Hustler TrimStar 48"/54" Parts Manual Hustler Turf Equipment P.O. Box 7000 Hesston, Kansas 6706-097
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Table of Contents Section General Information.................................... - Section Mower Frame Assembly................................. - California Components TS............................... -4 Hydro Installation...................................... -6 Section Deck Lift and Installation................................. - Cover Install.......................................... -6 Section 4 Engine 7HP, 9HP Kaw................................ 4- Engine Install, HP KAW ES............................. 4-4 Fuel System Install..................................... 4-8 Instrument Panel....................................... 4-0 Instrument Panel....................................... 4- Instrument Panel....................................... 4-6 Throttle.............................................. 4-8 54" ES Console Assembly............................... 4-0 Electrical Schematic 6097............................ 4-6 Section 5 Tire Installation........................................ 5- Tire Assembly......................................... 5-4 Caster Wheel Assembly................................. 5-5 Section 6 Deck, Decal Assembly 48"............................... 6-48" Deck Pulley Assembly............................... 6-4 48" Deck Belt & Blade Assembly.......................... 6-6 48" Deck Belt Routing and Tensioning...................... 6-9 Deck Decals, 54"....................................... 6-0 54" Deck Pulley Assembly............................... 6-54" Deck Belt & Blade Assembly.......................... 6-4 54" Deck Belt Routing and Tensioning...................... 6-7 Index........................................................ i- 5 09/0 c-
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Section General Information This Manual covers TrimStar models 9940, 9965 and 997 Frequently Ordered Parts PART NO. DESCRIPTION 7986 Pump Drive Belt 60969 TS 48" BELT, B.00 EL 60788 TS 54" BELT, B.0 EL 795757 BLADE, F6.50"-H-F-CW 797696 BLADE, F8.50"-H-F-CW 068478 Fuel Filter 79785 Kawasaki KAI Air Filter Precleaner 797860 Kawasaki KAI Air Filter Cartridge 77079 Engine Oil Filter Service Literature PART NO. DESCRIPTION 5 TrimStar Owner s Manual 797795 Kawasaki KAI 7/9HP 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. PART NO. DESCRIPTION 000 FLEXIBLE TRIM 7877 HOSE, 0.50" LOW PRESSURE 0588 FUEL LINE 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. 5 090 -
Options Available From Your Dealer PART NO. DESCRIPTION 08 48" TrimStar Hydro Mulch Kit 0897 54" TrimStar Hydro Mulch Kit 05 Roll-On Striping Sulky 9999 TrimStar Side Catcher 479 Adapter kit Hardware Description Codes & Abbreviations The following codes are used throughout this parts manual. Refer to this list when ordering parts. ABBREVIATION DESCRIPTION ABBREVIATION DESCRIPTION Standard Torques CB Carriage Bolt MB Machine Bushing CE Clevis Pin MS Machine Screw CP Cotter Pin NT Nut CS Cap Screw SC Self Tapping Cap Screw CW Cup Washer SH Socket Head FDRW Fender Washer SB Shoulder Bolt FW Flat Washer SS Set Screw HX Hex Head OD Outside Diameter LW Lock Washer ID Inside Diameter 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.50 8.. M.. 7 M4..75 0 40 M5 4.5 6..48 48 65 M6 7.7 0.4.500 7 99 M8 8.5 5.56 05 4 M0 7 50.65 45 00 M 64 87.750 60 50 M4 80 08.5.875 40 565 M6 60 5.00 65 850 M0 0 45 M4 555 750 NOTE: Loctite 59 to be used on all pipe threads. Lubricate all grease zerks. - 5 090
Section Mower Frame Assembly.................................. - California Components TS................................. -4 Hydro Installation........................................ -6 5_090 -
Mower Frame Assembly 7 6 7 5 4 8 8 8 8-5_090
Mower Frame Assembly INDEX NO. PART NO. QTY. DESCRIPTION 5507 FRAME INSTALL 5508 FRAME INSTALL 60069 7 CN.-8X.00 MAX THK 77980CE DECAL,HOT CE 4 797647 DECAL, TSH IZT BELT 5 0879 SERIAL NO PLATE TURF 6 000 FLEXIBLE TRIM " TOTAL 7 000 FLEXIBLE TRIM " TOTAL 8 808485 8 RIVET NUT, 5/6-8 NOTES:. Used on 9940 and includes items 8.. Used on 9965 and includes items 8. 5_090 -
California Components TS INDEX NO. PART NO. QTY. DESCRIPTION 60908 DECAL, SPARK ARRESTOR 0879CA DECAL, CA EMISSIONS NOTES: -4 5_090
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Hydro Installation 4 5 6 7 8 9 0 5 Front 6 9 6 4 7 45 45 8 5 5.4" 6.4" 6-6 5_090
Hydro Installation INDEX NO. SERVICE PART NO. QTY. DESCRIPTION 0480 CS.-8X.750 HX G5 7685 FW.4X.687X.05/.080H 047 4 NT.-8 HX G5 ZNYC 4 60996 EXPANSION TANK, ZT800 5 076 OVERFLOW BRKT, TS 6 6000 4 SPRING CLAMP,.75" DIA 7 7877 HOSE, 0.50" LOW PRESSURE 4" LH 8 7877 HOSE, 0.50" LOW PRESSURE 44" RH 9 778746 RING, " ID SPLIT 0 598 CHAIN 8" ( LINKS) 0684 SPRING /4 COIL PL. 785 BUSHING, UHMW 079 PUMP IDLER ARM 4 786848 PULLEY, IDLER 4"OD X.6 5 0596 FW.760X.65X.08 ZNYC 6 60084 SB.750X.000 SH.65-7 088 FW.65X.00X.4 ZNYC 8 7887 CS.65-X.5 HX G5 Z 9 7986 BELT, A 6" EL NOTES:. Torque to 00 ft-lbs.. Spring tension, hook to hook is 5.4"-6.4" (see detail). 5_090-7
Hydro Installation 0 0 8 0 5 6 8 6 7 8 7 9 4 0 7 5 6-8 5_090
Hydro Installation INDEX NO. SERVICE PART NO. QTY. DESCRIPTION 0 70087 8 CS.-8X.500 HX G5 6050 CB.50-0 X.65 ZNYC 608 TOW LINK ROD 57 PLATE, TS TOW VALVE 4 66 TOW VALVE BRACKET, LS (NOT SHOWN) 5 67 TOW VALVE BRACKET, RS 6 76855 6 FW.8X.65X.05/.080H 7 06855 4 NT.50-0 HXZY NL 8 04988 SPRING LC-04F-5 9 609 FITTING, 90-9/6 SAE 0 6070 ZT800, RH TRANS 6079 ZT800, LH TRANS 0640 CS.75-6X.00 G5 ZNYC 767954 FW.406X.8 X.060 SAE 4 789 BALL STUD 5 600987 ZT SPACER TUBE 6 07 CHARGE PUMP COVER, RH 7 070 CHARGE PUMP COVER, LH 8 000 6 WIRE TIE, SMALL/SHORT NOTES:. Torque to 7 ft-lbs. 4. Service parts available for the transaxles: PART NUMBER DESCRIPTION PART NUMBER DESCRIPTION 600767 OVERFLOW TANK CAP 60 ZT800 BRAKE ARM - 007 60097 BRAKE ARM RETAINER CLIP 604 4-BOLT HUB KIT SDFST 600974 RIGHT FILTER GUARD 60094 ZT800 FAN/PULLEY KIT 600975 LEFT FILTER GUARD 6008 SPRING, EXTENSION RTN 600976 FILTER, OIL 5_090-9
-0 5_090
Section Deck Lift and Installation.................................. - Cover Install............................................ -6 5_090 -
Deck Lift and Installation 5 6 7 8 4 0 9 0 4 5 4 6 7 4 5 8 9 0 5 4 5 6 7 8 9 0 0 0 0 4 5 6 5 4 7 6 7 7 7 8 9 6-5_090
Deck Lift and Installation INDEX NO. PART NO. QTY. DESCRIPTION 797 GRIP 0570 DECK LIFT HANDLE 7685 4 FW.4X.687X.05/.080H 4 066 CS.-8X.000 HX G5 5 047 NT.-8 HX G5 ZNYC 6 7659 BUSHING 7 4884 STOP, HEIGHT ADJ 8 059 DECK INDICATOR 9 086660 NT.75-6 HXZY NL 0 767954 4 FW.406X.8 X.060 SAE 05450 NT.75-6 HX GRD 5 ZNY 76796 FW.5X.06X.090 SAE 0089 NT.500- HX G5 ZNYC 4 00847 NT.750-0 HX G5 ZNYC 5 7890 BLOCK, DECK LIFT MT /4" 6 050 LOWER HANDLE 7 55007 DECK LIFT COVER 8 0644 CS.75-6X.000 HX G5 9 705954 CS.500-X.5 HX G5 Z 0 657 BEARING DISC 78550 SB.50X.75SH.75-6TD 6095 WASHER, WAVY 6094 DECK LIFT ROD 4 7894 5 CLIP E,.00 X.65X.05 5 6068 5 FW.78X.50X.0 ZNYC 6 05495 4 GREASE FITTING STRAIGHT 7 70464 6 NT.47-4 HX FLG ZN 8 60 4 DECK LIFT CHAIN 9 055749 7 CS.47-4X.750 HX G5 0 48458 YOKE, DECK LEVELER 75670 CS.-8X.50 FLTHR G 788 CS.47-4X.750 FULTH NOTES: 5_090 -
Deck Lift and Installation 9 9 7 4 7-4 5_090
Deck Lift and Installation INDEX NO. SERVICE PART NO. QTY. DESCRIPTION 078949 CS.500-X.00 GR ZN 4 78567 NT.50- HX LK NY NOTES: 5_090-5
Cover Install -6 5_090
Cover Install INDEX NO. PART NO. QTY. DESCRIPTION 7900 4 KNOB,5/6-8 X /4"MALE 0608 DECK COVER 48/54 TS 6006 DECAL, DECK HEIGHT INDICATOR NOTES: 5_090-7
-8 5_090
Section 4 Engine 7HP, 9HP Kaw.................................. 4- Engine Install, HP KAW ES.............................. 4-4 Fuel System Install...................................... 4-8 Instrument Panel....................................... 4-0 Instrument Panel....................................... 4- Instrument Panel....................................... 4-6 Throttle............................................... 4-8 54" ES Console Assembly................................ 4-0 Electrical Schematic 6097............................. 4-6 5_090 4-
Engine 7HP, 9HP Kaw BLK RED BLK 7 5 8 Toward Engine 6 5 6 7 8 4 9 0 4 4 4-5_090
Engine 7HP, 9HP Kaw INDEX NO. PART NO. QTY. DESCRIPTION 7950 ENGINE, KAWASAKI 7HP 60757 ENGINE, KAWASAKI 9HP 047 5 NT.-8 HX G5 ZNYC 7685 5 FW.4X.687X.05/.080H 4 795 HARNESS, CLUTCH PIGTAIL 5 79654 VALVE,OIL DRAIN M0X.5 6 79949 PULLEY, A SEC, 4.5 OD 7 77 KEY /4 SQ X 0.66 LG(FS) 8 60784 CLUTCH, WARNER TG000 9 7647 FW.454X.50X.50 0 6084 CS.47-0 X.5 HX G5 0480 5 CS.-8X.750 HX G5 0759 PULLEY COVER, 48/54 0587 CS.-8X.500 HX G5 4 78498 BUMPER, RUBBER 5 000 WIRE TIE, SMALL 6 557 CLUTCH ANCHOR PLATE 7 7877 HOSE, 0.50" LOW PRESSURE " 8 06445 CS.-8X.000 HX G5 NOTES:. Used on 9940.. Used on 9965.. Items supplied with engine. 4. Torque to 45-48 ft-lbs. Replace (do not reuse) capscrew if removed or loosened. Use only hand tools to install this fastener. 5. Engine oil capacity:see engine owner s manual. 6. Engine speed: 600±50 RPM. 5_090 4-
Engine Install, HP KAW ES BRN TO SOL 7 4 ORG YEL BLK TO BATT 8 8 6 5 6 4 PUR 5 0 9 5 6 5 7 6 Toward Engine 7 4 8 9 0 5 4 4-4 5_090
Engine Install, HP KAW ES INDEX NO. PART NO. QTY. DESCRIPTION 6077 ENG, KAW HP W/ HD AIR 047 6 NT.-8 HX G5 ZNYC 7685 FW.4X.687X.05/.080H 4 0480 5 CS.-8X.750 HX G5 5 5509 ENGINE PLATE COVER 6 6085 DECAL, BATTERY 7 06445 CS.-8X.000 HX G5 8 7077 CS M 8-.5X0 0.9HXFLZ 9 7874 MUFFLER, HP KAW 0 787 MANIFOLD, HP KAW 78649 KAW () CLAMP, EXHAUST 6069 HEAT SHIELD 0497 9 NT.50-0 HX GR.5 ZNYC 4 76855 9 FW.8X.65X.05/.080H 5 79654 VALVE,OIL DRAIN M0X.5 6 7877 HOSE, 0.50" LOW PRESSURE, " LONG 7 000 WIRE TIE, SMALL/SHORT 8 77 KEY /4 SQ X 0.66 LG(FS) 9 7876 PULLEY 0 60785 CLUTCH, WARNER CMS00 7647 FW.454X.50X.50 557 CLUTCH ANCHOR PLATE 78498 BUMPER, RUBBER 4 795 HARNESS, CLUTCH PIGTAIL 5 785048 CS.47-0X.00 HX G5 Z 6 0587 CS.-8X.500 HX G5 7 7976 BATTERY CABLE, POS RED 8 78005 BATTERY CABLE, NEG BLK NOTES:. Part of wiring harness.. Torque to 45-48 ft-lbs. Replace (do not reuse) capscrew if removed or loosened. Use only hand tools to install this fastener.. Engine oil capacity: See engine owner s manual. 4. Engine speed : 600±50 RPM. 5. Items supplied with engine. 6. Item 5 includes item 6. 5_090 4-5
Engine Install, HP KAW ES 9 4 TO ENGINE 8 7 0 0 40 TO ENGINE 7 4 PUR ORG RED/ BLK 4 BLK 4 6 4 5 7 5 8 9 4-6 5_090
Engine Install, HP KAW ES INDEX NO. PART NO. QTY. DESCRIPTION 9 74566 BATTERY HOLD DOWN COVER 0 05599 CS.50-0X.750 HX G5 09868 4 LW.50 INT-EXT TOOTH Z 740696 BATTERY VULH-8 04455 NT #0- HX ZN 4 0087 STARTER SOLENOID HW KIT 5 066 CS.-8X.000 HX G5 6 0649 CS.50-0X.65 HX G5 7 0865 BATTERY BOX 8 79489 BATTERY CLAMP ROD 9 60069 CN.-8X.00 MAX THK 40 7748 BATTERY CBL BOOT-RED (FS) NOTES: 5_090 4-7
Fuel System Install 4 5 8 9 6 7 4-8 5_090
Fuel System Install INDEX NO. PART NO. QTY. DESCRIPTION 77906 FUEL CAP,.5" 79044 FUEL TANK 000 CLIP 4 0588 FUEL LINE 7" 5 060 CONSOLE SUPPORT 6 7685 4 FW.4X.687X.05/.080H 7 0480 4 CS.-8X.750 HX G5 8 05450 4 NT.75-6 HX GRD 5 ZNY 9 767954 4 FW.406X.8 X.060 SAE NOTES:. Valve and grommet included with new fuel tank.. Service parts available for the fuel tank: PART NUMBER DESCRIPTION PART NUMBER DESCRIPTION 78595 FLANGE GROMMET 78944 FUEL SHUT-OFF VALVE 5_090 4-9
Instrument Panel 5 9 6 7 4 8 0 9 9 9 4 5 7 8 6 9 0 9 5 Console 0 4-0 5_090
Instrument Panel INDEX NO. PART NO. QTY. DESCRIPTION 779 GRIP,.875 X 4.56 BLK 77556 BEARING, STEERING 0766 STEERING BAR 4 785766 STEERING ROD, ADJUSTER 5 045 4 NT.-4 HX ZNYC 6 6089 PIVOT SPACER BUSHING 7 76999 6 SC #0 X.750 PHILLIPS T 8 77957 CB.-8X.750 SHTNK 9 7685 8 FW.4X.687X.05/.080H 0 058776 5 NT.-8 HXZY NL 07784 4 MS # 6- X.000 RD SL 486 ARM 0499 KNOB,.RD.75-6X50 4 0645 NEUTRAL LOCK HANDLE ROD 5 478 SPACER, SWITCH WB 6 047456 GM.750X.88X.00X. 7 0969 WN #6- X.00 TP 6 8 77965 4 RP.078X.50 LONG ZN 9 045765 FW.00X.500X.4 ZN 0 784 BEARING NOTES: 5_090 4-
Instrument Panel Console 44 4 9 44 6 4 0 9 9 9 4 9 4 0 40 5 6 7 9 45 46 9 6 5 6 4 8 7 9 6 8 0 4-5_090
Instrument Panel INDEX NO. SERVICE PART NO. QTY. DESCRIPTION 45 ARM W/AM WB DAMPNER 047 NT.-8 HX G5 ZNYC 789 BALL STUD, DAMPER 4 78849 DAMPER, CENTERING 5 05086 PIVOT PIN 6 76859 6 BUSHING,IGUS#080 7 09 NEUTRAL LOCK YOKE 8 0465 SPRING.5 9 0764 FW.406X.000X.06 ZNYC 0 086660 NT.75-6 HXZY NL 60798 BRAKE ROD ASSY 788554 LOCK COLLAR,.500X.000 0647 NEUTRAL LOCK SPACER 4 785 CS.-8X4.50 HX G5 5 0646 NEUTRAL SWITCH BRKT 6 7049 FW.9X.500X.048 ZNYC 7 0598 NT #0-4 HX NL ZN 8 6095 PUMP ADJUSTMENT ROD 9 069 BELLCRANK 40 60098 CB 0-4 X.500 ZYNC 4 05450 6 NT.75-6 HX GRD 5 ZNY 4 7974 SWITCH,PLUNGER SNAP MOUNT 4 6095 WAVY WASHER 44 76796 FW.5X.06X.090 SAE 45 075 CP.56DX.000 LG HML Z 46 078 CE.500X4.50.56X4.4 NOTES: 5_090 4-
STEERING CONTROL ADJUSTMENT. DISENGAGE PARK BRAKE LEVER ENGAGE LOCKING HARDWARE STEERING ROD ASSEMBLY FIG. NEUTRAL ADJUSTMENT. Remove brake link from lower brake bell crank.. With the mower on the assembly stand, place the H-bar lock in the run position with the engine running.. If rear wheels rotate forward or rearward, loosen the locking hardware on the turnbuckle assembly 4. Tighten or loosen the turnbuckle until rear wheel comes to a stop. Retighten locking hardware. 5. Neutral should now be set. 6. Release park brake. 7. With engine running, rotate H-Bar forward, and then into reverse. 8. Wheels should both return to neutral when H-Bar is pulled forward out of reverse. If not, repeat step -4 until they do. Return brake lever to park position and check to make sure wheels are not rotating. 9. If wheels rotate, repeat steps - 8. DRIVE STRAIGHT LINKAGE ADJUSTMENT. With mower on assembly stand (wheels off the ground), and engine running, move park brake lever into drive position.. Check drive wheel rotation speed using contact tachometer.. Loosen the locking hardware on the top steering rod assembly on the side that is rotating slower. 4. Lengthen the steering rod assembly by rotating the center adjustment rod until both wheels are rotating at the same speed. 5. Tighten the locking hardware on the steering rod assembly and verify all locking hardware is tight. 6. Recheck wheel speed and repeat steps through 5 as necessary. 4-4 5_090
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Instrument Panel 5 6 5 5 6 50 54 6 47 48 49 5 6 6 54 56 55 4 56 58 59 57 60 4-6 5_090
Instrument Panel INDEX NO. PART NO. QTY. DESCRIPTION 4 47 55007 CONSOLE TS SERV ASSY 48 6094 DECAL, TS INST PNL NO-ES 49 78888 DECAL, TRIMSTAR ID 50 76966 HOUR METER 5 776476 SWITCH, PTO 5 77658 IGN SWITCH 5 785808 KEY ASSEMBLY 54 60097 CABLE, CHOKE 55 0558 4 CS.75-6X.750 HX G5 56 767954 8 FW.406X.8 X.060 SAE 57 60967 DECAL, ENGINE COMPART 58 777 DECAL 'MADE IN U.S.A.' 59 55007 H-BAR TS SERV ASSY 60 7700 DECAL, H-BAR STEERING 6 60970 WIRE HARNESS 6 6097 WIRE HARNESS OPC NOTES:. Part of 60970 (Wire Harness).. Part of 6097 (Wire Harness Operator Presence Control).. Item 47 includes (items 48, 49, 57 and 58). 4. Item 59 includes (item 60). 5_090 4-7
Throttle 4 4-8 5_090
Throttle INDEX NO. PART NO. QTY. DESCRIPTION 60098 CB 0-4 X.500 ZYNC 77865 CABLE, THROTTLE 7049 FW.9X.500X.048 ZNYC 4 0598 NT #0-4 HX NL ZN NOTES: 5_090 4-9
54" ES Console Assembly 5 9 4 6 7 8 0 9 9 Steering Cover 9 4 7 5 8 6 9 0 Console 9 5 0 4-0 5_090
54" ES Console Assembly INDEX NO. PART NO. QTY. DESCRIPTION 779 GRIP,.875 X 4.56 BLK 77556 BEARING, STEERING 0766 STEERING BAR 4 785766 STEERING ROD, ADJUSTER 5 045 4 NT.-4 HX ZNYC 6 6089 PIVOT SPACER BUSHING 7 76999 6 SC #0 X.750 PHILLIPS T 8 77957 CB.-8X.750 SHTNK 9 7685 8 FW.4X.687X.05/.080H 0 058776 5 NT.-8 HXZY NL 07784 6 MS # 6- X.000 RD SL 486 ARM 0499 KNOB,.RD.75-6X50 4 0645 NEUTRAL LOCK HANDLE ROD 5 478 SPACER, SWITCH WB 6 047456 GM.750X.88X.00X. 7 0969 WN #6- X.00 TP 6 8 77965 4 RP.078X.50 LONG ZN 9 045765 FW.00X.500X.4 ZN 0 784 BEARING NOTES: 5_090 4-
54" ES Console Assembly Console 46 9 4 46 45 4 47 7 4 0 5 44 4 8 9 5 7 7 4 7 4 9 9 0 9 9 7 5 6 7 9 4 8 7 6 40 5 9 0 4-5_090
54" ES Console Assembly INDEX NO. SERVICE PART NO. QTY. DESCRIPTION 60098 6 CB 0-4 X.500 ZYNC 45 ARM W/AM WB DAMPNER 047 NT.-8 HX G5 ZNYC 4 789 BALL STUD, DAMPER 5 78849 DAMPER, CENTERING 6 05086 PIVOT PIN 7 76859 6 BUSHING,IGUS#080 8 09 NEUTRAL LOCK YOKE 9 0465 SPRING.5 0 0764 FW.406X.000X.06 ZNYC 086660 NT.75-6 HXZY NL 60798 BRAKE ROD ASSY 788554 LOCK COLLAR,.500X.000 4 6095 WASHER, WAVY.558 X.005 5 0647 NEUTRAL LOCK SPACER 6 785 CS.-8X4.50 HX G5 7 0646 NEUTRAL SWITCH BRKT 8 7049 4 FW.9X.500X.048 ZNYC 9 0598 4 NT #0-4 HX NL ZN 40 6095 PUMP ADJUSTMENT ROD 4 069 BELLCRANK 4 05450 6 NT.75-6 HX GRD 5 ZNY 4 000 DOUBLE POLE SWITCH 44 05586 NT # 6- HX NL ZN 45 078 CE.500X 4.50.56 X 4.4 46 76796 FW.5 X.06 X.090 SAE 47 075 CP.56DX.000 LG HML Z NOTES: 5_090 4-
54" ES Console Assembly 48 5 55 5 5 5 56 RED/BLK 54 65 TAN/RED BLK 50 ORG 6 ORG YEL/BLK RED/BLK ORG/GRN 54 5 49 59 58 57 8 60 4 9 9 58 6 6 6 64 NEUTRAL SWITCH CONNECTION 4-4 5_090
54" ES Console Assembly INDEX NO. PART NO. QTY. DESCRIPTION 7 8 48 5509 CONSOLE TS SERV ASSY 49 6095 DECAL, TS INST PANEL 50 78888 DECAL, TRIMSTAR ID 5 76966 HOUR METER 5 776476 SWITCH, PTO 5 757 INDICATOR LIGHT, RED(FS) 54 045898 IGN SWITCH 55 785808 KEY ASSEMBLY 56 786657 CABLE, CHOKE 57 0558 4 CS.75-6X.750 HX G5 58 767954 8 FW.406X.8 X.060 SAE 59 60094 CABLE, THROTTLE 60 60967 DECAL, ENGINE COMPART 6 777 DECAL 'MADE IN U.S.A.' 6 55007 H-BAR TS SERV ASSY 6 7700 DECAL, H-BAR STEERING 64 6097 WIRE HARNESS 65 6097 WIRE HARNESS OPC NOTES: 5. Part of 6097 (Wire Harness). 6. Part of 6097 (Wire Harness Operator Presence Control). 7. Item 48 includes (items 49, 50, 60, and 6). 8. Item 6 includes (item 6). 5_090 4-5
Electrical Schematic 6097 4-6 5_090
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Brake Install 4 5 6 7 8 9 0 7 5 4 4-8 5_090
Brake Install INDEX NO. PART NO. QTY. DESCRIPTION 086660 4 NT.75-6 HXZY NL 767954 9 FW.406X.8 X.060 SAE 059 LOWER BRAKE BELLCRANK 4 7659 BUSHING,IGUS#0608 (FS) 5 080655 CS.75-6X.500 HX G5 6 6070 LOWER BRAKE ROD ASSY 7 05450 NT.75-6 HX GRD 5 ZNY 8 064006 CS.-8X.65 HX G5 9 7685 FW.4X.687X.05/.080H 0 060 BRAKE PULL BRKT 48/54 TS 047 NT.-8 HX G5 ZNYC 7844 SPRING, BRAKE 05599 CS.50-0X.750 HX G5 4 76855 FW.8X.65X.05/.080H 5 090 BRAKE SPRING LINK, LH 6 090 BRAKE SPRING LINK, RH (NOT SHOWN) 7 0497 NT.50-0 HX GR.5 ZNYC NOTES::. Items supplied with ZT800 transmission. PARK BRAKE ADJUSTMENT 5 6.00" 7 8 0 FIG.. Item 8 (064006) and (05599), and associated hardware, should be loose. After final adjustments are made, tighten all the associated hardware.. Assemble item 7 (05450) nuts onto item 6 (6070) to the end of the threads on the brake link assembly. Leave these nuts loose at this time.. Place washer onto brake link, and slide through hole in item 0 (060) Brake pull 5_090 4-9
bracket. Assemble item 6 (6070) brake link assembly onto brake item (059) bell crank. 4. Assemble remaining hardware and item (7844) spring onto brake link. Install item (086660) onto end of brake link (6070). 5. Place the H-bar handle in the neutral position and the park brake lever in the engaged position. 6. Tighten item (086660) to the.00" dimension shown. 7. Check engagement of internal park brake pawl by manually rotating transmission axle in both directions. If pawl is engaged, the axle should not rotate. 8. Tighten item 8 (064006) on both sides of item 0 (060) Brake pull bracket. 9. Tighten item (05599) on both sides. 0. Adjust item 7 (05450) so that there is.0 between the washer and the FIRST nut. With two wrenches, tighten the second nut down to the first, maintaining the.0 dimension.. Brakes are now set.. Place the H-bar handle in the run position and the park brake lever in the disengaged position.. The washer under the double jam nuts (item 7, 05450) should still be free to rotate, and have approximately.06 clearance. If not, readjust jam nuts to this dimension. 4. With brakes still in the disengage/run position, verify that wheels rotate freely without brakes grabbing. If brakes are grabbing, adjust item 7 (05450) locking nuts closer to end of brake rod assembly until wheels rotate freely. Re-engage brake lever to ensure that brakes are set. 5. Repeat engagement and disengagement as required to ensure that brakes are set in the engaged position, and are off in the run position. NOTES: 4-0 5_090
Section 5 Tire Installation......................................... 5- Tire Assembly.......................................... 5-4 Caster Wheel Assembly.................................. 5-5 5_090 5-
Tire Installation 4 5 6 7 6 8 9 0 9 5-5_090
Tire Installation INDEX NO. PART NO. QTY. DESCRIPTION 600668 TIRE/WHEEL ASSY 06077 8 WHEEL NUT 705954 CS.500-X.5 HX G5 Z 4 4467 FW.50X.5X.87 SPL 5 7976 FW.5X.75X.5 ZNY 6 784 4 BEARING 7 78460 SPACER 8 78567 NT.50- HXZY NL 9 76796 4 FW.5X.06X.090 SAE 0 9689 CASTER FORK 0460 CS.500-X6.50 HX G5 Z 788604 TIRE/WHEEL ASSY X4-5 06969 GAGE WHEEL SPACER NOTES:. Apply grease to zerks (see owners manual).. Torque to 65-75 ft. lbs.. Inflate tires to 8- psi. 5_090 5-
Tire Assembly INDEX NO. PART NO. QTY. DESCRIPTION 600684 TIRE 0X0-0 600700 WHEEL 0X7 RIM, 4-4BC 095 TIRE VALVE TR-4 5-4 5_090
Caster Wheel Assembly INDEX NO. PART NO. QTY. DESCRIPTION 788604 TIRE/WHEEL ASSY X4-5 77806 BEARING CAP 7784 /4" ROLLER BEARING NOTES: 5_090 5-5
5-6 5_090
Section 6 Deck, Decal Assembly 48"................................ 6-48" Deck Pulley Assembly................................. 6-4 48" Deck Belt & Blade Assembly............................ 6-6 48" Deck Belt Routing and Tensioning....................... 6-9 Deck Decals, 54"....................................... 6-0 54" Deck Pulley Assembly................................ 6-54" Deck Belt & Blade Assembly........................... 6-4 54" Deck Belt Routing and Tensioning...................... 6-7 5_090 6-
Deck, Decal Assembly 48" 4 5 6 7 8 INDEX NO. PART NO. QTY. DESCRIPTION 5500 48" DECK 60069 4 CN.-8X.00 MAX THK 60787 DECK WARNINGS DECAL 4 60796 DISCHARGE CHUTE DECAL 5 7849CE DECK BELT ROUTING DECAL 6 79976 48" DECK ID DECAL 7 797845 FUSION DECAL 8 609 THROWN OBJECTS DECAL NOTES:. Item (5500) includes items through 8. 6-5_090
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48" Deck Pulley Assembly 6 7 8 4 5 9 4 0 4 5 5 6 7 8 7 9 0 9 0 9 8 7 7 4 6 5 6-4 5_090
48" Deck Pulley Assembly INDEX NO. SERVICE PART NO. QTY. DESCRIPTION 05007 CS.65-X.750 HX G5 0468 FW.656X.00X.078 ZNYC 797449 FW.650X.5X.8 ZNYCG5 4 78856 PULLEY, IDLER NHI 5.00" 5 60096 SPACER, DECK IDLER 6 598 CHAIN DECK LIFT SPRING 7 0684 SPRING 8 050 IDLER, DECK 9 79790 6 CS.-8X.50FLT SH ZY 0 6044 IDLER SLIDE, UHMW 7887 CS.65-X.5 HX G5 Z 78474 5 CW.6.50X.87 PNT 79689 PULLEY 5.00"OD 4 0697 NT.65- HX G5 ZNYC 5 05 PULLBAR 6 047 NT.-8 HX G5 ZNYC 7 7685 0 FW.4X.687X.05/.080H 8 974 PULLBAR PIN 9 0480 CS.-8X.750 HX G5 0 05450 NT.75-6 HX GRD 5 ZNY 767954 4 FW.406X.8 X.060 SAE 78506 BLADE SPINDLE ASSEMBLY 0056 CS.75-6X.75 HX G5 4 058776 6 NT.-8 HXZY NL 5 7878 CS.65-X.00 FULL HX 6 794875 CS.65- X.500 FLTHD 7 78567 4 NT.500- HX G8 ZY NL 8 0599 4 NT.500- HX JAM ZNYC 9 76796 8 FW.5X.06X.090 SAE 0 0997 4 ANTI-SCALP WHEEL 78708 4 CS.500-X4.50 HX G5 78866 4 WHEEL ASSY, ANTI SCALP. Includes items 8 through.. Torque to 0 ft.- lbs.. Torque to 8ft.-lbs. NOTES: 5_090 6-5
48" Deck Belt & Blade Assembly 6 8 4 5 7 8 9 0 5 9 7 0 8 7 6 4 6-6 5_090
48" Deck Belt & Blade Assembly INDEX NO. PART NO. QTY. DESCRIPTION 4 60969 BELT, B.00 EL 0849 PULLEY COVER RS 48" 0848 PULLEY COVER LS 48" 4 60806 DISCHARGE CHUTE 5 6084 TORSION SPRING 6 6084 CHUTE PIN 7 448 CHUTE BRACKET 8 086660 NT.75-6 HXZY NL 9 767954 FW.406X.8 X.060 SAE 0 7900 4 KNOB,5/6-8 X /4"MALE 0595 CB.75-6X.00 STD CD 795757 BLADE, F6.50"-H-F-CW 78474 CW.6.50X.87 PNT 4 7887 CS.65-X.5 HX G5 Z 5 78866 ANTI SCALP WHEEL ASSY 6 0599 NT.500- HX JAM ZNYC 7 76796 FW.5X.8.06 X.090 SAE HD ZN 8 0997 ANTI SCALP WHEEL 9 78708 CS.500- X 4.5 HX G5 ZNYC 0 056077 CS.50-0X.000 HX G5 609 SPACER, CHUTE STOP 76855 FW.8X.65X.05/.080H 06855 NT.50-0 HXZY NL 4 086660 NT.75-6 HXZY NL 5 767954 FW.406X.8X.060 SAE 6 075 CHUTE MOUNT 7 058776 NT.-8 HXZY NL 8 79898 CHUTE, RUBBER DISCHARGE 9 0697 SB.75X.500 SH.- NOTES:. Torque to 8 ft. lbs.. Do not torque, Item 4 (Discharge Chute) must pivot freely.. Includes items 6 through 9. 5_090 6-7
4. Items 0-9 used on mowers with serial numbers prior to 0070596. 0 8 9 5 7 4 5 6 FIG. 6-8 5_090
48" Deck Belt Routing and Tensioning 5.50" 6.00" NOTES:. Spring length after tensioning new belt. Measured from outside of hook to outside of hook. 5_090 6-9
Deck Decals, 54" 4 5 6 7 8 INDEX NO. PART NO. QTY. DESCRIPTION 550 54" DECK 60069 4 CN.-8X.00 MAX THK 60787 DECK WARNINGS DECAL 4 60796 DISCHARGE CHUTE DECAL 5 7849CE DECK BELT ROUTING DECAL 6 7997 54" DECK ID DECAL 7 797845 FUSION DECAL 8 609 THROWN OBJECTS DECAL NOTES:. Item (550) Includes items through 8. 6-0 5_090
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54" Deck Pulley Assembly 6 7 4 8 5 9 0 4 4 5 5 6 7 8 7 9 0 9 0 9 8 7 7 6 5 4 6-5_090
54" Deck Pulley Assembly INDEX NO. PART NO. QTY. DESCRIPTION 05007 CS.65-X.750 HX G5 0468 FW.656X.00X.078 ZNYC 797449 FW.650X.5X.8 ZNYCG5 4 78856 PULLEY, IDLER NHI 5.00" 5 60096 SPACER, DECK IDLER 6 598 CHAIN, LINKS 7 0684 SPRING 8 050 IDLER, DECK 9 79790 6 CS.-8X.50FLT SH ZY 0 6044 IDLER SLIDE, UHMW 7887 CS.65-X.5 HX G5 Z 78474 5 CW.6.50X.87 PNT 786889 PULLEY, DECK DRIVE 5.5 4 0697 NT.65- HX G5 ZNYC 5 05 PULLBAR 6 047 NT.-8 HX G5 ZNYC 7 7685 0 FW.4X.687X.05/.080H 8 974 PULLBAR PIN 9 0480 CS.-8X.750 HX G5 0 05450 NT.75-6 HX GRD 5 ZNY 767954 4 FW.406X.8 X.060 SAE 058776 6 NT.-8 HXZY NL 78506 BLADE SPINDLE ASSEMBLY 4 0056 CS.75-6X.75 HX G5 5 7878 CS.65-X.00 FULL HX 6 794875 CS.65- X.500 FLTHD 7 78567 4 NT.500- HX G8 ZY NL 8 0599 4 NT.500- HX JAM ZNYC 9 76796 8 FW.5X.06X.090 SAE 0 0997 4 ANTI-SCALP WHEEL 78708 4 CS.500-X4.50 HX G5 78866 4 WHEEL ASSY, ANTI SCALP NOTES:. Includes items 8 through.. Torque to 0 ft.-lbs.. Torque to 8 ft.-lbs. 5_090 6-
54" Deck Belt & Blade Assembly 4 8 9 5 6 7 8 0 5 4 6-4 5_090
54" Deck Belt & Blade Assembly INDEX NO. PART NO. QTY. DESCRIPTION 4 60788 BELT, B.0 EL 084 PULLEY COVER RS 54" 08 PULLEY COVER LS 54" 4 60806 DISCHARGE CHUTE 5 6084 TORSION SPRING 6 448 CHUTE MOUNT 7 6084 CHUTE PIN 8 086660 NT.75-6 HXZY NL 9 767954 FW.406X.8 X.060 SAE 0 0595 CB.75-6X.00 STD CD 7900 4 KNOB,5/6-8 X /4"MALE 797696 BLADE, F8.50"-H-F-CW 78474 CW.6.50X.87 PNT 4 7887 CS.65-X.5 HX G5 Z 5 78866 ANTI SCALP WHEEL ASSY 6 0599 NT.500- HX JAM ZNYC 7 76796 FW.5X.8.06 X.090 SAE HD ZN 8 0997 ANTI SCALP WHEEL 9 78708 CS.500- X 4.5 HX G5 ZNYC 0 056077 CS.50-0X.000 HX G5 609 SPACER, CHUTE STOP 76855 FW.8X.65X.05/.080H 06855 NT.50-0 HXZY NL 4 086660 NT.75-6 HXZY NL 5 767954 FW.406X.8X.060 SAE 6 075 CHUTE MOUNT 7 058776 NT.-8 HXZY NL 8 79898 CHUTE, RUBBER DISCHARGE 9 0697 SB.75X.500 SH.- NOTES:. Torque to 8 ft. lbs.. Do not torque, Item 4 (Discharge Chute) must pivot freely.. Includes items 6 through 9. 5_090 6-5
4. Items 0-9 used on mowers with serial numbers prior to 0080989. 0 8 9 5 7 4 5 6 FIG. 6-6 5_090
54" Deck Belt Routing and Tensioning NOTES:. Spring length after tensioning new belt. Measured from outside of hook to outside of hook. 5_090 6-7
6-8 5_090
Numerical Index Part No. Page No. Index Part Numbers 000 4-9 000-9, 4-, 4-5 0056 6-5, 6-0089 - 00847-05495 - 0588 -, 4-9 0640-9 0697 6-5, 6-075 4-, 4-095 5-4 000 4-0497 4-5, 4-9 05007 6-5, 6-0596 -7 0595 6-7, 6-5 088-7 09868 4-7 0087 4-7 0997 6-5, 6-000 -, - 047-7, -, 4-, 4-5, 4-, 4-, 4-9, 6-5, 6-0480 -7, 4-, 4-5, 4-9, 6-5, 6-0465 4-, 4-066 -, 4-7 0644-0684 -7, 6-5, 6-0969 4-, 4-045 4-, 4-04988 -9 0460 5-0499 4-, 4-04455 4-7 045765 4-, 4-045898 4-5 0468 6-5, 6-047456 4-, 4-0587 4-, 4-5 0599 6-5, 6-05450 -, 4-9, 4-, 4-, 4-9, 6-5, 6-055749 - 0558 4-7, 4-5 05586 4-05599 4-7, 4-9 058776 4-, 4-, 6-5, 6-0598 4-, 4-9, 4-06077 5- Part No. Page No. 064006 4-9 0649 4-7 06445 4-, 4-5 068478-06855 -9 078 4-, 4-0764 4-, 4-07784 4-, 4-078949 -5 080655 4-9 0879-0879CA -4 086660 -, 4-, 4-, 4-9, 6-7, 6-5 05-050 6-5, 6-08 6-5 084 6-5 0848 6-7 0849 6-7 0897-08 - 090 4-9 090 4-9 059-050 - 059 4-9 0570-060 4-9 060 4-9 0608-7 069 4-, 4-0645 4-, 4-0646 4-, 4-0647 4-, 4-070 -9 07-9 079-7 0759 4-076 -7 0766 4-, 4-0865 4-7 09 4-, 4-57 -9 5-479 - 557 4-, 4-5 66-9 67-9 448 6-7, 6-5 598-7, 6-5, 6-657 - Part No. Page No. 05086 4-, 4-06969 5-45 4-, 4-974 6-5, 6-05 6-5, 6-9689 5-486 4-, 4-478 4-, 4-4467 5-4884 - 48458-60 - 6069 4-5 55007 4-7, 4-5 55007 4-7 55007-5509 4-5 5509 4-5 5507-5508 - 5500 6-550 6-0 60096 6-5, 6-600668 5-600684 5-4 600700 5-4 600767-9 60097-9 600974-9 600975-9 600976-9 600987-9 6000-7 60069 -, 4-7, 6-, 6-0 6008-7 60094 4-5 60097 4-7 60098 4-, 4-9, 4-609 -9 60-9 6077 4-5 604-9 6044 6-5, 6-6050 -9 6068-6070 4-9 6079-9 6070-9 60757 4-60784 4-60785 4-5 60787 6-, 6-0 5 09/0 i-
Part No. Page No. Part No. Page No. Part No. Page No. 60788 -, 6-5 60796 6-, 6-0 60798 4-, 4-6085 4-5 6084 6-7 6084 4-6089 4-, 4-60908 -4 609 6-, 6-0 6094 4-7 6095 4-5 6094-6095 4-, 4-6095 -, 4-, 4-60967 4-7, 4-5 60969 -, 6-7 60970 4-7 6097 4-5 6097 4-7, 4-5 60996-7 6006-7 60094-9 6008-9 608-9 70464-7049 4-, 4-9, 4-705954 -, 5-70087 -9 757 4-5 77 4-, 4-5 7976 5-7077 4-5 777 4-7, 4-5 78550-740696 4-7 74566 4-7 75670-7647 7659 4-, 4-5 -, 4-9 767954-9, -, 4-9, 4-7, 4-5, 4-9, 6-5, 6-7, 6-, 6-5 76796 -, 4-, 4-, 5-, 6-5, 6-76859 4-, 4-76855 -9, 4-5, 4-9 7685-7, -, 4-, 4-5, 4-9, 4-, 4-, 4-9, 6-5, 6-76966 76999 4-7, 4-5 4-, 4-7700 4-7, 4-5 779 4-, 4-7748 4-7 77079-77806 5-5 7784 5-5 77556 4-, 4-776476 4-7, 4-5 77658 4-7 77865 4-9 778746-7 77957 4-, 4-77965 4-, 4-77980CE - 77906 4-9 78005 4-5 785-7 7894-7849CE 6-, 6-0 78567-5, 5-, 6-5, 6-78708 6-5, 6-7874 4-5 787 4-5 788-78856 6-5, 6-7887 -7, 6-5, 6-7, 6-, 6-5 789-9, 4-, 4-7890 - 78474 6-5, 6-7, 6-, 6-5 78649 4-5 78506 7878 6-5, 6-6-5, 6-7876 4-5 78944 4-9 784 4-, 4-, 5-7844 4-9 78460 5-78498 4-, 4-5 785048 4-5 785 4-, 4-78595 4-9 785766 4-, 4-785808 4-7, 4-5 786657 4-5 786848-7 786889 6-7877 -, -7, 4-, 4-5 78866 6-5, 6-78849 4-, 4-788554 4-, 4-788604 5-, 5-5 78888 4-7, 4-5 795 4-, 4-5 7950 4-7900 -7, 6-7, 6-5 79044 4-9 797-7974 4-79689 6-5 7976 4-5 79489 4-7 7986 -, -7 79976 6-794875 6-5, 6-795757 -, 6-7 79654 4-, 4-5 797449 6-5, 6-797647 - 797696 -, 6-5 797795-797845 6-, 6-0 79785-797860 - 79790 6-5, 6-7997 6-0 79949 4-808485 - 9940-9965 - 997-9999 - i- 5 09/0