Hustler 103234 User Manual

Hustler TrimStar

Hydro Walkbehind

Parts Manual

103234 Rev. 8/06

•••••

P.O. Box 7000

•••

Hesston, Kansas

•

67062-2097

Chapter 1

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Chapter 2 Contents

36" Deck Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

36" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

36" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

48" Deck Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

48" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

48" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Caster Wheel Assembly–788064 . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Spindle Assembly–350595K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Chapter 3 Contents

Tractor Frame Rivet Nut Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Hydro Transmission Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Steering Lower Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

H-Bar Steering Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Table of Contents

Chapter 4 Contents

Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Electrical Schematic—792838 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Chapter 5 Contents

Drive Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

36" Belt Routing and Tensioning. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

48" Deck Belt Routing and Tensioning . . . . . . . . . . . . . . . . . . . . . . 5-4

Tractor Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

36" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

48" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1

103234 8/06 c-1

c-2 103234 8/06

Chapter 1

General Information

This Manual covers TrimStar (15/36) model 927400 & TrimStar (17/48) model 927426.

Frequently Ordered Parts

PART NO. DESCRIPTION

788711 Pump Drive Belt
788729 TS 48" Deck Drive Belt, B-Section (65.29 EL)
788745 TS 48" Deck Belt, B-Section (86.0 EL)
797514 TS 36" Deck Drive Belt, A-Section (66.0 EL)
788737 TS 36" Deck Belt, A-Section (49.8 EL)
068478 Fuel Filter
797852 Kawasaki KAI Air Filter Precleaner
797860 Kawasaki KAI Air Filter Cartridge
772079 Engine Oil Filter

Service Literature

PART NO. DESCRIPTION

104893 TrimStar Owner’s Manual
797787 Kawasaki KAI 15HP Engine Manual
797795 Kawasaki KAI 17/19HP 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.

103234 8/06 1-1

Hardware Description Codes & Abbreviations

The following codes are used throughout this parts manual. Refer to this list when ordering parts.

ABBREVIATION DESCRIPTION

CB Carriage Bolt
CE Clevis Pin
CP Cotter Pin
CS Cap Screw

CW Cup Washer

FDRW Fender Washer

FW Flat Washer

HX Hex Head
LW Lock Washer
MB Machine Bushing
MS Machine Screw
NT Nut
SC Self Tapping Cap Screw
SH Socket Head
SB Shoulder Bolt
SS Set Screw
OD Outside Diameter

ID Inside Diameter

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 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 320 435

1.00 625 850 M24 555 750

NOTE:

Loctite® 592 to be used on all pipe threads.
Lubricate all grease zerks.

1-2 103234 8/06

Chapter 2 Contents

36" Deck Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

36" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

36" Deck Pulley Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

48" Deck Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

48" Deck Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

48" Deck Pulley Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Caster Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Spindle Assembly–350595K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

103234 8/06 2-1

36" Deck Carrier Assembly

12

2

3

4

3

4

6
7
8

1

9

7

8

10

1

9

13

11

13

1

9

14

6

5

4

10

1

9

11

1

3

4

3

15

36" DECK

16

18

24

25

14

17

15

13

23

19

20

21

23

22

16

18

13

24

12

17

23

19
20

21

23

22

25

2-2 103234 8/06

36" Deck Carrier Assembly

INDEX NO.

1 547596 381137 1 TRIMSTAR 36 FRAME

2

2 100883 100883 1 DECK MAIN COVER

3 778399 778399 8 FW .781 X 1.375 X .250 ZNY

4 778373 778373 4 .875 X 1 PLASTIC BUSHING

5 792002 792002 4 5/16-18 X 3/4" MALE KNOB

6 705954 705954 2 CS .500-13 X 1.25 HX G5 ZN

7 344267 344267 2 FW .510 X 2.15 X .187 SPL

8 712976 712976 2 FW .531 X 1.375 X .125 ZNY

9 784223 784223 4 BEARING

10 784603 784603 2 FASTRAK SPACER

11 339689 339689 2 CASTER FORK

12 042630 042630 2 CS .500-13 X 6.50 HX G5 ZNY

13 767962 767962 4 FW .531 X 1.063 X .090 SAE

14 781567 781567 2 NT .50-13 HXZY NL

15 788604 788604 2 WHEEL/TIRE ASSY 11 X 4-5

16 306969 306969 2 GAGE WHEEL SPACER

17 025593 025593 4 HP .177 X 3.25 WW# 206 ZN

18 102343 102343 2 FRONT DECK HEIGHT PIN

19 102350 102350 2 REAR DECK HEIGHT PIN

20 706176 706176 2 NT .375-24 HX JAM G5 ZN

21 778431 778431 2 .375-24 SPHERICAL ROD END

22 054502 054502 2 NT .375-16 HX GRD 5 ZNY

23 767954 767954 4 FW .406 X .812 X .060 SAE

24 005116 005116 2 CS .375-16X1.375 HX G5

25 758631 758631 2 RP .250X 1.375 HEAVY SPIRAL

SERVICE

PAR T NO.

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Assemble with extended inner race down.

2. Service part frame includes rivet nuts and decals see“Tractor Frame
Rivet Nut Assembly” on page 3-2 and “Tractor Decals” on page 5-6.

103234 8/06 2-3

36" Deck Assembly

3

1

2

3

5

3

4

6

8

5

3

10

7

10

11

3

9

2-4 103234 8/06

36" Deck Assembly

INDEX NO.

1 798918 798918 1 RUBBER DISCHARGE CHUTE

2 058776 058776 2 NT .312-18 HXZY NL

3 767954 767954 10 FW .406 X .812 X .060 SAE

4 063297 063297 2 SB .375 X .500 SH .312-18 TD ZN

5 054502 054502 4 NT .375-16 HX GRD 5 ZNY

6 102335 102335 1 DISCHARGE CHUTE MOUNT

7 011320 011320 2 CB .375-16 X .750 STD ZN

8 547612 100552 1 36" TRIMSTAR DECK

1

9 036244 036244 2 CS .375-16 X 1.00 HX G5

10 808485 808485 2 5/16-18 THREAD RIVET NUT

11 102996 102996 1 ANTI-BLOWOUT BAFFLE

SERVICE

PAR T NO.

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Service part frame includes rivet nuts and decals, see “36" Deck Decals”
on page 5-8.

103234 8/06 2-5

36" Deck Pulley Assembly

1

2

3

19

13

24

12

1

21

16

17

10

4

5

9

7

3

15

4

10

18

16

7

6

7

8

11

12

16

8

22

23

16

14

1

20

24

7

5

24

28

2

26

30

31

25

7

31

26

27

29

2

24

27

30

2-6 103234 8/06

36" Deck Pulley Assembly

INDEX NO.

1 797514 797514 1 BELT, A-SEC 66.0 EL

2 788737 788737 1 BELT, A-SECT 49.8 EL

3 781872 781872 2 CS .625-11 X 1.25 HX G5 ZN

4 028118 028118 2 FW .625 X 1.00 X .134 ZNYC

5 788364 788364 2 4.288" IDLER PULLEY

6 023317 023317 1 NT .500-13 UNT LK G5 ZN

7 767962 767962 11 FW .531 X 1.063 X .090 SAE

8 781153 781153 2 UHMW BUSHING

9 008193 008193 1 NT .500-13 HX G5 ZNYC

10 770867 770867 2 PLASTIC .75 X 1 BUSHING

11 382101 382101 1 IDLER ARM

12 036384 036384 2 SPRING 1/4 COIL PL 1.23

13 340885 059931 1 CHAIN (24 LINKS)

14 259812 059931 1 CHAIN (13 LINKS)

15 340158 340158 1 IDLER PIVOT BUSHING

16 016527 016527 9 CS .500-13 X 1.00 HX G5 Z

17 108059 108059 1 FW .515X1.500X.250 ZY

18 372730 372730 1 SLIDE IDLER

19 100875 100875 1 RIGHT PULLEY COVER

20 103002 103002 1 LEFT PULLEY COVER

21 796946 796946 1 5.75 OD JACKSHAFT PULLEY

22 078386 078386 1 FW .510 X 1.750 X .18 ZNYC

23 797043 797043 1 3.50 EOD DECK PULLEY

24 792002 792002 4 5/16-18 X 3/4" MALE KNOB

25 077859 077859 1 CS .500-13 X 3.25 HX G5

26 350595 350595 2 SPINDLE ASSEMBLY

4

27 212472 212472 2 KEY 1/4 SQ X 1.00 LONG

28 793794 793794 1 20.50"-L-F-CW BLADE

29 793802 793802 1 13.75"-L-F-CW BLADE

30 782474 782474 2 CW .631 2.250 X .187 PNT

31 029934 029934 2 CS .625-11 X 3.00 HX G5

32 705954 705954 1 CS .500-13X1.25 HX G5 Z

SERVICE

PAR T NO.

MFG. PART

NO.

QTY. DESCRIPTION

NOTES

1. Torque to 65-75 ft.-lbs.

2. Torque to 118 ft.-lbs.

3. See “36" Belt Routing and Tensioning” on page 5-3.

4. See “Spindle Assembly–350595K” on page 2-15.

103234 8/06 2-7

48" Deck Carrier Assembly

2

3

1

12

6

7

8

1

9

10

1

9

13

15

3

11

13

17

14

16

4

5

3

3

6

9

8

1

9

10

1

9

13

15

11

19

4

13

12

4

25

48" DECK

18

22

17

23

20

21

23

24

2-8 103234 8/06

18

22

23

17

19

20

21

25

23

24

48" Deck Carrier Assembly

INDEX NO.

1 547604 351353 1 TRIMSTAR 48 FRAME

2

2 381491 381491 1 DECK MAIN COVER

3 778399 778399 8 FW .781 X 1.375 X .250 ZNY

4 778373 778373 4 .875 X 1 PLASTIC BUSHING

5 792002 792002 4 5/16-18 X 3/4" MALE KNOB

6 705954 705954 2 CS .500-13 X 1.25 HX G5 ZN

7 344267 344267 2 FW .510 X 2.15 X .187 SPL

8 712976 712976 2 FW .531 X 1.375 X .125 ZNY

9 784223 784223 4 BEARING

10 784603 784603 2 FASTRAK SPACER

11 339689 339689 2 CASTER FORK

12 042630 042630 2 CS .500-13 X 6.50 HX G5 ZNY

13 767962 767962 4 FW .531 X 1.063 X .090 SAE

14 781567 781567 2 NT .50-13 HXZY NL

15 788604 788604 2 WHEEL/TIRE ASSY 11 X 4-5

16 306969 306969 2 GAGE WHEEL SPACER

17 025593 025593 4 HP .177 X 3.25 WW# 206 ZN

18 381582 381582 2 FRONT DECK HEIGHT PIN

19 381616 381616 2 REAR DECK HEIGHT PIN

20 706176 706176 2 NT .375-24 HX JAM G5 ZN

21 778431 778431 2 .375-24 SPHERICAL ROD END

22 054502 054502 2 NT .375-16 HX GRD 5 ZNY

23 767954 767954 4 FW .406 X .812 X .060 SAE

24 005116 005116 2 CS .375-16X1.375 HX G5

25 758631 758631 2 RP .250X 1.375 HEAVY SPIRAL

SERVICE

PAR T NO.

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Assemble with extended inner race down.

2. Service part frame includes rivet nuts and decals see“Tractor Frame
Rivet Nut Assembly” on page 3-2 and “Tractor Decals” on page 5-6.

103234 8/06 2-9

48" Deck Assembly

6

14

3

4

5

3

7

8

7

1

9

10

2

11

10

14

5

12

15

13

12

10

11

10

7

9

14

5

2-10 103234 8/06