Hustler Raptor SD 48" CE Parts Manual

Transcription

1 Hustler Raptor SD 8" CE Parts Manual 00 South Ridge Road Hesston, Kansas 70

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3 Table of Contents General Information Service Literature Options Available From Your Dealer Using This Manual Standard Torques Section Frame Fenders & Instrument Panel Battery Section Hydraulic System Transmission Assembly Transmission Service Parts Steering & Brake Steering Cover Assembly Section Wheel & Tire Front Tire Breakdown X Front Tire Breakdown X Drive Wheel Breakdown Section 5 Engine Engine Service Parts Fuel System Fuel Tank Service Parts Section 8" Service Deck " Deck Pulleys & Spindles " Deck Deck Lift Right Side Deck Lift Left Side Section 7 Seat Seat Service Parts CE_05 c-

4 c- 87CE_05

5 General Information This manual covers Hustler Raptor SD model 5CE. Service Literature PART NO. 085CE DESCRIPTION OPERATOR S MANUAL WARRANTY STATEMENT SERVICE MANUAL Options Available From Your Dealer PART NO DESCRIPTION 8 MULCH KIT LIGHT KIT STEERING LEVER EXTENSION -BAG CATCHER KIT ENGINE GUARD KIT FLEX FORKS KIT 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 This manual is part of a service package for the Hustler mowers. Use of this manual in conjunction with other Hustler mower and component manuals will provide the information necessary to service and maintain Hustler mowers. This Parts Manual provides a complete parts listing for the unit. Use this manual when ordering parts. 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 authorized dealer for current information and parts. The Service Manual is a service guide for use by Service Technicians. It provides the necessary information needed to perform normal maintenance requirements on these units. The Operator's Manual provides fundamental operational information and operational safety that is needed when operating the mower. The component manuals are furnished by the various manufacturers to be used for the troubleshooting and servicing of their products. 87CE_05 -

6 Hardware Description Codes & Abbreviations The following codes are used throughout this parts manual. Refer to this list when ordering parts. ABBREVIATION CB CE CN CP CS CW FDRW FW HX LW DESCRIPTION ABBREVIATION DESCRIPTION CARRIAGE BOLT MB MACHINE BUSHING CLEVIS PIN MS MACHINE SCREW CLIP NUT NT NUT COTTER PIN SC SELF TAPPING CAP SCREW CAP SCREW SH SOCKET HEAD CUP WASHER SB SHOULDER BOLT FENDER WASHER SS SET SCREW FLAT WASHER OD OUTSIDE DIAMETER HEX HEAD ID INSIDE DIAMETER LOCK WASHER 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 FT-LBS N-M SIZE FT-LBS N-M M.. 7 M M M M M M M M M0 0 5 M CE_05

7 Section Frame Fenders & Instrument Panel Battery CE_05 -

8 - 87CE_05 Frame

9 Frame INDEX NO. PART NO. QTY N/A CE DESCRIPTION SEAT SUPPORT SPRING SUPPORT CS.75- X.75 HX FLK CS.75- X.75 HX FLK PLN RS REAR BRACKET HOT DECAL BUMPER (WITH DECAL) ENGINE PLATE (WITH DECALS) NT.75- HX FLK PLN ENGINE COMPARTMENT DECAL LS REAR BRACKET CN.50-0 X.5 MAX THK HYDRO BRACKET RS FRAME CHANNEL RS FRONT BRACKET CROSS SUPPORT PUMP BELT WARNING DECAL NT.75- HX FLK ZNYC LS FRAME CHANNEL (WITH DECALS) SERIAL NUMBER / SPEC DECAL FRONT CROSS FRAME FAIRING FOOT PAN (WITH DECAL) SAFE OPERATION DECAL PUSH BUTTON MOUNT WIRE TIE BATTERY TRAY CE MARK DECAL CE 05 DBA LIMIT DECAL NOTES:. Serial number decal. In the event the serial number decal becomes damaged or illegible, please contact your dealer to order a replacement.. Torque all the hardware to a minimum of 5 N-m. 87CE_05 -

10 Fenders & Instrument Panel CE_05

11 Fenders & Instrument Panel INDEX NO PART NO QTY. 8 DESCRIPTION CHOKE CABLE PTO SWITCH HOUR METER KEY ASSEMBLY INSTRUMENT PANEL (WITH DECAL) INSTRUMENT PANEL DECAL IGNITION SWITCH CS.50-0 X.75 HX G5 CB 0- X.500 ZYNC FW. X.500 X.08 ZNYC NT #0- HX NL ZN THROTTLE CABLE CS.50-0 X.75 HX FLG RS FENDER (WITH DECAL) LS FENDER (WITH DECAL) CN.50-0 X.5 MAX THK FOOTREST (WITH DECAL) HUSTLER ID DECAL CS.75- X.75 HX FLK NT.75- HX FLK ZNYC WIRE HARNESS CLUTCH CONNECTOR REPAIR KIT HUSTLER DECAL NOTES: 87CE_05-5

12 Battery NEGATIVE BATTERY CABLE POSITIVE BATTERY CABLE BATTERY 5-87CE_05

13 Battery INDEX NO. PART NO. QTY DESCRIPTION TIE DOWN STRAP CS X 7.50 HX G5 FW.8 X.5 X.05/.080 HD ZN/YL RED BATTERY CABLE BOOT NT.50-0 HX G5 ZNYC LW.50 INT-EXT TOOTH Z CS.50-0 X.75 HX G5 WIRE TIE CN.50-0 X.5 MAX THK NOTES:. When performing service on the mower, disconnect the negative battery cable and do not reconnect it to the battery until the engine is ready to be started. 87CE_05-7

14 -8 87CE_05

15 Section Hydraulic System Transmission Assembly Transmission Service Parts Steering & Brake Steering Cover Assembly CE_05 -

16 Hydraulic System CE_05

17 Hydraulic System INDEX NO. PART NO. QTY N/A DESCRIPTION CS.-8 X.50 HX G5 CB.75- X.75 STD ZN CS.-8 X.00 HX G5 Z NT.75- HX FLK ZNYC DRIVE BELT IDLER SPACER IDLER ARM FW.0 X.5 X. HRD Z NT.75- NL G5 CS.75- X.50 HX G5 FW.0 X.8 X.00 SAE PULLEY.0" IDLER NT.75- HX G5 ZNY SPRING CS.75- X.5 FULTH HP.080D X. TOW VALVE LINK FW. X.87 X.05/.080H NT 0.-8 NL G5 CS.75- X.75 HX FLK TRANSMISSION ASSEMBLY NOTES:. Torque to N-m. 87CE_05 -

18 Transmission Assembly 5 LEFT SIDE SHOWN RIGHT SIDE SIMILAR BRAKE ARM BRAKE CLIP A B FRONT OF MOWER - 87CE_05

19 Transmission Assembly INDEX NO. PART NO. QTY cm DESCRIPTION NT.-8 HX NL G5 FW. X.87 X.05/.080H OVERTRAVEL SPRING SPRING ROD BRAKE ACTUATOR FITTING, 0 - / SAE LS TRANSMISSION CS.75- X.5 HX G5 FW.0 X.8 X.00 SAE SPRING CLAMP HOSE, 0.50" LOW PRESSURE WIRE TIE NT.75- NL G5 CROSS BRACE RS TRANSMISSION CS.50-0 X.75 HX G5 LS BRAKE SPRING LINK NT.50-0 HX FL LK ZNY RS BRAKE SPRING LINK (NOT SHOWN) NOTES: TRANSMISSION TO TANK HOSE LENGTHS A B 7 cm LS TRANSMISSION 8 cm RS TRANSMISSION 87CE_05-5

20 Transmission Assembly 0 5 TRANSMISSION ASSEMBLY INDEX NO. PART NO. QTY DESCRIPTION NT.50-0 HX ZY NL FW.8 X.5 X.05/.080 HD ZN/YL EXPANSION TANK MOUNT OVERFLOW TANK CS.50-0 X.75 HX G5 OVERFLOW TANK CAP NOTES: - 87CE_05

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22 Transmission Service Parts CE_05

23 Transmission Service Parts 0708 RIGHT SIDE TRANSMISSION INDEX NO. PART NO. QTY. DESCRIPTION HG RTN CW HG RTN SPRING FAN/PULLEY KIT LS FILTER GUARD (WITH HARDWARE) OIL FILTER BOLT HUB KIT (WITH HUB NUT) BRAKE ARM RETAINING CLIP 070 LEFT SIDE TRANSMISSION INDEX NO. PART NO. QTY DESCRIPTION HG RTN CCW HG RTN SPRING FAN/PULLEY KIT RS FILTER GUARD (WITH HARDWARE) OIL FILTER BOLT HUB KIT (WITH HUB NUT) BRAKE ARM RETAINING CLIP NOTES: 87CE_05 -

24 Steering & Brake FRONT OF MOWER LEFT SIDE SHOWN RIGHT SIDE SIMILAR FRONT OF MOWER CE_05

25 Steering & Brake INDEX NO. PART NO. QTY N/A DESCRIPTION DAMPER BALL STUD FW. X.87 X.05/.080H NT.-8 HX ZY NL CN.-8 X.0 MAX THK SB. X.75 SH.50-0 YOKE, 5/- NT.- HX ZNYC STEERING ROD FW.8 X.5 X.05/.080 HD ZN/YL NT.50-0 HX ZY NL STEERING BAR (WITH GRIP) STEERING BAR GRIP NT.75- HX G5 ZNY FW.0 X.8 X.00 SAE CS.75- X.50 HX G5 CS.75- X.75 HX FLK NT.75- HX FLK ZNYC NT.-8 HX G5 ZNYC STEERING BUSHING CLIP STEERING COVER ASSEMBLY NOTES:. Part of the transmission assembly. 87CE_05 -

26 - 87CE_05 Steering Cover Assembly

27 Steering Cover Assembly INDEX NO. PART NO. QTY DESCRIPTION CS.50-0 X.00 HX FLTHD FW.8 X.5 X.05/.080 HD ZN/YL DRIVE STRAIGHT STOP /-0 THREAD RIVET NUT CS.50-0 X.75 HX G5 NUT PLATE.0 CENTERS PUSH BUTTON SWITCH NT.75- NL G5 STEERING COVER (WITH DECALS) CS.500- X.5 HX G5 STEERING SPACER LS STEERING BOX FW. X.87 X.05/.080H NT.-8 HX NL G5 BRAKE ROD BUSHING LS BRAKE BELLCRANK NT.500- NL G5 CS 0- X.75 HX FLK ZN CS.75- X.50 HX G5 Z RS STEERING BOX RS BRAKE BELLCRANK BUSHINGS NOTES: 87CE_05 -

28 Steering Cover Assembly CE_05

29 Steering Cover Assembly INDEX NO. PART NO. QTY DESCRIPTION FW.5 X.5 X.50 ZNY BUSHING TRANSPORT LATCH FW.0 X.8 X.00 SAE CS.75- X.75 HX FLK INDICATOR (WITH DECAL) DECK HEIGHT DECAL CS.75- X.5 HX G5 NT.75- HX FLK ZNYC RS STEERING DECAL ID DECAL LS STEERING DECAL NOTES: 87CE_05-5

30 - 87CE_05

31 Section Wheel & Tire Front Tire Breakdown X Front Tire Breakdown X Drive Wheel Breakdown CE_05 -

32 Wheel & Tire CE_05

33 Wheel & Tire INDEX NO. PART NO. QTY N/A DESCRIPTION TIRE/WHEEL 0 X 8-0 WHEEL NUT CS.500- X.5 HX G5 ZN FW.50 X.5 X.87 SPL FW.5 X.75 X.5 ZNY BEARING SPACER TIRE/WHEEL ASSEMBLY NOTES:. Torque to 88 0 N-m. 87CE_05 -

34 Front Tire Breakdown X CE_05

35 Front Tire Breakdown X 5.0 INDEX NO. PART NO. QTY DESCRIPTION FORK NT HX ZY NL FW.70 X.5 X.08 ZNYC CS X 8.00 HX G5 TIRE/WHEEL ASSEMBLY X 5.00 TIRE X 5.00 WHEEL BEARING WHEEL TIRE VALVE NOTES: 87CE_05-5

36 Front Tire Breakdown X CE_05

37 Front Tire Breakdown X.5 INDEX NO. PART NO. QTY DESCRIPTION FORK CS X.50 HX ZY FW.70 X.5 X.08 ZNYC NT HX ZY NL TIRE/WHEEL TIRE, X.50- WHEEL BEARING WHEEL, X.50 VALVE STEM NOTES: 87CE_05-7

38 Drive Wheel Breakdown TIRE/WHEEL ASSEMBLY INDEX NO. PART NO. QTY DESCRIPTION TIRE 0 X 8-0 WHEEL TIRE VALVE NOTES: -8 87CE_05

39 Section 5 Engine Engine Service Parts Fuel System Fuel Tank Service Parts CE_05 5-

40 Engine CE_05

41 Engine INDEX NO. PART NO. QTY. N/A cm K DESCRIPTION KAWASAKI /FRV ENGINE O-RING OIL DRAIN VALVE OIL DRAIN HOSE MUFFLER NT.75- HX FLK ZNYC CLUTCH ANCHOR FW.0 X.8 X.00 SAE CS.75- X.00 HX G5 CS.75- X.5 HX G5 P85 WIRE TIE STUB SHAFT PUMP PULLEY CLUTCH KIT FW.5 X. X. HRD CS.7-0 X 5.00 HX G5 CLUTCH HARNESS PIGTAIL FW.0 X.50 X 0. NOTES:. Supplied with the engine.. Torque to 5 N-m. Replace (do not reuse) the cap screw if it s removed or loosened. Use only hand tools to install this fastener.. Torque to 7 N-m. Replace (do not reuse) the cap screw if it s removed or loosened. Use only hand tools to install this fastener.. Torque the nuts to 0 N-m. 87CE_05 5-

42 Engine 8 BLK RED 0 5A FUSE RED BLK 5 5 A CE_05

43 Engine INDEX NO. PART NO. QTY cm 7 07 DESCRIPTION CS.50-0 X.75 HX G5 FW.8 X.5 X.05/.080 HD ZN/YL NT #0- HX ZN STARTER SOLENOID NT.50-0 HX G5 ZNYC LW. INT-EXT TOOTH CS M8 X.5 X HX G0. HOSE CLAMP /" FUEL LINE /" FORMED VAPOR LINE NOTES: FUEL & VAPOR LINE LENGTHS A cm TANK TO FUEL FILTER (FUEL) 5. Part of the fuel system.. Part of the wire harness. 87CE_05 5-5

44 Engine Service Parts INDEX NO. PART NO. QTY DESCRIPTION IN-LINE FUEL FILTER AIR FILTER OIL FILTER NOTES: 5-87CE_05

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46 Fuel System 7 A B C 5 B CE_05

47 Fuel System INDEX NO. PART NO. QTY cm cm DESCRIPTION FUEL TANK ASSEMBLY RATCHETING GAS CAP,.5" LEFT TANK MOUNT RIGHT TANK MOUNT SEAL /8 X / CS.50-0 X.75 HX G5 FW.8 X.5 X.05/.080 HD ZN/YL /" FORMED VAPOR LINE /" HOSE BARB CROSS /" FORMED VAPOR LINE BOOT, /" TO /" BARB VAPOR SYSTEM FILTER WIRE TIE PUSH BUTTON MOUNT WEATHERSTRIP NOTES: WEATHERTRIP LENGTH A.5 cm B cm C 0 cm 87CE_05 5-

48 Fuel Tank Service Parts INDEX NO. PART NO. QTY DESCRIPTION VENT FITTING GROMMET SUCTION HOSE ASSEMBLY 7.75" GROMMET NOTES: CE_05

49 Section 8" Service Deck " Deck Pulleys & Spindles " Deck Deck Lift Right Side Deck Lift Left Side CE_05 -

50 8" Service Deck 5 INDEX NO. PART NO. QTY DESCRIPTION 8" DECK (WITH DECALS) DANGER/CHUTE DECAL BELT ROUTING DECAL 8" DECK DECAL DANGER/OBJECTS DECAL NOTES: - 87CE_05

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52 8" Deck Pulleys & Spindles CE_05

53 8" Deck Pulleys & Spindles INDEX NO. PART NO. QTY DESCRIPTION NT.500- NL G5 FW.5 X.0 X.00 SAE IDLER PULLEY,.00" FLAT NT.-8 HX NL JAM G ZN FW.0 X.75 X.05 ZN SPRING TENSIONER ANCHOR IDLER SPRING IDLER SLED IDLER SLIDE CB.50- X.00 STD ZN CS.500- X.5 HX G5 ZN FW.55 X.5 X.5 HD ZY PULLEY SPACER DRIVE PULLEY B-SEC NT.75- HX G5 ZNY FW.0 X.8 X.00 SAE IDLER PULLEY, 5.00" O.D. IDLER PULLEY,.00" FLAT SPINDLE ASSEMBLY CS.75- X.75 HX G5 CB.50- X.50 STD ZN CB.-8 X.0 G5 ZN NOTES:. Torque to N-m.. Torque to N-m. 87CE_05-5

54 8" Deck CE_05

55 8" Deck INDEX NO PART NO QTY. DESCRIPTION RS PULLEY COVER (WITH DECAL) CS.50-0 X.75 HX FLG DO NOT SERVICE DECAL BELT, B-SECTION LS PULLEY COVER (WITH DECAL) DISCHARGE CHUTE DISCHARGE CHUTE PIN CHUTE SPRING NT.75- NL G5 PULLER PIN HP.5 X.75 ZN RS PULLER LS PULLER NT.500- NL G5 FW.5 X.0 X.00 SAE PLASTIC WHEEL ASSEMBLY NT.-8 HX NL G5 FW.0 X.75 X.05 ZN BLADE,.50"-MUL-F-CW CW. X.5 X.87 PNT CS.5- X.5 HX G5 Z FW.0 X.8 X.00 SAE MULCH CLOSE OFF CB.75- X.75 STD ZN CENTER MULCH WRAPPER LEFT MULCH WRAPPER BLADE,.50"-L-F-CW BLADE,.50"-MUL-F-CW BLADE, F.50"-H-F-CW BLADE,.50"-GAT-F-CW BLADE,.50"-CAT-F-CW CS.500- X.5 HX G5 FW.5 X.0 X.00 SAE PLASTIC WHEEL NT.500- HX JAM ZNYC NOTES:. Torque to 0 N-m.. Torque to N-m on these self-tapping screws.. Do not torque the nut; the discharge chute must pivot freely. 87CE_05-7

56 Deck Lift Right Side CE_05

57 Deck Lift Right Side INDEX NO. PART NO. QTY DESCRIPTION INDICATOR PIN NT.75- HX FLK ZNYC REAR DECK LIFT BAR NT.75- HX G5 ZNY FW.0 X.8 X.00 SAE PIVOT SPACER BUSHING LIFT PEDAL LINK CS.75- X.5 HX G5 NT.75- NL G5 FW. X. X.5 UHMW PIVOT DECK LIFT LINK CE.75 X.00 W/BALE PIVOT BLOCK CS.75- X.75 HX FLK CS.75- X.00 HX G5 FRONT DECK LIFT BAR PIVOT SPACER BUSHING FW.5 X.0 X.00 SAE NT.500- NL G5 CS.500- X.50 HX G5 NOTES: 87CE_05 -

58 Deck Lift Left Side CE_05

59 Section 7 Seat Seat Service Parts CE_05 7-

60 Seat CE_05

61 Seat INDEX NO. PART NO. QTY DESCRIPTION STANDARD SEAT SEAT PAN (WITH DECAL) PUSH BUTTON MOUNT NT.75- HX NL G5 WIRE TIE FW. X.87 X.05/.080H CS.-8 X.5 HX G5 CS.75- X.75 HX FLK COMPRESSION SPRING.5 X.00 X.88 NT.75- HX FLK ZNYC CS.75- X.00 HX G5 BATTERY WARNINGS DECAL FW.0 X.00 X.05 ZNYC NOTES:. Do not torque; the seat pan must pivot freely.. Torque to.5 N-m.. When replacing the seat pan, order () washers (item ). 87CE_05 7-

62 Seat Service Parts INDEX NO. PART NO. QTY DESCRIPTION SEAT SWITCH LS ARMREST KIT RS ARMREST KIT ARMREST STOP ASSEMBLY NOTES: 7-87CE_05