICATOR4 781294 781294 7 CLIP E, 1.00 X.625X .0505 784686 784686 6 FW .812X 1.469X.134 THK6 704643 704643 8 NT .437-14 HX FLG ZN7 782995 782995 2 DECK LIFT SPRING8 055749 055749 3 CS .437-14X1.750 HX G5 ZNYC9 781831 781831 1 CS .437-14X1.750 FULTH
10 360131 018846 4 DECK LIFT CHAIN (3 LINKS)11 756270 756270 1 CS .312-18X1.50 FLTHR G12 034272 034272 1 NT .312-18 HX G5 ZNYC13 348458 348458 1 DECK LEVELER YOKE W/A14 781229 781229 1 CE .750X2.25 X1.75 HEADLESS15 767962 767962 2 FW .531X 1.063X.090 SAE16 015495 015495 4 STRAIGHT GREASE FITTING1
3-6 109188CE 06/08
Hydraulic System Installation
11
12
26
14
15
13
28
17
18
20
19
25
21
2
6
54
78
9
10
2614
13
12
33
29
5
4
109
16
3
3
27
26
28
23
24
24
1
2
22
3
3
109188CE 06/08 3-7
Hydro Transmission Installation
NOTES:
1. Torque to 23 N-m.2. Torque to 135 N-m.3. Torque to 373 N-m.4. Service parts available for the transaxles:
INDEX NO. SERVICE PART NO.
MFG. PART NO. QTY. DESCRIPTION
1 710087 710087 4 CS .312-18X2.500 HX G52 038828 038828 4 CS .312-18X2.250 HX G53 768523 768523 16 FW .343X.687X.051/.080H4 786848 786848 2 IDLER PULLEY 4.00"OD5 028118 028118 2 FW .625X1.00X.134 ZNYC6 794446 794446 1 CS .625-11X1.500 HX G57 600979 600979 1 PUMP DRIVE BELT8 025007 025007 1 CS .625-11X1.750 HX G59 025296 025296 2 FW .760X 1.625X.08 ZNYC
10 781153 781153 2 BUSHING11 107881 107881 1 PUMP IDLER W/A FASTRAK12 601084 601084 1 SB .750X 2.000 SH.625-1113 016410 016410 2 CS .375-16X2.00 G5 ZNYC14 767954 767954 2 FW .406X .812 X.060 SAE15 600987 600987 1 ZT SPACER TUBE16 034272 034272 8 NT .312-18 HX G5 ZNYC17 036384 036384 1 SPRING 1/4 COIL PL 1.2318 601404 601404 1 LH TRANS ZT280019 601403 601403 1 RH TRANS ZT280020 601088 601088 2 TOW LINK ROD 48/5421 048553 048553 2 CP .062DX1.000 LG HML Z22 600759 600759 1 OVERFLOW TANK ASSY23 055939 055939 2 CS .250-20X .750 HX G524 768515 768515 4 FW .281X.625X.051/.080H25 068551 068551 2 NT .250-20 HXZY NL26 601001 601001 4 SPRING CLAMP .75" DIA27 601018 601018 2 OVERFLOW HOSE 10" LONG28 600880 600880 2 HYD FITTING 45 DEG29 000331 000331 2 WIRE TIE SMALL/SHORT
PART NUMBER DESCRIPTION PART
NUMBER DESCRIPTION
600767 OVERFLOW TANK CAP 601206 ZT2800 FAN, 7"600972 BRAKE ARM RETAINER CLIP 601207 ZT2800 PULLEY, 4.5"600974 RIGHT FILTER GUARD 601221 ZT2800 BRAKE ARM - 2007600975 LEFT FILTER GUARD 601433 4-BOLT HUB KIT SDFST
3-8 109188CE 06/08
Steering Sub-Assembly
NOTES:
1. Includes Item 1 (781260 Steering Bar Grip).
ITEM NO. SERVICE PART NO.
MFG. PART NO. QTY. DESCRIPTION
1 781260 N/A 2 STEERING BAR GRIP2 360487 360487 2 STEERING BAR3 767954 767954 12 FW .406 X .812 X .060 SAE HD ZN4 705178 705178 4 CS .375-16X1.750 HX G55 086660 086660 6 NT .375-16 HXZY NL6 107843 107843 1 STEERING ARM W/A LH (SHOWN)
107842 107842 1 STEERING ARM W/A RH7 768523 768523 4 FW .343X .687 X .051/.080 HD ZN/YL8 600991 N/A 2 SHORT BRAKE LINK ROD9 023655 023655 2 NT .312-24 HXZY NL
10 107848 107848 1 STEER PIVOT W/A LH (SHOWN)107847 107847 1 STEER PIVOT W/A RH
11 770867 770867 4 IGUS BUSHING12 705178 705178 2 CS .375-16X1.750 HX G5
2
3
7
3
8
10
4
113
12
3
5
5 11
1
3
9
3
7
3
CONNECTS TOPARK BRAKELINKAGE
6
1
109188CE 06/08 3-9
This page intentionally left blank.
3-10 109188CE 06/08
Steering AssemblySee “Steering Sub-Assembly” on page 3-8.
5
1
2
7
17
4
18
11
3
8
9
16
5
13 10
33
7
3
3
3
10
12
14
15
1
6
20
10
1021
19
109188CE 06/08 3-11
Steering Assembly
NOTES:
1. Supplied with transmission. Torque to 230-310 in-lbs. Use Loctite ® 242.
ITEM NO.
SERVICE PART NO.
MFG. PART NO. QTY DESCRIPTION
1 784439 784439 2 LOCK COLLAR 0.757 ID2 023655 023655 2 NT .312-24 HXZY NL3 768523 768523 17 FW .34 3X .687 X .051/.080 HD ZN/YL4 600981 600981 2 PUMP ROD ASSEMBLY5 034272 034272 4 NT .312-18 HX G5 ZN6 029876 029876 2 LW .312 INT-EXT TOOTH Z7 781922 781922 4 DAMPER BALL STUD8 600221 600221 2 CENTERING DAMPENER9 109318 109318 2 PUMP ARM ZT2800
10 768515 768515 12 FW .281X.625X.051/.080H11 041152 041152 2 NT .312-24 HX ZN12 704163 704163 2 CS .250-20X2.00 HX G5 Z13 068551 068551 2 NT .250-20 HXZY NL14 005116 005116 2 CS .375-16 X 1.375 HX G5 ZN15 706168 706168 2 NT .375-16 HX JAM GR5 Z16 036236 036236 1 CS .312-18 X 1.000 HX G5 ZN17 361295 361295 1 PIVOT TUBE W/A PLATED18 601404 N/A 1 ZT2800 LH (SHOWN)
601403 N/A 1 ZT2800 RH 19 108968 108968 2 STEER TUBE SUPPORT20 055939 055939 4 CS .250-20X .750 HX G521 024927 024927 4 NT .250-20 HX GR.5 ZNYC
3-12 109188CE 06/08
Park Brake Assembly
4
1
7
1615
2
2
3
9
12
2
1
2
10
9
13
2
5
6
11
2
8
1419
18 1712
8
7 9
9
11
2
5
2
6
BELL CRANKDETAIL
CONNECTS TOSTEER PIVOT W/A
HYDRO-
TRACTOR FRAME
TRANSMISSION
109188CE 06/08 3-13
Park Brake Assembly
NOTES:
ITEM NO.
SERVICE PART NO.
MFG. PART NO. QTY DESCRIPTION
1 086660 086660 4 NT .375-16 HX LK NY2 767954 767954 12 FW .406 X .812 X .060 SAE HD ZN3 601087 601087 2 PLUNGER SWITCH4 005108 005108 2 CS .375-16X3.50 HX G5 Z5 601410 601410 2 BRAKE ROD ASSEMBLY6 054502 054502 2 NT .375-16 HX GRD 5 ZN7 023655 023655 2 NT .312-24 HXZY NL8 768523 768523 4 FW .34 3X .687 X .051/.080 HD ZN/YL9 765339 765339 4 BUSHING
10 107893 107893 1 BRAKE BELL CRANK LS (SHOWN)107892 107892 1 BRAKE BELL CRANK RS
11 080655 080655 2 CS .375-16X1.500 HX G512 600991 600991 2 SHORT BRAKE LINK ROD13 601131 601131 2 BRAKE ARM RET. SPRING14 109203 109203 1 BRAKE SPRING LINK LS (SHOWN)
109202 109202 1 BRAKE SPRING LINK RS15 601221 N/A 2 ZT2800 BRAKE ARM16 055939 055939 2 CS .250-20X .750 HX G517 601247 N/A 2 BRAKE ARM RETAINING CLIP18 016816 016816 2 NT .250-20 HX FL LK ZNY19 601051 601051 2 OVERTRAVEL SPRING
3-14 109188CE 06/08
109188CE 06/08 4-1
Chapter 4 Contents
Kawasaki 23 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Fuel System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Instrument Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Electrical Schematic - Kawasaki (601341) . . . . . . . . . . . . . . . . . . . 4-10
4-2 109188CE 06/08
Kawasaki 23 HP Engine Installation
STARTERSOLENOIDGROUND
PUR/RED RED/BLK2
2
1
87
21
32
30
18
18
17
1633
34 21
3
13
31
22
19
26
3
23
28
1
2
4
5
6
910
12
19
15
3
14
3
2TO BULLET
2
11
6
TO ENGINEOIL SENSORYELLOW
2
PART OFENGINE}
1918
241825
27
329
35}
TERMINALS
2TO BULLETTERMINALS
20
5
6
6
3637
18
38
18
39
39
1819
7
109188CE 06/08 4-3
Kawasaki 23 HP Engine Installation
NOTES:
1. Includes mounting hardware.2. Part of Item 20 (601341 Tractor Wire Harness).3. Engine oil capacity: Refer to engine owner’s manual.
ITEM NO.
SERVICE PART NO.
MFG. PART NO. QTY DESCRIPTION
1 601277 601277 1 KAWASAKI 23HP ENGINE2 058776 058776 4 NT .312-18 HXZY NL3 768523 768523 10 FW .343 X .687 X .051/.080 HD ZN/YL4 043570 043570 1 HOSE CLIP5 796524 796524 1 OIL DRAIN VALVE M20X2.56 050161 050161 4 CS .312-18X1.750 HX G57 783761 783761 1 SINGLE PULLEY8 712372 712372 1 KEY 1/4 SQ X 0.66 LG9 000331 000331 1 WIRE TIE SMALL/SHORT
10 784918 784918 1 RUBBER BUMPER11 601326 601326 1 WARNER CLUTCH12 791251 791251 1 CLUTCH PIGTAIL13 763417 763417 1 FW .454X1.50X.25014 785659 785659 1 CS .437-20X2.50 HX G5 Z15 796219 N/A 1 NEG. BATTERY CABLE 36"16 029876 029876 1 LW .312 INT-EXT TOOTH ZN17 601062 601062 1 POS BATTERY CABLE 17"18 768515 768515 11 FW .281 X .625 X .051/.080 HD ZNYC19 024927 024927 5 NT .250-20 HX GR.5 ZNYC20 601341 601341 1 WIRE HARNESS21 601319 601319 2 POS BATTERY CABLE BOOT22 601312 N/A 1 POS BATTERY CABLE 4"23 044255 044255 1 NT #10-32 HX ZN24 030817 030817 1 STARTER SOLENOID25 055939 055939 2 CS .250-20X .750 HX G526 016253 016253 2 CB .312-18X .750 FUL ZN27 601002 601002 1 HORIZONTAL MUFFLER28 108969 108969 1 MUFFLER HEAT SHIELD29 034272 034272 2 NT .312-18 HX G5 ZN30 601004 601004 1 EXHAUST MANIFOLD31 108288 108288 1 HEAT SHIELD32 780841 N/A 2 KAW (23) MUFFLER GASKET33 785378 785378 1 1.50" MUFFLER CLAMP34 017004 N/A 4 LW .312 MED SPRING ZNYC35 782664 N/A 4 NT M8-1.25 HX STAINLESS36 109338 109338 1 HEATSHIELD FST KAW675CC37 601429 601429 1 UBOLT .250-20X 1.125 DIA38 601452 601452 1 UBOLT .250-20 X 1.250 ID39 024927 N/A 4 NT .250-20 HX GR.5 ZNYC
104786 104786 1 OIL DRAIN HOSE (NOT SHOWN)
1
11
4-4 109188CE 06/08
4. Engine RPM to be set at 2550± 50 (928382CE).5. Supplied with engine.6. Route item 22 (4" positive battery cable) with the purple and red wires
through item 21 (positive battery cable boot) prior to fastening hardware to the solenoid.
7. Torque to 61-65 N-m8. Air filter service parts:
785261 MAIN AIR FILTER ELEMENT785279 AIR FILTER ELEMENT763318 VACUATOR VALVE
109188CE 06/08 4-5
This page intentionally left blank
4-6 109188CE 06/08
Fuel System Installation
FUEL LINE CONNECTSTO FUEL FILTER
1
1
1
1
2
3
4
6
11
118
13
4
9
7
6
5
7
15
6
4
4
5
5
6
5
1
1
4
9
10
1012
14
9
89
ENGINE NOT SHOWNFOR CLARITY
12
13
109188CE 06/08 4-7
Fuel System Installation
NOTES:
1. Torque to 27.12 N-m.2. Included with new fuel tank.3. Service parts for fuel tanks (not shown):
ITEM NO.
SERVICE PART NO.
MFG. PART NO. QTY DESCRIPTION
1 779306 779306 2 3.5" FUEL CAP2 601320 601320 1 RIGHT SIDE FUEL TANK3 601321 601321 1 LEFT SIDE FUEL TANK4 000323 000323 6 CLIP5 712919 712919 8 FW .406 X 1.00 X .12 HRD ZNYC6 055822 055822 8 CS .375-16X .750 HX G57 000398 000398 2 CLAMP8 034280 034280 2 CS .312-18X .750 HX G59 768523 768523 4 FW .343X.687X.051/.080H
10 034272 034272 2 NT .312-18 HX G5 ZNYC11 745059 745059 1 3-WAY FUEL VALVE12 015818 015818 1 FUEL LINE (24" LONG)13 015818 015818 1 FUEL LINE (11" LONG)14 015818 015818 1 FUEL LINE (13" LONG)15 000331 000331 3 WIRE TIE SMALL/SHORT
SERVICE PART NO. DESCRIPTION
785295 FLANGE GROMMET
601529 SUCTION HOSE ASSY 26.5
1
22
4-8 109188CE 06/08
Instrument Panel Installation
RIGHT SIDEFUEL TANK
1
20a10a
1
3
8 12
13
10
16
15
1516
6
1
4
FUSE SIZEAND LOCATION
69
71
5 2
11
17
14
109188CE 06/08 4-9
Instrument Panel Installation
NOTES:
1. Part of 601341(Wire Harness).
ITEM NO.
SERVICE PART NO.
MFG. PART NO. QTY DESCRIPTION
1 601095 601095 1 CHOKE CABLE2 776476 776476 1 PTO SWITCH3 712257 712257 1 RED INDICATOR LIGHT4 769166 769166 1 HOUR METER5 785808 785808 1 KEY SET6 045898 045898 1 KEY SWITCH7 026237 N/A 2 RELAY8 601094 601094 1 THROTTLE CABLE9 601089 601089 2 RIVET .188 DIA BLK HD
10 601098 601098 2 CB 10-24 X .500 ZNYC11 107902 107902 1 INSTRUMENT PANEL12 704932 704932 2 FW .219 X .500 X .048 ZNYC13 059832 059832 2 NT #10-24 HX NL ZN14 102707 102707 1 CE THROTTLE STOP15 768515 768515 3 FW .281 X .625 X .051/.080 HD16 055947 055947 3 CS .250-20 X .500 HX G517 000331 000331 1 WIRE TIE SMALL/SHORT
4-10 109188CE 06/08
Electrical Schematic - Kawasaki (601341)
109188CE 06/08 5-1
Chapter 5 Contents
Front Wheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Front Wheel Breakdown - 786061. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Drive Wheel Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Engine Guard & Anti-Rollover Wheel Assembly . . . . . . . . . . . . . . . . 5-6
5-2 109188CE 06/08
Front Wheel Assembly
TRACTORFRAME
1
1
2
3
3
3
3
1
2
4
3
4
6
88
10
9
1
23
5
4
8
6
10
5
7
7
8
4
4
4
109188CE 06/08 5-3
Front Wheel Assembly
NOTES:
1. Apply grease to zerks (see owners manual).2. Tighten, then back off until wheel spins freely.3. Assemble with extended inner race down. Apply a thin continuous bead
of Loctite® 609 to O.D. of outer races of bearings prior to assembling bearing into frame.
4. Apply Loctite® 242 to threads.
ITEM NO. SERVICE PART NO.
MFG. PART NO. QTY DESCRIPTION
1 705954 705954 2 CS .500-13 X 1.25 HX G5 ZN2 344267 344267 2 FW .510 X 2.15 X .187 SPL ZN3 712976 712976 2 FW .531 X 1.375 X .125 ZNYC4 784223 784223 4 BEARING W/O COLLAR5 784603 784603 2 SPACER6 366625 366625 2 FORK7 786731 786731 2 CS .750-10 X 8.00 HX GR5 ZNYC8 025296 025296 4 FW .760 X 1.625 X .08 ZN9 061101 061101 2 NT .750-10 HX NL ZN
10 786061 786061 2 WHEEL & TIRE ASSY
5-4 109188CE 06/08
Front Wheel Breakdown - 786061
NOTES:
1. Inflate tire to 55.2-82.7 kPa.
ITEM NO.
SERVICE PART NO.
MFG. PART NO. QTY DESCRIPTION
1 786103 N/A 2 WHEEL BEARING2 747402 N/A 1 TIRE 13 X 5.003 786079 N/A 1 WHEEL4 019521 N/A 1 TIRE VALVE5 015511 N/A 1 GREASE FITTING 45 DEG 1/4
2
3
1
5
1
4
109188CE 06/08 5-5
Drive Wheel Assembly Installation
NOTES:
1. Torque to 88.1-101.7 Nm.2. Inflate tire to 88.1-101.7 kPa.
ITEM NO.
SERVICE PART NO.
MFG. PART NO. QTY DESCRIPTION
1 601349 601349 1 TIRE/WHEEL ASSEMBLY FOR 60" & 54" (QTY PER TRACTOR)2 601348 N/A TIRE 20 X 12-10 3 601347 N/A WHEEL4 019521 N/A TIRE VALVE5 061077 061077 4 WHEEL NUT (QTY PER WHEEL)
1 600668 600668 1 TIRE/WHEEL ASSEMBLY (QTY PER 48" TRACTOR)2 600684 N/A TIRE 20 X 10-103 600700 N/A WHEEL4 019521 N/A TIRE VALVE5 061077 061077 4 WHEEL NUT (QTY PER WHEEL)
2
1
1
2
3
45
5-6 109188CE 06/08
Engine Guard & Anti-Rollover Wheel Assembly
NOTES:
1. Includes items 1 through 4.
ITEM NO.
SERVICE PART NO.
MFG. PART NO. QTY DESCRIPTION
1 781708 N/A 2 CS .500-13X4.250 HX G52 767962 N/A 4 FW .531 X 1.063 X .090 SAE HD ZN3 031997 N/A 2 ANTI-SCALP WHEEL4 053199 N/A 2 NT .500-13 HX JAM ZNYC5 344267 344267 4 FW .510X 2.15X.187 SPL6 781567 781567 2 NT .500-13 H8ZY NL7 052860 052860 6 CS .375-16X1.250 HX G58 767954 767954 6 FW .406X .812 X.060 SAE9 108847 108847 1 ENGINE GUARD
788166 788166 2 ANTI-SCALP WHEEL ASSEMBLY
TRACTORFRAME
1
6
2
9
3
4
8
5
5
7
1
109188CE 06/08 6-1
Chapter 6 Contents
54" Side Discharge Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
54" Side Discharge Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . 6-4
Spindle Assembly–783506 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-2 109188CE 06/08
54" Side Discharge Deck Assembly
13
10
4
14
7
12
10
12
1
2
3
6
5
4
13
8
11
14
9
10
4
7
4
4
12
10
11
12
13
1413
73
16
17
15
11
16
11
17
18 18
18
74
109188CE 06/08 6-3
54" Side Discharge Deck Assembly
NOTES:1. Do not torque, Item 2 (601117 Discharge Chute) must pivot freely.2. Includes items 10, 11, 12, and 13.3. Service part deck includes decals (see “54" Side Discharge Deck
Decals” on page 8-4.
ITEM NO.
SERVICE PART NO.
MFG. PART NO. QTY DESCRIPTION
1 548834CE 108100 1 54" DECK WACRATED2 601117 601117 1 RUBBER CHUTE ASSEMBLY3 034280 034280 3 CS .312-18X .750 HX G54 768523 768523 14 FW .343X.687X.051/.080H5 108537 108537 1 PIN CHUTE MTG W/A6 108049 108049 1 BRACKET CHUTE W/A7 034272 034272 7 NT .312-18 HX G5 ZNYC8 767954 767954 2 FW .406 X .812 .060 SAE HD ZN9 086660 086660 2 NT .375-16 HXZY NL
10 781708 N/A 4 CS .500-13 X 4.25 HX G5 ZN11 767962 N/A 8 FW .531 X 1.063 X .090 SAE HD ZN12 031997 N/A 4 ANTI-SCALP WHEEL13 053199 N/A 4 NT .500-13 HX JAM ZN14 781567 781567 4 NT .50-13 HX LK NY15 025395 025395 2 CB .375-16 X 1.00 STD CD16 109247 109247 1 PULLER & PIN ASSY RS17 109248 109248 1 PULLER & PIN ASSY LS18 601069 601069 4 CN .312-18X.200 MAX THK
788166 788166 4 ANTI SCALP WHEEL ASSY
3
2
6-4 109188CE 06/08
54" Side Discharge Deck Pulley Assembly
1
3
21
21
17
22
19
27
20
2224
20
26
17
18
1
2
5
6
913
14
12 11
3
4
17
16
17
4
55
10
7
DECK ASSY16
23
8
15
2122
22
6
25
27
21
22
1
109188CE 06/08 6-5
54" Side Discharge Deck Pulley Assembly
NOTES:1. Torque to 160Nm. 2. Apply grease to zerk (see owner’s manual).3. See “54" Deck Belt Routing and Tensioning” on page 7-6 for belt
tensioning.4. See “Spindle Assembly–783506” on page 6-6 for breakdown.
ITEM NO.
SERVICE PART NO.
MFG. PART NO. QTY DESCRIPTION
1 789388 789388 1 B-SECTION BELT (54" DECK)791335 791335 1 B-SECTION BELT (48" DECK)
2 797910 797910 6 CS .312-18 X 1.50 FLT SH ZNYC3 025007 025007 1 CS .625-11 X 1.75 HX G5 ZNYC4 046821 046821 3 FW .656X 2.00X.078 ZNYC5 797449 797449 3 FW .650X1.125X.18 ZNYCG56 781856 781856 3 5.00" IDLER PULLEY7 028118 028118 1 FW .62 X 1.00X.134 ZN8 600296 600296 1 SPACER DECK IDLER9 601434 601434 2 IDLER UHMW SLIDE
10 350884 350884 1 DECK IDLER11 781302 781302 1 IDLER SPRING12 259812 059931 1 CHAIN DECK LIFT SPRING (13 LINKS)13 108124 108124 1 PULLEY COVER RS 54"
108149 108149 1 PULLEY COVER RS 48"14 108123 108123 1 PULLEY COVER LS 54"
108148 108148 1 PULLEY COVER LS 48"15 016972 016972 2 NT .625-11 HX G5 ZNYC16 781872 781872 6 CS .625-11X1.25 HX G5 Z17 782474 782474 8 CW .631 2.250 X .187 PNT18 786889 786889 3 PULLEY DECK DRIVE 5.25 (54" DECK)
792689 792689 3 PULLEY DECK DRIVE 5.0 (48" DECK)19 054502 054502 12 NT .375-16 HX GRD 5 ZNY20 767954 767954 24 FW .406X .812 X.060 SAE21 064006 064006 4 CS .312-18X .625 HX G522 768523 768523 10 FW .343X.687X.051/.080H23 058776 058776 6 NT .312-18 HXZY NL24 783506 783506 3 BLADE SPINDLE ASSEMBLY25 005116 005116 12 CS .375-16X1.375 HX G526 797696 797696 3 BLADE, F18.50"-H-F-CW (54" DECK)
795757 795757 3 BLADE, F16.50"-H-F-CW (48" DECK)27 783738 783738 2 CS .625-11X3.00 FULL HX
42
6-6 109188CE 06/08
Spindle Assembly–783506
NOTES:
ITEM NO.
SERVICE PART NO.
MFG. PART NO. QTY. DESCRIPTION
1 783548 N/A 1 BLADE SPINDLE RETAINING RING2 783555 N/A 2 BLADE SPINDLE BEARING3 783530 N/A 1 BLADE SPINDLE SPACER4 783514 N/A 1 BLADE SPINDLE HOUSING5 783522 N/A 1 BLADE SPINDLE SHAFT
1
2
2
3
4
5
109188CE 06/08 7-1
Chapter 7 Contents
Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
54" Deck Belt Routing and Tensioning . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-2 109188CE 06/08
Seat Installation
1
12
3
7 4
3
10
11
7
3
5
1
6
8
3
2
11
3 9
13
14
9
1
1
1
109188CE 06/08 7-3
Seat Installation
NOTES:
1. Do not torque, Item 6 and Item 10 (Seat Pan and Stop) must pivot freely.2. Service parts available for Michigan standard seat:
ITEM NO.
SERVICES PART NO.
MFG. PART NO. QTY DESCRIPTION
1 793661 793661 1 STANDARD SEAT2 034280 034280 1 CS .312-18X .750 HX G53 768523 768523 11 FW .343 X .687 X .051/.080 HD ZN/Y4 108321 108321 1 SEAT LATCH, 48/54 FST5 808485 808485 1 RIVET NUT, 5/16-18 THREAD6 548776 107861 1 SEAT PAN7 000331 000331 2 BLACK CABLE TIE8 034272 034272 4 NT .312-18 HX G5 ZN9 064014 064014 3 CS .312-18X .875 HX G5
10 109240 109240 1 SEAT PAN STOP11 058776 058776 3 NT .312-18 HXZY NL12 052860 052860 2 CS .375-16 X 1.25 HX G5 ZNYC13 767954 767954 2 FW .406X .812 X.060 SAE14 601450 601450 2 SEAT SPRING
PART NO. DESCRIPTION
793307 SLIDE KIT793315 SEAT SWITCH797464 ARMREST ASSY LH RND797472 ARMREST ASSY RH RND797480 ARMREST W/O BRACKET793273 ARMREST STOP ASSEMBLY
7-4 109188CE 06/08
Deck InstallationTRACTORASSEMBLY
DECKASSEMBLY
1
1
4
2
3
5
5
3
56
7
1211
109 9
109
10
9
10
1112
1314
1314
8
6
2
109188CE 06/08 7-5
Deck Installation
NOTES:
1. 54" deck installation is shown.2. Install in rear hole of frame bracket.
ITEM NO.
SERVICE PART NO.
MFG. PART NO. QTY DESCRIPTION
1 055749 055749 4 CS .437-14 X 1.750 HX G5 ZN2 078949 078949 2 CS .500-13X2.000 G5 ZNY3 767962 767962 4 FW .531X 1.063X.090 SAE4 008193 008193 2 NT .500-13 HX G5 ZNYC5 704643 704643 8 NT .437-14 HX FLG ZN6 109200 109200 2 HANGER EXT FRONT7 109238 109238 1 HANGER EXT. REAR LS8 109239 109239 1 HANGER EXT. REAR RS9 728147 728147 8 FW .468X 1.00X.090 HT T
10 768523 768523 8 FW .343X.687X.051/.080H11 041707 041707 4 NT .437-14 HX G5 ZNYC12 034272 034272 4 NT .312-18 HX G5 ZNYC13 047746 047746 4 CS .437-14X1.000 HX G514 036236 036236 4 CS .312-18X1.000 HX G5
7-6 109188CE 06/08
54" Deck Belt Routing and Tensioning
NOTES:
1. Spring length after tensioning new belt. Measured from outside of hook to outside of hook.
2. Route belt as shown.
DECKASSEMBLY
1
109188CE 06/08 8-1
Chapter 8 Contents
Tractor Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
54" Side Discharge Deck Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8-2 109188CE 06/08
Tractor Decals
BOTTOM OFSEAT PAN
7
2
8
13
14
18
6
9
1
16
4
17
10
3
5
12
15
11
109188CE 06/08 8-3
Tractor Decals
NOTES:
ITEM NO.
SERVICE PART NO.
MFG. PART NO. QTY. DESCRIPTION
1 601421 601421 1 FASTRAK SUPER DUTY DECAL2 785139CE 785139CE 1 FASTRAK STEERING DECAL LS3 N/A 083279 1 TURF PRODUCT SERIAL NO PLATE4 789766CE 789776CE 1 CE 105 DBA LIMIT DECAL5 776310 776310 1 CE MARK DECAL6 785220CE 785220CE 1 FASTRAK STEERING DECAL RS7 793588 793588 1 HUSTLER NAME PLATE8 785154CE 785154CE 1 DECK HEIGHT INDICATOR DECAL9 777029CE 777029CE 1 MAXIMUM ANGLE CE DECAL
10 601100CE 601100CE 1 INSTRUMENT PANEL DECAL11 789727CE 789727CE 1 EYE/EAR/FOOT PRTOECTION DECAL12 789701CE 789701CE 1 READ OWNER’S MANUAL DECAL13 789719CE 789719CE 1 READ SERVICE MANUAL DECAL14 600941 600941 1 PATENT DECAL15 791848 791848 1 FUEL INDICATOR DECAL16 601099 601099 1 TOW VALVE DECAL17 771436CE 771436CE 1 STABILIZER DECAL18 727016CE 727016CE 1 BATTERY DECAL
8-4 109188CE 06/08
54" Side Discharge Deck Decals
NOTES:
ITEM NO.
SERVICE PART NO.
MFG. PART NO. QTY. DESCRIPTION
1 789701CE 789701CE 1 READ OWNER’S MANUAL DECAL2 778688CE 778688CE 1 BELT ROUTING CE DECAL3 789685CE 789685CE 2 THROWN OBJECT DECAL4 727438CE 727438CE 2 FINGERS AND TOES DECAL5 727420CE 727420CE 1 DISCHARGE CHUTE CE DECAL6 727453CE 727453CE 2 DECK COVER CE DECAL7 799171 799171 1 Z 54" DECK ID DECAL8 785055 785055 1 3.70 X 9.00 STEP TREAD
1
3 4
3
67
6
4
8
2
5
109188CE 06/08 9-1
NOTES:
9-2 109188CE 06/08
109188CE 06/08 i-1
Numerical IndexPart PageNo. No.
Part PageNo. No.
Part PageNo. No.
IndexPart Numbers000323 4-7000331 3-3, 3-7, 4-3, 4-7,
4-9, 7-3000398 4-7005108 3-13005116 3-11, 6-5008193 7-5011320 2-3015495 3-5015511 5-4015818 4-7016253 4-3016410 3-7016816 3-13016972 6-5017004 4-3019521 5-4, 5-5023655 3-8, 3-11, 3-13024927 3-3, 3-11, 4-3025007 3-7, 6-5025296 3-7, 5-3025395 2-3, 6-3026237 4-9028118 3-7, 6-5029868 3-3029876 3-11, 4-3030817 4-3031997 5-6, 6-3034272 3-5, 3-7, 3-11, 4-3,
4-7, 6-3, 7-3, 7-5034280 4-7, 6-3, 7-3036236 3-11, 7-5036384 3-7038828 3-7041152 3-11041707 7-5043570 4-3044255 4-3045898 4-9046821 6-5047746 7-5048553 3-7050161 4-3052860 5-6053199 5-6, 6-3054502 2-3, 3-13, 6-5055749 3-5, 7-5055822 4-7055939 3-3, 3-7, 3-11, 3-13,
4-3055947 4-9
058776 4-3, 6-5, 7-3059832 4-9059931 6-5061077 5-5061101 5-3064006 6-5064014 7-3068478 1-1068551 3-7, 3-11078949 7-5080655 3-13083279 8-3086660 2-3, 3-8, 3-13, 6-3102707 4-9104786 4-3107842 3-8107843 3-8107847 3-8107848 3-8107861 7-3107881 3-7107892 3-13107893 3-13107902 4-9108049 6-3108100 6-3108123 6-5108124 6-5108148 6-5108149 6-5108288 4-3108321 7-3108537 6-3108821 2-2108840 2-3108847 5-6108968 3-11108969 4-3109200 7-5109202 3-13109203 3-13109238 7-5109239 7-5109240 7-3109247 6-3109248 6-3109318 3-11109338 4-3259812 6-5344267 5-3, 5-6348284 3-5348318 3-5
348417 3-3348458 3-5350884 6-5360131 3-5360487 3-8361295 3-11366625 5-3548743 2-2548768 2-3548776 7-3548834CE 6-3600221 3-11600296 6-5600668 5-5600684 5-5600759 3-7600767 3-7600880 3-7600941 8-3600972 3-7600974 3-7600975 3-7600976 1-1600979 1-1, 3-7600981 3-11600987 3-7600991 3-8, 3-13600994 2-2601001 3-7601002 4-3601004 4-3601018 3-7601051 3-13601062 4-3601069 3-3, 6-3601084 3-7601087 3-13601088 3-7601089 4-9601094 4-9601095 4-9601098 4-9601099 8-3601100CE 8-3601117 6-3601131 3-13601206 3-7601207 3-7601221 3-7, 3-13601247 3-13601277 4-3601312 3-3, 4-3
Part PageNo. No.
Part PageNo. No.
Part PageNo. No.
i-2 109188CE 06/08
601319 4-3601320 4-7601321 4-7601324 2-2601326 4-3601341 4-3, 4-9601348 5-5601349 5-5601403 3-7, 3-11601404 3-7, 3-11601410 3-13601421 8-3601429 4-3601433 3-7601434 6-5601450 7-3601452 4-3601457 1-1601529 4-7704163 3-11704643 3-5, 7-5704932 4-9705178 3-8705954 5-3706168 3-11710087 3-7712257 4-9712372 4-3712919 4-7712976 5-3714618 3-3727016CE 8-3727420CE 8-4727438CE 8-4727453CE 8-4728147 7-5740696 3-3745059 4-7747402 5-4756270 3-5763318 4-4763417 4-3765339 3-13767954 2-3, 3-7, 3-8, 3-13,
5-6, 6-3, 6-5, 7-3767962 3-5, 5-6, 6-3, 7-5768515 3-7, 3-11, 4-3, 4-9
768523 3-3, 3-7, 3-8, 3-11, 3-13, 4-3, 4-7, 6-3, 6-5, 7-3, 7-5
769166 4-9770867 3-8771428 3-3771436CE 8-3772079 1-1776310 8-3776476 4-9777029CE 8-3778423 1-1778688CE 8-4779306 4-7780841 4-3781153 3-7781229 3-5781260 3-8781294 3-5781302 6-5781567 5-6, 6-3781708 5-6, 6-3781831 3-5781856 6-5781872 6-5781922 3-11782292 1-1782474 6-5782664 4-3782995 3-5783506 6-5783514 6-6783522 6-6783530 6-6783548 6-6783555 6-6783738 6-5783761 4-3784066 5-4, 5-5784223 5-3784439 3-11784488 3-5784603 5-3784686 3-5784918 4-3785055 8-4785139CE 8-3
785154CE 8-3785220CE 8-3785261 1-1, 4-4785279 1-1, 4-4785295 4-7785378 4-3785485 2-3785493 2-3785659 4-3786103 5-4786731 5-3786848 3-7786889 6-5788166 5-6, 6-3789388 1-1, 6-5789685CE 8-4789701CE 8-3, 8-4789719CE 8-3789727CE 8-3789766CE 8-3791251 4-3791335 1-1, 6-5791848 8-3792689 6-5793273 7-3793307 7-3793315 7-3793588 8-3793661 7-3794446 3-7794644 3-3794685 1-1795757 1-1, 6-5796219 3-3, 4-3796524 4-3797449 6-5797464 7-3797472 7-3797480 7-3797696 1-1, 6-5797910 6-5799171 8-4808485 2-2, 7-3808493 2-2928382CE 1-1