HUSTLER TrimStar User manual

200 South Ridge Road
Hesston, Kansas
67062
®
Hustler®Parts Manual

Inspect spark arrester daily; replace every 500 hours or as needed.
The Engine Owner’s Manual provides information regarding the U.S. Environmental Protection Agency
(EPA) and the California Emission Control Regulation of emission systems, maintenance and warranty.
Keep Engine Owner’s Manual with your unit. Should the Engine Owner’s Manual become damaged or
illegible, replace immediately. Replacements may be ordered per the information found in the Product
Information section of the owner’s manual.
Federal law and California State law prohibit the following acts or the causing thereof:
1. The removal or rendering inoperative by any person other than for purposes of maintenance,
repair, replacement, of any device or element of design incorporated into any equipment for
the purposes of emissions control prior to or after its sales or delivery to the ultimate
purchaser or while it is in use, or
2. The use of the equipment after such device or element of design has been removed or
rendered inoperative by any person.
WARNING
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.
NOTICE OF REQUIREMENT OF SPARK ARRESTER MUFFLER
This equipment may create sparks that can start fires around dry vegetation. California Public Resources Code
Section 4442.6 provides that it is unlawful to use or operate an internal combustion engine on any forest-covered,
brush-covered, or grass-covered land unless the engine is equipped with a spark arrester maintained in effective
working order. A spark arrester is a device constructed of nonflammable materials specifically for the purpose of
removing and retaining carbon and other flammable particles over 0.0232 of an inch in size from the exhaust flow of
an internal combustion engine that uses hydrocarbon fuels or which is qualified and rated by the United States
Forest Service. Other states or federal areas may have similar laws. The Operator Should Contact Local Fire
Agencies For Laws or Regulations Relating to Fire Prevention Requirements. THIS EQUIPMENT DOES NOT HAVE
A SPARK ARRESTER AND YOU SHOULD CONTACT YOUR AUTHORIZED DEALER FOR THE PURCHASE OF
A SPARK ARRESTER.

General Information 1
Frame & Cover
Frame 3-1
Cover 3-2
Transmissions, Drive Belt, Handlebar, Instrument Panel & Brake
Transmissions, Hoses & Drive Belt (Multi-Page) 4-1
Transmission Service Parts 4-2
Instrument Panel (Multi-Page) 4-3
Handlebar - Steering Sub-Assembly 4-4
Brake 4-5
Wheels & Tires
Wheels & Tires 5-1
Front Wheel Assembly 5-2
Drive Wheel Breakdown 5-3
Engine, Muffler, Clutch & Fuel System
Engine, Muffler & Clutch (Multi-Page) 6-1
Engine Service Parts 6-2
Battery 6-3
Fuel System 6-4
Fuel Tank Service Parts 6-5
Deck, Deck Belt, Blades & Deck Lift
Service Deck 7-1
Deck Pulleys & Spindles 7-2
Spindle Service Parts - 607208 7-3
Deck, Deck Belt & Blades 7-4
Deck Lift & Mounting Hardware (Multi-Page) 7-5

General Information
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 noti-
fication. 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 oper-
ating the mower.
The component manuals are furnished by the various manufacturers to be used for the troubleshooting and servicing
of their products.
Hardware Description Codes & Abbreviations
The following codes are used throughout this parts manual. Refer to this list when ordering parts.
ABBREVIATION CARRIAGE BOLT MACHINE BUSHING
CLEVIS PIN MACHINE SCREW
CLIP NUT NUT
COTTER PIN SELF TAPPING CAP SCREW
CAP SCREW SOCKET HEAD
CUP WASHER SHOULDER BOLT
FENDER WASHER SET SCREW
FLAT WASHER OUTSIDE DIAMETER
HEX HEAD INSIDE DIAMETER
LOCK WASHER WELD NUT
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
DESCRIPTION ABBREVIATION DESCRIPTION
CB MB
CE MS
CN NT
CP SC
CS SH
CW SB
FDRW SS
FW OD
HX ID
LW WN
.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 M14 80 108.5
.875 420 565 M16 160 215
1.00 625 850 M20 320 435
M24 555 750

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Frame 48" TrimStar Parts Manual - 939504CE - HTTSRS048KAWFS600VC
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Frame & Cover
Frame 48" TrimStar Parts Manual - 939504CE - HTTSRS048KAWFS600VC
Thu May 28 06:43:18 UTC 2020 3-1

Comments for Page: Frame
1. Serial number decal. In the event the serial number decal becomes damaged or illegible, please contact your dealer to order a replacement.
2. EPA compliance decal.
3. The frame includes the decals and hardware.
Élément Numéro de pièce Qté Nom
1 555170 1 SVC FRAME, 48" CE TS
2 601069 10 CN .312-18x.200 MAX THK
3 N/A 2 SERIAL NO. / SPEC DECAL
4 776310 1 DECAL, CE MARK
5 794834CE 1 CE 100 DBA LIMIT DECAL
6 602041 1 DECAL, HOT
7 808485 8 RIVET NUT, 5/16-18 THRE
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Frame & Cover
Cover 48" TrimStar Parts Manual - 939504CE - HTTSRS048KAWFS600VC
Thu May 28 06:43:19 UTC 2020 3-2

Élément Numéro de pièce Qté Nom
1 036236 4 CS .312-18X1.000HXG5
2 712927 8 FW 0.344X1.00X.12 HD ZN
3 114003 1 DECK COVER, 48/54
4 114509 1 HEAT SHIELD, W/A
5 036244 2 CS .375-16X1.00 HX G5 ZN
6 086660 2 NT .375-16NLG8
7 602061CE 1 DECK HEIGHT DECAL
8 602562 1 DECAL, NO SERVICE
Cover 48" TrimStar Parts Manual - 939504CE - HTTSRS048KAWFS600VC
Thu May 28 06:43:19 UTC 2020 3-2

Transmissions, Drive Belt, Handlebar, Instrument Panel & Brake
Transmissions, Hoses & Drive Belt (Multi-Page) 48" TrimStar Parts Manual - 939504CE - HTTSRS048KAWFS600VC
Thu May 28 06:43:20 UTC 2020 4-1

Élément Numéro de pièce Qté Nom
1 043067 4 CS .312-18X3.000HXG5
2 768523 38 FW 0.343SAE
3 710087 4 CS .312-18X2.500HXG5
4 034280 10 CS .312-18X0.750HXG5
5 111157 2 PLATE, TS TOW VALVE
6 607498 1 TRANS - L, ZT2800
7 607499 1 TRANS - R, ZT2800
8 058776 12 NT .312-18NLG5
9 110730 1 CHARGE PUMP COVER, LH
10 110731 1 CHARGE PUMP COVER, RH
11 778746 1 RING, 2" ID SPLIT
12 259812 1 CHAIN, 13 LINK
13 036384 1 SPRING 1/4 COIL PL 1.23
14 025296 1 FW .760X1.63X0.08 ZN
15 781153 2 BUSHING, UHMW
16 110739 1 PUMP IDLER ARM W/A
17 604514 1 FW .760X1.38X.08 ZN
18 601084 1 SB .750X 2.000 SH.625-11
19 793836 1 DRIVE BELT
20 607525 1 PULLEY, IDLER
21 028118 1 FW 0.625X1.00X.13 ZN
22 781872 1 CS .625-11X1.250HXG5
23 034272 2 NT .312-18HXG5
24 781922 2 BALL STUD
25 125533-3 1 SUPPORT - BRAKE PULL
26 055939 2 CS .250-20X0.75 HX G5 ZN
27 016410 2 CS .375-16X2.000HXG5
28 109202 1 BRAKE SPRING LINK, RS
29 600987 1 ZT SPACER TUBE
30 109203 1 BRAKE SPRING LINK, LS
31 016816 2 NT .250-20FLKG5
32 602228 2 TOW LINK ROD
33 601503 2 CB .250-20 X .625 ZN
34 111616 1 TOW VALVE BRACKET, LS
35 111617 1 TOW VALVE BRACKET, RS
36 768515 6 FW 0.281SAE
Transmissions, Hoses & Drive Belt (Multi-Page) 48" TrimStar Parts Manual - 939504CE - HTTSRS048KAWFS600VC
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Transmissions, Hoses & Drive Belt (Multi-Page) 48" TrimStar Parts Manual - 939504CE - HTTSRS048KAWFS600VC
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Élément Numéro de pièce Qté Nom
37 041988 2 SPRING LC-042F-5
38 068551 4 NT .250-20 HXZY NL
39 036236 2 CS .312-18X1.000HXG5
40 601996 1 EXPANSION TANK, ZT2800
41 016253 6 CB .312-18X .750 FUL ZN
42 043570 6 CLIP - HOSE - SINGLE(FS)
43 016832 6 NT .312-18FLKG5
44 601001 4 SPRING CLAMP, .75" DIA
45 605899 1 HOSE 23" 787713
46 605900 1 HOSE 43" 787713
47 601219 2 FTG, 90 - 9/16 SAE
48 600767 1 CAP, OVERFLOW TANK
Transmissions, Hoses & Drive Belt (Multi-Page) 48" TrimStar Parts Manual - 939504CE - HTTSRS048KAWFS600VC
Thu May 28 06:43:20 UTC 2020 4-1

Transmissions, Hoses & Drive Belt (Multi-Page) 48" TrimStar Parts Manual - 939504CE - HTTSRS048KAWFS600VC
Thu May 28 06:43:20 UTC 2020 4-1

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Transmissions, Hoses & Drive Belt (Multi-Page) 48" TrimStar Parts Manual - 939504CE - HTTSRS048KAWFS600VC
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Transmissions, Hoses & Drive Belt (Multi-Page) 48" TrimStar Parts Manual - 939504CE - HTTSRS048KAWFS600VC
Thu May 28 06:43:21 UTC 2020 4-1

Comments for Page: Transmissions, Hoses & Drive Belt (Multi-Page)
1. Torque to 100 ft-lbs.
2. Torque to 30 ft-lbs.
3. Left side transmission.
4. Right side transmission
Transmissions, Hoses & Drive Belt (Multi-Page) 48" TrimStar Parts Manual - 939504CE - HTTSRS048KAWFS600VC
Thu May 28 06:43:21 UTC 2020 4-1

Transmissions, Drive Belt, Handlebar, Instrument Panel & Brake
Transmission Service Parts 48" TrimStar Parts Manual - 939504CE - HTTSRS048KAWFS600VC
Thu May 28 06:43:21 UTC 2020 4-2

Comments for Page: Transmission Service Parts
1. The 4 bolt hub kit includes the nut.
Élément Numéro de pièce Qté Nom
1 602094 1 FAN / PULLEY KIT
2 604901 1 HG RTN CW
Not Shown 604902 1 HG RTN CCW
3 602208 1 SPRING, EXT RTN 52401
4 600972 1 CLIP, RETAINING
5 604957 1 BRAKE ARM, ZT3400
6 600974 1 GUARD, TRANS FILTER
Not Shown 600975 1 GUARD, TRANS FILTER
7 600976 1 HYDRAULIC OIL FILTER
8 600970 1 KIT, HUB, 4 BOLT
Transmission Service Parts 48" TrimStar Parts Manual - 939504CE - HTTSRS048KAWFS600VC
Thu May 28 06:43:22 UTC 2020 4-2

Transmissions, Drive Belt, Handlebar, Instrument Panel & Brake
Instrument Panel (Multi-Page) 48" TrimStar Parts Manual - 939504CE - HTTSRS048KAWFS600VC
Thu May 28 06:43:22 UTC 2020 4-3