Hustler FasTrak Super Duty CE Parts Manual Excel Industries, Inc. P.O. Box 7000 Hesston, Kansas 67062-2097
Table of Contents Section General Information.................................... - Section 2 Frame CE............................................ 2-2 Footrest.............................................. 2- Engine Guard......................................... 2-6 Section Hydraulic System...................................... -2 Steering.............................................. - Steering Sub-Assembly.................................. -0 Brake................................................ -2 Section Wheel and Tire........................................ -2 Drive Wheel Breakdown................................. - Section 5 Engine, 2 HP Kaw..................................... 5-2 Fuel................................................. 5-6 Section 6 Battery............................................... 6-2 Instrument Panel....................................... 6- Electrical Schematic 60............................ 6-6 Section 7 5" Deck Decals....................................... 7-2 5" Deck Pulley Assembly............................... 7-5" Deck............................................. 7-8 5" Deck Belt Routing and Tensioning..................... 7-0 Deck Lift............................................. 7-2 Deck Mounting Hardware................................ 7- Section 8 Seat................................................. 8-2 ROPS............................................... 8- Index........................................................ i- 0988CE_050 c-
c-2 0988CE_050
Section General Information This Manual covers Hustler Fastrak Super Duty model 92882CE. Frequently Ordered Parts PART NO. DESCRIPTION PART NO. DESCRIPTION 600979 Pump Drive Belt 06878 Fuel Filter Kawasaki 795 Deck Belt 8" 772079 Engine Oil Filter Kawasaki 78988 Deck Belt 5" 600976 Oil Filter ZT 2800 782292 Deck Belt 60" 79685 F20.50"-L-F-CW Blade 78526 Main Air Filter Element Kaw 797696 F8.50"-L-F-CW Blade 785279 Air Filter Element Kaw 795757 F6.50"-L-F-CW Blade 602882 Panel Air Filter Honda 60288 Foam Outer Filter Honda 7856 Engine Oil Filter Honda Service Literature PART NO. DESCRIPTION 799CE CE Owner s Manual 7782 Kawasaki 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. Hardware Description Codes & Abbreviations The following codes are used throughout this parts manual. Refer to this list when ordering parts ABBREVIATION DESCRIPTION ABBREVIATION DESCRIPTION CB Carriage Bolt MB Machine Bushing CE Clevis Pin MS Machine Screw CP Cotter Pin NT Nut CN Clip Nut SC Self Tapping Cap Screw CS Cap Screw SH Socket Head CW Cup Washer SB Shoulder Bolt FDRW Fender Washer SS Set Screw 0988CE_050 -
ABBREVIATION DESCRIPTION ABBREVIATION DESCRIPTION Standard Torques FW Flat Washer OD Outside Diameter HX Hex Head ID Inside Diameter LW Lock Washer 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 NM SIZE FT-LBS NM.250 8.2. M..2 7 2 M 2.2.75 0 0 M5.5 6..8 8 65 M6 7.7 0..500 7 99 M8 8.5 25.562 05 M0 7 50.625 5 200 M2 6 87.750 260 50 M 80 08.5.875 20 565 M6 60 25.00 625 850 M20 20 5 M2 555 750 NOTE: Loctite 592 to be used on all pipe threads. Lubricate all grease zerks. -2 0988CE_050
Section 2 Frame CE............................................. 2-2 Footrest............................................... 2- Engine Guard........................................... 2-6 0988CE_050 2-
Frame CE 8 2 5 6 0 7 9 2 7 20 2 5 6 8 9 2-2 0988CE_050
Frame CE INDEX NO. PART NO. QTY. DESCRIPTION 6020 HOT DECAL 2 60967 ENGINE COMPARTMENT DECAL 60099 TOW VALVE DECAL 72772 MADE IN USA DECAL 5 602 FASTRAK SUPER DUTY DECAL 6 78257 FIRST ZERO TURN DECAL 7 N/A TURF PRODUCT SERIAL NO PLATE 8 7760 CE MARK DECAL 9 789776CE CE 05 DBA LIMIT DECAL 0 60099 2 RIVET NUT, /8-6 THREAD 8089 8 RIVET NUT, /8-6 THREAD 2 602562 NO SERVICE DECAL 7988 FUEL INDICATOR DECAL 60069 2 CN.2-8 X.200 MAX THK 5 600899 PUMP BELT WARNING DECAL 6 80885 RIVET NUT, 5/6-8 THREAD 7 7859 STEERING LS DECAL 8 785220 STEERING RS DECAL 9 7855CE DECK HEIGHT INDICATOR DECAL 20 6098 SAFE OPERATION DECAL 2 587CE FRAME (USED ON 92882CE). Service part frames include decals. NOTES: 0988CE_050 2-
Footrest 25.mm 5.mm.2mm 5.mm 28.mm.75mm 2 5 6 7 6 8 2-0988CE_050
Footrest INDEX NO. PART NO. QTY DESCRIPTION 58768 FLOOR PAN 2 78585 2 STEP TREAD, UPPER 7859 2 STEP TREAD, LOWER 020 2 CB.75-6 X.750 STD ZN 5 086660 2 NT.75-6 HXZY NL 6 76795 FW.06 X.82 X.060 SAE 7 02595 2 CB.75-6 X.000 STD CD 8 05502 2 NT.75-6 HX G5 ZN NOTES:. Item (Floor Pan) includes Items 2 & (Step Treads). 0988CE_050 2-5
Engine Guard 0 9 8 9 2 2 5 6 7 INDEX NO. PART NO. QTY. DESCRIPTION 085 HEAT SHIELD CE 2 78866 2 WHEEL ASSY, ANTI SCALP 267 FW.50X 2.5X.87 SPL 78567 2 NT.500- HX G8 ZY NL 5 052860 6 CS.75-6X.250 HX G5 6 76795 6 FW.06X.82 X.060 SAE 7 0887 ENGINE GUARD 8 78708 2 CS.500-X.250 HX G5 9 767962 FW.5X.06X.090 SAE 0 0997 2 ANTI-SCALP WHEEL 0599 2 NT.500- HX JAM ZNYC NOTES:. Install Item (Heat Shield) between the engine guard and the frame. 2. Item 2 (Anti-scalp Wheel) includes (items 8 ). 2-6 0988CE_050
Section Hydraulic System........................................ -2 Steering............................................... -5 Steering Sub-Assembly.................................. - Brake................................................ - 0988CE_050 -
-2 0988CE_050 Hydraulic System 2 2 5 5 6 7 8 9 0 0 9 7 2 8 5 9 6 20 2 22 26 2 25 2 2 28 26 27 26 28 29 2
Hydraulic System INDEX NO. PART NO. QTY DESCRIPTION 70087 CS.2-8 X 2.500 HX G5 2 08828 CS.2-8 X 2.250 HX G5 76852 6 FW. X.687 X.05/.080 HD ZN/YL 78688 2 IDLER PULLEY.0 OD 5 0288 2 FW.625 X.00 X. ZNYC 6 796 CS.625- X.500 HX G5 7 600979 BELT, FASTRAK PUMP DRIVE 8 025007 CS.625- X.750 HX G5 9 025296 2 FW.760 X.625 X.08 ZNYC 0 785 2 UHMW BUSHING 0788 PUMP IDLER W/A, FASTRAK 2 6008 SB.750 X 2.000 SH.625-060 2 CS.75-6X2.00 G5 ZN 76795 2 FW.06 X.82 X.060 SAE 5 600987 ZT SPACER TUBE 6 0272 8 NT.2-8 HX G5 ZN 7 068 SPRING / COIL PL.2 8 600 ZT00 LH 9 600 ZT00 RH 20 60088 2 TOW LINK ROD 2 0855 2 CP.062DX.000 LG HML Z 22 600759 OVERFLOW TANK 2 05599 2 CS.250-20X.750 HX G5 ZN 2 76855 FW.28X.625X.05/.080 HD ZN/YL 25 06855 2 NT.250-20 HXZY NL 26 6000 SPRING CLAMP /" DIA 27 6008 2 OVERFLOW HOSE 28 600880 2 HYDRAULIC FITTING 5 DEG 29 000 2 WIRE TIE, SMALL/SHORT NOTES:. Torque to 2 N-m. 2. Torque to 6 N-m.. Torque axle hub nuts to 7 N-m.. Service parts available for the transaxles: PART NUMBER DESCRIPTION PART NUMBER DESCRIPTION 600767 OVERFLOW TANK CAP 609 FAN/PULLEY KIT 600972 BRAKE ARM RETAINER CLIP 6022 ZT2800 BRAKE ARM - 2007 60097 RIGHT FILTER GUARD 60 -BOLT HUB KIT SDFST 600975 LEFT FILTER GUARD 600976 OIL FILTER ZT 2800 0988CE_050 -
Steering STEERING SUB-ASSEMBLY 7 2 6 8 7 8 8 5 0 6 9 8 2 5 9 8 20-0988CE_050
Steering INDEX NO. PART NO. QTY DESCRIPTION 789 2 LOCK COLLAR.750 2 02655 2 NT.2-2 HX NL ZN 76852 7 FW. X.687 X.05/.080 HD ZN/YL 60022 2 DAMPER, STEERING 5 60098 2 PUMP ROD ASSEMBLY 6 78922 BALL STUD, DAMPER 7 706 2 CS.250-20 X 2.000 HX G5 ZN 8 76855 2 FW.28 X.625 X.05/.080 HD ZN/YL 9 06855 2 NT.250-20 HX ZN NL 0 098 2 PUMP ARM 0272 NT.2-8 HX G5 ZNYC 2 052 2 NT.2-2 HX ZNYC 05599 CS.250-20 X.750 HX G5 ZN 08968 2 STEER TUBE SUPPORT 5 0056 2 CS.75-6 X.75 HX G5 ZN 6 70668 2 NT.75-6 HX JAM GR5 ZN 7 0626 CS.2-8 X.000 HX G5 ZN 8 6295 PIVOT TUBE 9 029876 2 LW.2 INT-EXT TOOTH ZN 20 02927 NT.250-20 HX GR5 ZN. Supplied with transmission. CONTROL LEVER ADJUSTMENT NOTES: The control levers can be adjusted for operator comfort. By loosening the nuts that attach the upper control lever to the lower lever (FIG. ), the upper control lever can be pivoted to fit the operator s personal preference. The control levers can also be adjusted up and down. Remove the hardware and slide the upper control lever up or down and align the holes in it with the holes in lower lever. Re-install the hardware and tighten. The control levers should be adjusted so that they align with each other when in the neutral position (FIG. 2). UPPER CONTROL LEVER CAP SCREWS ALIGN HANDLES LOWER CONTROL LEVER FIG. FIG. 2 0988CE_050-5
STEERING LINKAGE The neutral adjustment for the control levers in the neutral position is discussed in this section. The tractor steering has been factory adjusted to eliminate creeping when the control levers are in the neutral position (FIG. ). However, should the tractor begin to creep, the control lever linkage can be adjusted as follows: CONTROL LEVER CONTROL LEVER IN THE NEUTRAL POSITION FIG. CONTROL LEVER NEUTRAL ADJUSTMENT Before considering any adjustment, check the tire air pressure. Unequal tire pressure will cause the tractor to drift to one side. Refer to tire pressure information in the section of this manual. NOTE: Proper park brake adjustment must be completed before the control lever neutral adjustment can be done. Fine adjustment to the unit s steering is made with the transmission control rod. (FIG. ). Neutral is properly adjusted when the control levers are in the park brake position and the transmissions do not whine. If this occurs, the control linkage may be adjusted as follows:. Park the unit on a flat surface, raise the rear of the tractor and block with certified jack stands (FIG. 6). With the park brakes set, start the engine. Once the engine is started, if the transmissions whine while the park brake is engaged, then neutral needs to be reset. Turn off the engine. WARNING: Never work under the machine or attachment unless it is safely supported with jack stands. Make certain machine is secure when it is raised and placed on the jack stands. The jack stands should not allow the machine to move when the engine is running and the drive wheels are rotating. Use only certified jack stands. Use only appropriate jack stands, with a minimum weight rating of 2000 pounds to block the unit up. Use in pairs only. Follow the instructions supplied with the vehicle stands. WARNING: This is a dangerous operation - keep hands, hair, clothing, etc., clear of the cooling fans on top of the transmissions! Exercise extreme caution. WARNING:.Never attempt to make any adjustments or repairs to the tractor drive system while the engine is running. The following procedures should be performed by trained maintenance personnel only. 2. Loosen and back off the jam nuts on both ends of the steering control rod assembly (FIG. ). Set the steering control lever in the neutral/brake position.. Remove the female spade connectors from the seat switch (located under the seat). These will need to be connected together now to bypass the seat switch to perform the following functions. This must only be done by a qualified authorized dealer.. Make sure the steering damper ball studs attached to the frame at the rear of the damper on either side are loose and allowed to slide in the slot. 5. Both steering control levers need to be in the brake position when starting the engine, but need to quickly be moved out of the brake position once engine is started so the -6 0988CE_050
CONTROL LEVER IN THE NEUTRAL POSITION JAM NUT CONTROL LEVERS IN PARK BRAKE POSITION STEERING CONTROL ROD JAM NUT FIG. FIG. 5 brakes do not fight the transmissions since they have not yet been adjusted. 6. Start the engine. Move the control lever to just engage the brake (neutral) slot and hold it in that position (Do not engage the control lever far enough to engage the brakes in the brake slot) (FIG. 5). WARNING: This operation is extremely dangerous. Pay close attention when adjusting the transmission control rod so you do not get your fingers, tools, or anything else close to the ZT 2800 transmission s cooling fans. 7. Beginning with the RH side of the tractor, adjust the steering control rod so that the RH drive axle just starts turning in the forward rotation while the steering lever remains in the neutral position. Now, turn the steering rod back the opposite direction to the point when the drive axle stops spinning. From that point, turn the steering rod back again ½ turn. This ensures that the steering rod is adjusted so that the transmission control arm is centered in the neutral band of the transmission. 8. Move the lever forward and backward and make sure that the drive axle spins forward and backward correctly. Return the steering lever to neutral and re-check to make sure the drive axle is stopped in the neutral position. Lock the steering control lever into the brake position. You should not hear the transmission whine if neutral is properly set. 9. Turn off the engine. 0. With the engine off, move the RH steering control lever into the neutral position and pull the lever all the way back to the rear of the tractor as if you were going full speed in reverse. Now, slowly bring the lever back to the neutral position and lock it into the brake position. This sets the steering damper in the correct neutral position. Tighten the ball stud at the rear of the damper that is attached to the frame side panel on the RH side (FIG. 7). Once this is tightened, you should be able to move the steering control lever to the reverse position, let it go, and the steering lever should return itself to the neutral position. This should finish the adjustment for the RH side steering control. Double check to make sure you have all fasteners tightened to the correct torque specifications.. Repeat steps thru 9 for the LH side. 2. Once both sides are properly adjusted, double check them together to make sure everything is working properly.. IMPORTANT: With the engine off, disconnect the two female spade connectors from each other (from step #) and reconnect them to the seat switch. This must be completed so the safety circuit is functioning properly. Refer to the machine s owner s manual for operation check. 0988CE_050-7
STEERING DAMPENER ENGINE GUARD JACK STANDS REAR DAMPENER BALL STUD NUT FIG. 6 FIG. 7 WARNING: Do not operate the tractor without plugging the tractor wiring harness into the seat switch. This switch is an important part of the safety start interlock system. Serious injury can result if the seat switch is not plugged into the tractor s wiring harness.. Check to make sure all tools or obstructions are removed from under the tractor. Assemble the drive wheels and wheel nuts. Torque the wheel nuts to 65-75 ft-lbs. 5. Jack up the rear of the tractor and remove the jack stands. Lower the tractor to the ground and remove the jack. 6. The control levers should be adjusted so that they align vertically with each other when in the neutral position (FIG. 2). Space between ends of control handles to be.50" ±.25". 7. Check the hydraulic oil level after final adjustments. Make sure oil level is within operating range specified. STEERING DAMPER The steering damper (FIG. 7) is spring loaded to return the control levers to the neutral position from the reverse position. This gives the operator a sense of neutral during operation. If the tractor does not return to neutral from reverse then adjust as follows: To set the steering dampers in the correct operating position follow these steps:. Shut engine off, place control levers in the park brake position, disengage deck clutch, remove ignition switch key and disconnect negative battery cable before doing any adjustments. 2. Place the control lever in the neutral position (FIG. ).. Loosen the steering damper s rear ball stud (FIG. 7).. Pull the damper spring housing, to the rear, past the point that the internal spring is engaged. 5. Release the damper spring housing and allow the internal spring to bring the housing back to the neutral position. 6. Tighten the nut on the steering damper s rear ball stud. 7. To check, move the control lever to the reverse position and release. The control lever should return to the neutral position. If not, repeat steps through 6. DRIVE STRAIGHT ADJUSTMENT:. Initially adjust cap screws (FIG. 8) all the way in so that the steering levers may go fully forward. 2. Drive tractor in an open area with both steering handles fully forward. The tractor will likely drift slightly to the left or right.. Whichever direction the tractor turns is the slow side. Leave the slow side cap screw and jam nut so that they are flush with the frame. Holding the cap screw in place, lock the jam nut.. On the fast side, through several iterations, back out the cap screw gradually until the fast side is slowed to the same speed as the other side and the tractor drives straight. After adjustment is finished, hold the cap screw still and tighten the jam nut. -8 0988CE_050
JAM NUT CAP SCREW FIG. 8 0988CE_050-9
Steering Sub-Assembly 2 5 6 5 7 7 8 INDEX NO. PART NO. QTY. DESCRIPTION 78260 STEERING BAR GRIP 2 6087 STEERING BAR 76795 2 FW.06 X.82 X.060 SAE HD ZN 70578 CS.75-6 X.750 HX G5 5 086660 6 NT.75-6 HXZY NL 6 078 STEERING ARM LEFT (SHOWN) 0782 STEERING ARM RIGHT 7 770867 2 BUSHING, PLASTIC.750X 8 0788 STEER PIVOT, LEFT (SHOWN) 0787 STEER PIVOT RIGHT. Includes Item (Steering Bar Grip). NOTES: -0 0988CE_050
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Brake 2 9 7 8 0 2 5 6 2 9 2 2 2 Mower Frame 5 2 7 2 5 9 8 Hydro Transmission -2 0988CE_050
Brake INDEX NO. PART NO. QTY. DESCRIPTION 086660 NT.75-6 HX LK NY 2 76795 2 FW.06 X.82 X.060 SAE HD ZN 60087 2 PLUNGER SWITCH 00508 2 CS.75-6X.50 HX G5 Z 5 600 2 BRAKE ROD ASSEMBLY 6 05502 2 NT.75-6 HX GRD 5 ZN 7 02655 NT.2-2 HXZY NL 8 76852 8 FW. X.687 X.05/.080 HD ZN/YL 9 7659 BUSHING 0 0789 BRAKE BELL CRANK LS 07892 BRAKE BELL CRANK RS 2 080655 2 CS.75-6X.500 HX G5 60099 2 SHORT BRAKE LINK ROD 60 2 BRAKE ARM RET. SPRING 5 0920 BRAKE SPRING LINK LS 6 09202 BRAKE SPRING LINK RS (NOT SHOWN) 7 05599 2 CS.250-20X.750 HX G5 8 0686 2 NT.250-20 HX FL LK ZNY 9 6005 2 OVERTRAVEL SPRING NOTES: PARK BRAKE SPRING ADJUSTMENT Occasionally check the park brake spring adjustment using the following method:. Shut engine off, place control levers in the park brake position, disengage deck clutch, remove ignition switch key and disconnect negative battery cable before doing any adjustments. 2. Position the control lever in the park brake position.. Measure the park brake spring. It should be compressed to -7/6. If it is not, adjust the nylock nut until the proper spring compression is achieved (FIG. 9). -7/6" COMPRESSED SPRING LENGTH.7" BRAKE ROD ASSEMBLY NYLOCK NUT OVERTRAVEL SPRING. Repeat for the other side. FIG. 9 0988CE_050 -
- 0988CE_050
Section Wheel and Tire......................................... -2 Drive Wheel Breakdown.................................. - 0988CE_050 -
Wheel and Tire 2 6 5 6 7 8 7 5 2 9 0 0 2-2 0988CE_050
Wheel and Tire INDEX NO. PART NO. QTY. DESCRIPTION 609 2 TIRE/WHEEL 20 X 2-0 (ONLY USED ON 92882CE) 600668 2 TIRE/WHEEL 20 X 0-0 (ONLY USED ON ) 2 875 2 BACKUP PLATE, WHEEL 06077 8 WHEEL NUT 70595 2 CS.500- X.25 HX G5 ZN 5 267 2 FW.50 X 2.5 X.87 SPL ZN 6 72976 2 FW.5 X.75 X.25 ZNYC 7 7822 BEARING W/O COLLAR 8 7860 2 SPACER 9 060 2 NT.750-0 HX NL ZN 0 025296 FW.760 X.625 X.08 ZN 66625 2 FORK 2 7867 2 CS.750-0 X 8.00 HX GR5 ZNYC 78606 2 WHEEL & TIRE ASSY NOTES:. Apply grease to zerks (see owners manual). 2. Tighten, then back off until wheel spins freely.. Assemble with extended inner race down.. Apply Loctite 22 to threads. 5. Torque to 88.-0.7 Nm. 6. Inflate tires to 55.6 82.7kPa. 0988CE_050 -
Drive Wheel Breakdown 2 INDEX NO. PART NO. QTY. DESCRIPTION 608 TIRE 20 X 2-0 ( 60" & 5" MOWER) 2 607 WHEEL ( 60" & 5" MOWER) 0952 TIRE VALVE 60068 TIRE 20 X 0-0 ( 8" MOWER) 2 600700 WHEEL ( 8" MOWER) 0952 TIRE VALVE. Inflate tire to88.-0.7 kpa. NOTES: - 0988CE_050
Section 5 Engine, 2 HP Kaw...................................... 5-2 Fuel.................................................. 5-6 0988CE_050 5-
Engine, 2 HP Kaw 0 } 2 5 2 PART OF ENGINE 20 TO ENGINE OIL SENSOR YELLOW 9 0 6 7 8 9 8 9 8 6 7 2 0 } 8 5 2 6 5 2 6 9 9 8 2 2 TO BULLET TERMINALS TO SPADE TERMINALS 2 5 9 8 2 2 2 2 RED/BLK 8 STARTER 25 SOLENOID GROUND 7 8 2 PUR/RED 22 5 29 28 27 6 26 8 9 5-2 0988CE_050
Engine, 2 HP Kaw ITEM NO. PART NO. QTY DESCRIPTION N/A KAWASAKI 2HP ENGINE 2 058776 NT.2-8 HXZY NL 76852 0 FW. X.687 X.05/.080 HD ZN/YL 0570 HOSE CLIP 5 79652 OIL DRAIN VALVE M20X2.5 6 0506 CS.2-8 X.750 HX G5 7 7876 SINGLE PULLEY 8 7272 KEY / SQ X 0.66 LG 9 000 5 WIRE TIE SMALL/SHORT 0 7898 RUBBER BUMPER 6026 WARNER CLUTCH 2 7925 CLUTCH PIGTAIL 767 FW.5 X.50X.250 785659 CS.7-20 X 2.50 HX G5 Z 5 79629 NEG. BATTERY CABLE 6" 6 029876 LW.2 INT-EXT TOOTH ZN 7 60062 POS BATTERY CABLE 7" 8 76855 FW.28 X.625 X.05/.080 HD ZNYC 9 02927 5 NT.250-20 HX GR.5 ZNYC 20 0786 OIL DRAIN HOSE 2 609 2 POS BATTERY CABLE BOOT 22 602 POS BATTERY CABLE " 2 0255 NT #0-2 HX ZN 2 0087 STARTER SOLENOID 25 05599 2 CS.250-20X.750 HX G5 26 0625 2 CB.2-8X.750 FUL ZN 27 60002 HORIZONTAL MUFFLER 28 08969 MUFFLER HEAT SHIELD 29 0272 2 NT.2-8 HX G5 ZN 0 6000 EXHAUST MANIFOLD 08288 HEAT SHIELD 2 7808 2 KAW MUFFLER GASKET 78578.50" MUFFLER CLAMP 0700 LW.2 MED SPRING ZNYC 5 78266 NT M8-.25 HX STAINLESS 6 098 HEATSHIELD FST KAW675CC 7 6029 UBOLT.250-20 X.25 DIA 8 6052 UBOLT.250-20 X.250 ID 9 02927 NT.250-20 HX GR.5 ZNYC 0 0588 " /" FUEL LINE 0002 2 HOSE CLAMP CLIP NOTES:. Includes mounting hardware. 2. Part of Wire Harness.. Engine oil capacity:refer to engine owner s manual. 0988CE_050 5-
. Supplied with engine. 5. Route item 22 (" positive battery cable) with the purple and red wires through item 2 (positive battery cable boot) prior to fastening hardware to the solenoid. 6. Torque to 6 65 Nms. If fastener is loosened or removed, do not re-use. Replace with new fastener. Use only hand tools to install this fastener. ENGINE SPEED MODEL NO. ENDING IN: CE HIGH IDLE 2550±50 RPM,, 5-0988CE_050
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Fuel RIGHT SIDE LEFT SIDE 2 5 5 5 5 6 6 7 8 9 9 0 0 2 0 0 6 7 8 6 5-6 0988CE_050
Fuel INDEX NO. PART NO. QTY DESCRIPTION 77906 2 FUEL CAP.5" 2 6020 FUEL TANK RIGHT SIDE 602 FUEL TANK LEFT SIDE 7299 8 FW.06 X.00 X.2 HRD ZN 5 055822 8 CS.75-6 X.75 HX G5 6 0002 HOSE CLAMP CLIP 7 0588 2" /" FUEL LINE 8 0588 " /" FUEL LINE 9 0280 2 CS.2-8 X.750 HX G5 ZN 0 76852 FW. X.687 X.05/.080 HD ZN/YL 75059 FUEL VALVE -WAY 2 000 WIRE TIE, SMALL/SHORT 0272 2 NT.2-8 HX G5 ZN 00098 2 CLAMP. Torque to 27 N-m. NOTES: 0988CE_050 5-7
5-8 0988CE_050
Section 6 Battery................................................ 6-2 Instrument Panel........................................ 6- Electrical Schematic 60.............................. 6-6 0988CE_050 6-
Battery 2 5 5 6 5 7 6 8 6-2 0988CE_050
Battery INDEX NO. PART NO. QTY. DESCRIPTION 768 2 CS.2-8X.000 HX G5 2 76852 2 FW.X.687X.05/.080H 87 STRAP, BATTERY CLAMP 05599 2 CS.250-20X.750 HX G5 5 029868 LW.250 INT-EXT TOOTH Z 6 02927 2 NT.250-20 HX GR.5 ZNYC 7 7728 BATTERY CBL BOOT-RED(FS) 8 796 2 GM.50 X 2.2 X.75 NOTES: 0988CE_050 6-
Instrument Panel 2 5 6 9 6 5 2 5 5 7 0 9 7 8 FUSE SIZE AND LOCATION 0a 20a ORG YEL BLK ORG 8 6-0988CE_050
Instrument Panel INDEX NO. EXCEL P/N QTY DESCRIPTION 60095 CABLE, CHOKE 2 77676 SWITCH, PTO 76966 HOUR METER 785808 KEY ASSEMBLY 5 05898 IGN SWITCH 6 72257 INDICATOR LIGHT, RED 7 6009 CABLE, THROTTLE 8 05982 2 NT #0-2 HX NL ZN 9 7092 2 FW.29 X.500 X.08 ZNYC 0 02707 STOP, CE THROTTLE 60089 2 RIVET.88 DIA. BLK HD 2 5505 INSTRUMENT PANEL 60098 2 CB 0-2 X.500 ZYNC 05597 CS.250-20X.500 HX G5 ZN 5 76855 FW.28 X.625 X.05/.080 HD ZN/YL 6 6022 DECAL, INST PANEL 7 000 6 WIRE TIE, SMALL/SHORT 8 60 WIRE HARNESS, FST KAW 9 02627 2 RELAY. Part of wiring harness. 2. Item includes 6022 (Dash Decal) NOTES: 0988CE_050 6-5
Electrical Schematic 60 6-6 0988CE_050
Section 7 5" Deck Decals........................................ 7-2 5" Deck Pulley Assembly................................. 7-5" Deck.............................................. 7-8 5" Deck Belt Routing and Tensioning...................... 7-0 Deck Lift.............................................. 7-2 Deck Mounting Hardware................................ 7-0988CE_050 7-
5" Deck Decals 2 2 5 6 7 8 INDEX NO. PART NO. QTY. DESCRIPTION 5502 5" DECK WELDMENT 2 60069 CN.2-8X.200 MAX THK 6062 DISCHARGE CHUTE DECAL 6087 2 DECK DANGERS DECAL 5 789 DECK BELT ROUTING DECAL 6 785055 STEP TREAD 7 72772 'MADE IN U.S.A.' DECAL 8 60892 THROWN OBJECTS DECAL NOTES:. Item (5502) includes Items 2 8 as a service deck. 7-2 0988CE_050
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5" Deck Pulley Assembly 9 8 2 5 6 7 0 2 2 20 8 2 2 5 2 2 25 2 26 27 8 9 8 6 7 2 22 27 26 2 2 27 22 8 8 28 29 25 2 2 26 2 7 25 2 29 0 2 20 7-0988CE_050
5" Deck Pulley Assembly INDEX NO. PART NO. QTY. DESCRIPTION 025007 CS.625-X.750 HX G5 2 0682 FW.656X 2.00X.078 ZNYC 7979 FW.650X.25X.8 ZNYCG5 78856 IDLER PULLEY NHI 5.00" 5 0288 FW.625X.00X. ZNYC 6 600296 DECK IDLER SPACER 7 5088 IDLER W/A 8 7802 IDLER SPRING 9 25982 CHAIN DECK LIFT SPRING 0 79790 6 CS.2-8X.50FLT SH ZY 60 2 UHMW IDLER SLIDE 2 06972 2 NT.625- HX G5 ZNYC 78872 CS.625-X.25 HX G5 Z 7827 5 CW.6 2.250X.87 PNT 5 786889 DECK DRIVE PULLEY 6 05502 2 NT.75-6 HX GRD 5 ZNY 7 76795 2 FW.06X.82 X.060 SAE 8 76852 0 FW.X.687X.05/.080H 9 0272 2 NT.2-8 HX G5 ZNYC 20 0280 2 CS.2-8X.750 HX G5 2 0927 RIGHT PULLER & PIN ASSY 22 0928 LEFT PULLER & PIN ASSY 2 78708 CS.500-X.250 HX G5 2 767962 8 FW.5X.06X.090 SAE 25 0997 ANTI-SCALP WHEEL 26 0599 NT.500- HX JAM ZNYC 27 78567 NT.500- HX G8 ZY NL 28 058776 6 NT.2-8 HXZY NL 29 7878 2 CS.625-X.00 FULL HX 0 0056 2 CS.75-6X.75 HX G5 78506 BLADE SPINDLE ASSEMBLY 2 78866 ANTI SCALP WHEEL ASSY NOTES:. 78866 (Anti-scalp Wheels) include Items 2 26. 2. Torque to 60 Nm. 0988CE_050 7-5
5" Deck Pulley Assembly 9 5 9 5 0 7 8 5 7 6 5 0 7 7 8 6 5 6 5 9 7 8 8 7 6 5 5 7 9 0 7 0 INDEX NO. PART NO. QTY. DESCRIPTION 0929 HANGER EXT REAR RIGHT SIDE 0928 HANGER EXT REAR LEFT SIDE 5 76852 8 FW.X.687X.05/.080H 6 0272 NT.2-8 HX G5 ZNYC 7 7287 8 FW.68X.00X.090 HT T 8 0707 NT.7- HX G5 ZNYC 9 0626 CS.2-8X.000 HX G5 0 0776 CS.7-X.000 HX G5 09200 2 HANGER EXT FRONT NOTES: 7-6 0988CE_050
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5" Deck 5 7 2 6 5 9 8 9 6 5 6 20 9 0 5 6 8 2 7 7-8 0988CE_050
5" Deck INDEX NO. PART NO. QTY. DESCRIPTION 60806 DISCHARGE CHUTE 2 60259 TORSION SPRING 608 CHUTE PIN 28 CHUTE BRACKET 5 086660 7 NT.75-6 HX G5 ZN NY 6 76795 6 FW.06 X.82 X.060 SAE 7 55089 PULLEY COVER, RS 5" 8 78988 BELT, B 52" EL 9 55090 PULLEY COVER, LS 5" 0 02595 2 CB.75-6 X.000 STD ZN 08202 BAFFLE MULCH W/A 5" 2 08200 2 BAFFLE MULCH, COMMON 5" 020 CB.75-6 X.750 STD ZN 76852 FW. X.687 X.05/.080 HD ZN/YL 5 06006 CS.2-8X.625 HX G5 6 7827 CW.6 X 2.250 X.87 PNT 7 78872 CS.625- X.250 HX G5 ZN 8 79770 BLADE, 8.50"-MUL-F-CW 9 602562 2 DECAL, NO SERVICE 20 7997 DECAL, 5" DECK ID 2 797696 BLADE, F8.50"-H-F-CW (NOT SHOWN) NOTES:. Torque to 60 N.m.. 2. Index 7 (55089) includes and index 9 ( No Service Decal) as a service part.. Index (55090) includes index 20 (Deck ID Decal) and index 9 ( No Service Decal) as a service part. 0988CE_050 7-9
5" Deck Belt Routing and Tensioning 2cm 2cm NOTES:. Spring length after tensioning new belt. Measured from outside of hook to outside of hook at deck leveling height. 5. Route belt as shown. 7-0 0988CE_050
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Deck Lift 2 5 6 7 8 6 9 0 5 5 6 2 6 5 0 5 6 6 5 6 5 5 7-2 0988CE_050
Deck Lift INDEX NO. PART NO. QTY. DESCRIPTION 88 STOP HANDLE 2 828 HEIGHT ADJUSTMENT STOP 7888 DECK LIFT INDICATOR 706 6 NT.7- HX FLG ZN 5 6068 6 FW.78 X.50 X.20 ZNYC 6 7829 7 CLIP E,.00 X.625 X.050 7 756270 CS.2-8 X.50 FLTHR G 8 0272 NT.2-8 HX G5 ZNYC 9 858 DECK LEVELER YOKE W/A 0 767962 6 FW.5 X.06 X.090 SAE 0595 STRAIGHT GREASE FITTING 2 782995 2 DECK LIFT SPRING 78229 CE.750 X 2.25 X.75 HEADLESS 60 DECK LIFT CHAIN ( LINKS) 5 05579 7 CS.7- X.750 HX G5 ZNYC 6 788 CS.7- X.750 FULTH. Apply grease to zerks. NOTES: 0988CE_050 7-
Deck Mounting Hardware 5 0 7 2 8 0 7-0988CE_050
Deck Mounting Hardware INDEX NO. PART NO. QTY. DESCRIPTION 7 07899 2 CS.500-X 2.00 GR ZN 8 0089 2 NT.500- HX G5 ZN 2. Install in rear hole of frame bracket. NOTES: DECK BELT ADJUSTMENT The spindle belt tension remains constant by means of a tension idler and spring. The spring tension should be such that the belt does not slip under normal operating load conditions, assuming the belt is not excessively worn or damaged. As the belt stretches and wears in, adjusment may become necessary. To increase belt tension, move the spring chain one (or more) link(s) at the anchor point on the deck frame. IMPORTANT: Do not over tension the spring to compensate for a badly worn belt or pulley. SPRING CHAIN SPRING CHAIN ANCHOR POINT IDLER SPRING DECK LEVELING PROCEDURE FIG.. Check tire pressures (8 2 psi) to make certain they are properly inflated before starting to level deck. NOTE: Stop engine. Make sure deck clutch switch is in the down (OFF) position. Remove ignition key. Place control levers in the brake position. 2. Place " high deck support blocks (two stacked 2"x" blocks can be used to create a " high support) at the four corners of the deck as indicated in FIG. 2.. Factory cutting height is set at ¼" by placing the height stop in the " hole, with the flat side of height adjusting stop against the stop handle.. Secure the height stop against the stop handle with a clamp. 5. Loosen all nuts on the deck lift threaded rods (FIG. ), and the hardware holding on the height indicator bar (on the right front) (FIG. ), until ALL the deck lift chains are loose, AND the deck 0988CE_050 7-5
is sitting tightly on all four blocks. BLOCK BLOCK BLOCK BLOCK FIG. 2 6. Loosen the two nuts on the front of height indicator so that the foot pedal is free, FIG.. NUTS HEIGHT INDICATOR BAR CLAMP " LIFT BLOCK DECK LIFTING ROD DECK LIFTING CHAIN NUTS FIG. FIG. 7. Set the amount of threads protruding on the deck lift rod from the lift block at approximately " (FIG. ). 8. Jam both nuts against the block. 9. Start the leveling process on the LEFT FRONT of the mower. 0. Push or pull on the deck lift pedal until the chain on the LEFT FRONT just becomes tight, making sure that the deck stays tight against the deck installation blocks (FIG. 2). While keeping the chain tight, tighten the nuts against the deck lift block on the height indicator (FIG. ). 2. Jam nuts tightly together against the deck lift block.. Go to the RIGHT FRONT of the mower.. Loosen the 7/6" flange nuts that clamp the adjuster to the deck lift arm (FIG. 5). 5. Loosen the 5/6" jam nut on the adjuster bolt, and back the adjuster bolt out to allow the 7-6 0988CE_050
adjuster to move up and down freely. (FIG. 5). DECK LIFT ARM ADJUSTER BOLT ADJUSTER JAM NUT CHAIN FLANGE NUTS FIG. 5 6. Tighten the adjuster bolt until the chain just becomes tight, making sure that the deck stays tight against the blocks. 7. Tighten the adjuster bolt jam nut to prevent the adjuster from moving. 8. Tighten the 7/6" hardware holding the chain and adjuster onto the deck lift arm. 9. Go to the RIGHT REAR of the mower. 20. Make sure that there is still slack in the chain. If not, loosen the two nuts on the block holding the threaded rod until there is slack in the deck lift chain (FIG. 6). JAM NUTS CHAIN FIG. 6 2. Tighten the appropriate nut until the chain just becomes tight, making sure that the deck stays tight against the blocks (FIG. 6). 22. Tighten the other nut on the opposite side of the block, and jam them tightly together against the block. 2. Repeat step 2 for the LEFT REAR of the mower. 2. Compress the deck lift assist spring so that there is ½" of space between the front nut on the spring, and the rear nut on the deck lift block. (FIG. 7). NUTS ½" FIG. 7 25. When completed, all chains should be tight, and deck should still be resting on the four blocks. 0988CE_050 7-7
7-8 0988CE_050
Section 8 Seat.................................................. 8-2 ROPS................................................. 8-0988CE_050 8-
Seat 2 20 2 6 5 7 7 8 0 9 2 8 5 8 7 6 8 9 8 6 2 8-2 0988CE_050
Seat INDEX NO. PART NO. QTY. DESCRIPTION 7966 SEAT, MICHIGAN STANDARD 2 797076 2 CS.7-20 X.00 HX G8 ZNYC 0729 FW.0 X.000 X.08 ZNY 60 SEAT BELT 5 7960 BAR, SEAT BELT CROSS 6 7065 2 NT.7-20 HX GR5 ZNYC 7 0280 CS.2-8X.750 HX G5 8 76852 FW.X.687X.05/.080H 9 80885 RIVET NUT, 5/6-8 THREAD 0 082 SEAT LATCH 000 2 WIRE TIE, SMALL/SHORT 2 55068 SEAT PAN 058776 NT.2-8 HXZY NL 0920 SEAT PAN STOP 5 0272 NT.2-8 HX G5 ZNYC 6 060 CS.2-8X.875 HX G5 7 052860 2 CS.75-6X.250 HX G5 8 76795 2 FW.06X.82 X.060 SAE 9 6050 2 SEAT SPRING 20 6085 BATTERY DECAL NOTES:. Part of 7966 (Standard Seat). 2. Do not torque item 6, the Seat Pan must pivot freely.. Item 2 includes, items 20 (72706) Battery Decal and item 2 (7857) Service Decal.. Service parts available for Michigan standard seat: PART NO. 7907 SLIDE KIT 795 SEAT SWITCH 7976 ARMREST ASSY LH RND 79772 ARMREST ASSY RH RND 79780 ARMREST W/O BRACKET 7927 ARMREST STOP ASSEMBLY DESCRIPTION 0988CE_050 8-
ROPS 2 5 9 9 6 7 8 7 8 8-0988CE_050
ROPS INDEX NO. PART NO. QTY DESCRIPTION 602585 ROPS ASSEMBLY 2 0682 CS.500- X.500 HX GR5 ZN 6072 ROPS STOP 027 6 NT.500- UNT LK G8 ZN 5 6070 2 KNOB, HAND FOR ROPS 6 607 2 LYNCH PIN W/ LANYARD 7 077859 5 CS.500-X.250 HX G5 ZN 8 767962 8 FW.5 X.06 X.09 SAE HRD ZN 9 6065 2 DECAL, ROP'S NOTES: 0988CE_050 8-5
8-6 0988CE_050
Numerical Index Part No. Page No. Index Part Numbers 0002 5-, 5-7 000 -, 5-, 5-7, 6-5, 8-00098 5-7 00508-0056 -5, 7-5 0089 7-5 020 2-5, 7-9 0595 7-0588 5-, 5-7 0625 5-060 - 0686-06972 7-5 0700 5-0729 8-0952 - 027 8-5 02655-5, - 02927-5, 5-, 6-025007 -, 7-5 025296 -, - 02595 2-5, 7-9 02627 6-5 0288 -, 7-5 029868 6-029876 -5, 5-0087 5-0997 2-6, 7-5 0272 -, -5, 5-, 5-7, 7-5, 7-6, 7-, 8-0280 5-7, 7-5, 8-0626 -5, 7-6 068-08828 - 052-5 0707 7-6 0570 5-0255 5-05898 6-5 0682 7-5 0776 7-6 0855-0506 5-052860 2-6, 8-0599 7-5 05502 2-5, 2-6, -, 7-5 05579 7-055822 5-7 05599 -, -5, -, 5-05599 6-05597 6-5 Part No. Page No. 058776 5-, 7-5, 8-05982 6-5 06077-060 - 0682 8-5 06006 7-9 060 8-06878 - 06855 -, -5 077859 8-5 07899 7-5 080655-086660 2-5, -, 7-9 02707 6-5 0786 5-0788 - 07892-0789 - 08200 7-9 08202 7-9 08288 5-082 8-085 2-6 0887 2-6 08968-5 08969 5-09200 7-6 09202-0920 - 0928 7-6 0929 7-6 0920 8-0927 7-5 0928 7-5 098-5 098 5-875 - 28 7-9 25982 7-5 267 2-6, - 828 7-88 7-87 6-858 7-5088 7-5 60 7-6295 -5 66625-587CE 2-58768 2-5 5502 7-2 55068 8- Part No. Page No. 5505 6-5 55089 7-9 55090 7-9 60022-5 600296 7-5 600668-60068 - 600759-600767 - 600880-600899 2-600972 - 60097-600975 - 600976 -, - 600979 -, - 60098-5 600987-60099 - 60099 2-6000 - 60002 5-6000 5-6008 - 6005-60062 5-60069 2-, 7-2 6008-60087 - 60088-60089 6-5 6009 6-5 60095 6-5 60098 6-5 60099 2-60 - 6022-602 5-609 5-6020 5-7 602 5-7 6026 5-60 6-5 608-609 - 600-600 - 600-602 2-6029 5-60 - 60 7-5 0988CE_050 i-
Part No. Page No. Part No. Page No. Part No. Page No. 60 8-6050 8-6052 5-6070 8-5 607 8-5 6072 8-5 6062 7-2 6065 8-5 6068 7-60806 7-9 6085 8-6087 7-2 608 7-9 609-60967 2-6098 2-6020 2-6022 6-5 602562 2-, 7-9 602585 8-5 60259 7-9 602882-60288 - 706-5 7065 8-706 7-7092 6-5 70595-70668 -5 70087-72257 6-5 7272 5-7299 5-7 72976-768 6-72772 2-, 7-2 7287 7-6 75059 5-7 756270 7-767 5-7659 - 76795 2-5, 2-6, -, -, 7-5, 7-9, 8-767962 2-6, 7-5, 7-, 8-5 76855 -, -5, 5-, 6-5 76852 -, -5, -, 5-, 5-7, 6-, 7-5, 7-6, 7-9, 8-76966 6-5 770867 2-6 7728 6-772079 - 7760 2-77676 6-5 7782-77906 5-7 7808 5-785 - 78229 7-78260 -0 7829 7-7802 7-5 78567 7-5 78708 2-6, 7-5 788 7-78856 7-5 78872 7-5, 7-9 78922-5 782292-7827 7-5, 7-9 78257 2-78266 5-782995 7-78506 7-5 7878 7-5 7876 5-78066 - 7822-789 -5 7888 7-7860 - 7898 5-785055 7-2 7859 2-7855CE 2-785220 2-78526 - 785279-78578 5-78585 2-5 7859 2-5 7856-785659 5-785808 6-5 7867-78688 - 786889 7-5 78866 2-6, 7-5 78988 -, 7-9 789776ce 2-7925 5-795 - 7988 2-7927 8-7907 8-795 8-7966 8-796 - 7960 8-796 6-79685 - 795757-79629 5-79652 5-797076 8-7979 7-5 7976 8-79772 8-79780 8-797696 -, 7-9 79770 7-9 79790 7-5 7997 7-9 799CE - 80885 2-, 8-8089 2-92882CE - i-2 0988CE_050