Hustler Zeon Parts Manual - · PDF file112480_1111 1-1 General Information This Manual covers the Hustler® Zeon model 929141 & 929141EX. Service Literature Options Available From

•••••••Hustler Turf Equipment

•••••P.O. Box 7000

•••Hesston, Kansas

•67062-2097

Hustler® ZeonParts Manual

t-2 112480_1111

112480_1111 c-1

Table of Contents

General InformationService Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Options Available From Your Dealer. . . . . . . . . . . . . . . . . . . . . . . . 1-1Using This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Hardware Description Codes & Abbreviations . . . . . . . . . . . . . . . . 1-1Standard Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Section 2Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Hood & Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Section 3Traction Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Steering Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Control Console—LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8Control Console—RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Section 4Wheels & Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Drive Wheel Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Front Wheel Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Section 5Battery Pack—Lead Acid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2Water Refill Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4Cable Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6Fan/Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14Cable Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16Charging Circuit, 7A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

Section 6Service Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4Deck Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Section 7Seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

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

c-2 112480_1111

112480_1111 1-1

General Information

This Manual covers the Hustler® Zeon model 929141 & 929141EX.

Service Literature

Options Available From Your Dealer

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 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.

PART NO. DESCRIPTION112479 OPERATOR’S MANUAL

PART NO. DESCRIPTION110737 LED LIGHTS KIT333724 STEER ARM EXTENSION KIT112844 42" MULCH KIT929711 ZEON CATCHER112400 ZEON RAPID CHARGE KIT

ABBREVIATION DESCRIPTION ABBREVIATION DESCRIPTIONCB CARRIAGE BOLT MB MACHINE BUSHINGCE CLEVIS PIN MS MACHINE SCREWCN CLIP NUT NT NUTCP COTTER PIN SC SELF TAPPING CAP SCREWCS CAP SCREW SH SOCKET HEADCW CUP WASHER SB SHOULDER BOLT

FDRW FENDER WASHER SS SET SCREWFW FLAT WASHER OD OUTSIDE DIAMETERHX HEX HEAD ID INSIDE DIAMETERLW LOCK WASHER

1-2 112480_1111

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.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 2151.00 625 850 M20 320 435

M24 555 750

112480_1111 2-1

Section 2

Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Hood & Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-2 112480_1111

Frame

1

2

3

4

5

610

9

8

7

12

11 11

11

1

112480_1111 2-3

Frame

NOTES:

1. In the event the serial number tag becomes damaged or illegible, please contact your dealer to order a replacement.

INDEX NO. PART NO. QTY. DESCRIPTION

1 550520 1 42" ZEON FRAME (WITH DECALS & HARDWARE)2 727172 1 MADE IN U.S.A.3 782573 1 FIRST ZERO TURN DECAL4 602406 1 ZEON FRONT LARGE DECAL5 601986 2 STEP TREAD LOWER6 601981 1 SMALL FRAME SAFE DECAL7 601987 1 STEP TREAD FOOT LIFT8 110063 2 STEP TREAD UPPER9 N/A 1 TURF PRODUCTS SERIAL NO.

10 601813 1 HUSTER ID DECAL11 600928 13 GM, 2.5 ID X 3.13ODX2.75G12 794644 1 GROMMET

2-4 112480_1111

Frame

14

14

13

13

13

112480_1111 2-5

Frame

NOTES:


13 601069 8 CN .312-18X.200 MAX THK14 601982 2 CN .250-20X .150 MAX THK

2-6 112480_1111

Hood & Cover

1

3

5

6

8

9

4

7

7

10

2

3

3

4

48

11

11

112480_1111 2-7

Hood & Cover

NOTES:

INDEX NO. PART NO. QTY DESCRIPTION

1 550523 1 REAR CONTROLLER COVER (WITH DECALS)2 602406 1 ZEON DECAL3 768523 8 FW .343 X .687 X .051/.080 HD ZN/YL

4 034280 8 CS .312-18 X .750 HX G5 ZN 5 111570 1 AIR FLOW COVER6 601982 2 CN .250-20 X .150 MAX THK7 768515 4 FW .281 X .625 X .051/.080 HD ZN/YL8 055939 4 CS .250-20X.750 HX G5 ZN9 550539 1 STEERING CONTROL COVER (WITH DECAL)

10 112377 1 LEFT TRACTION DRIVE COVER11 602562 3 NO SERVICE DECAL

2-8 112480_1111

112480_1111 3-1

Section 3

Traction Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Steering Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Control Console—LS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Control Console—RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3-2 112480_1111

Traction Drive1

3

2

2

2

87

6

8

2

5

6

74

4

9

10

11

POWER SUPPLY

2

CABLE

1

1

3

3

112480_1111 3-3

Traction Drive

NOTES:

1. Torque to 17 ft-lbs. 2. Torque to 45 in-lbs.3. Torque to 30 ft-lbs.


1 710087 4 CS .312-18 X 2.500 HX G5 ZN2 768523 16 FW .343 X .687 X .051/.080 HD3 043067 4 CS .312-18 X 3.000 HX G5 ZN4 603084 2 TRANSAXLE, ELECTRIC ZT5 602164 1 SPACER TUBE6 704718 2 FW .406 X .688 X .06 ZN7 080655 2 CS .375-16 X 1.500 HX G5 ZN8 034272 8 NT .312-18 HX G5 ZN9 044131 6 NT M 6 X 1.0-10-ZN

10 017038 6 LW .250 MED SPRING ZNYC11 017079 6 FW .250 X .560 X .04 SAE Z

3-4 112480_1111

Steering

1

5

6

3

16

1

4

89

10

11

7

2

1314

13

15

17 18 1920

22

19

2219

STEERINGSUB-ASSEMBLY

6 7

12

1921

SEE COVERDETAIL

COVER DETAIL

SENSOR DETAIL

24

23

17

112480_1111 3-5

Steering

NOTES:

1. Index sensors with slot oriented horizontally, as shown. 602124 (right side) is identified with a green sticker on the face of the accelerator; 602126 (left side) is identified with a blue sticker.


1 111613 1 LEFT SIDE STEERING T-SLOT (SHOWN)2 111600 1 RIGHT SIDE STEERING T-SLOT (NOT SHOWN)

3 601087 2 PLUNGER SWITCH4 791434 4 CS #10-24 X 2.000 HX G5 ZN5 602266 2 SENSOR ADAPTER RING6 602124 1 ACCELERATOR SENSOR,GREEN (NOT SHOWN)7 602126 1 ACCELERATOR SENSOR,BLUE (SHOWN)8 007567 4 FW .208 X .59 X .051 ZN .9 035626 4 NT #10-24 HX ZN10 111632 2 SPEED SENSOR COVER11 016774 4 NT #10-24 HX FL LK12 016253 8 CB .312-18 X 0.750 FULL ZN13 704791 4 FW .781 X 1.250 X .024 ZN

14 602027 2 WAVE WASHER .838 X 1.44215 025296 2 FW .760 X 1.625 X .08 ZN16 770867 2 PLASTIC BUSHING17 600221 2 STEERING DAMPER18 781922 2 DAMPER BALL STUD19 768523 12 FW .343 X .687 X .051/.080 HD ZN/YL20 029876 2 LW .312 INT-EXT TOOTH ZN21 034272 4 NT .312-18 HX G5 ZN22 058776 6 NT .312-18 HX ZY NL23 601425 1 CONNECTOR BODY24 601426 1 CAP LOCK

3-6 112480_1111

Steering Sub-Assembly

1

2

3

4

4

5

67

9

8

10

6

4

11

12

12

4

13

14

15

16

112480_1111 3-7

Steering Sub-Assembly

NOTES:


1 111437 2 CONTROL ARM2 111431 2 STEERING PIVOT3 705178 2 CS .375-16 X 1.75 HX G5 ZN4 767954 8 FW .406 X .812 X .060 SAE HRD ZN5 056036 2 CS .375-16 X 2.250 HX G5 ZN6 765339 4 BUSHING7 058776 2 NT .312-18 HX NL ZN8 602140 2 CAM FOLLOWER9 111443 2 OVER CENTER BRACKET

10 073858 2 FW .406 X .750 X .250 ZN11 601379 2 SB .375 X .375SH .312-1812 086660 4 NT .375-16 HX G5 ZN NY13 781922 2 BALL STUD14 768523 2 FW .343 X .687 X .051/.080 HD ZN/YL15 601051 2 OVERTRAVEL SPRING .718 OD X 1.63 LONG16 017129 4 FW .440 X 1.000 X .083 ZN

3-8 112480_1111

Control Console—LS

1

3

5

6

89

4

7

810

1211

13

14

2

15

112480_1111 3-9

Control Console—LS

NOTES:


1 602174 4 CS .250-20X1.5 BH EC2 602678 4 FW .281X .500X .0933 550521 1 LS FENDER SHELL ZEON (WITH DECALS)4 602407 1 HUSTLER ID DECAL5 601982 4 CN .250-20 X .150 MAX THK6 550525 1 LEFT CONTROL PANEL ZEON (WITH DECAL & HARDWARE)7 602177 1 INSTRUMENT PANEL DECAL8 768523 8 FW .343 X .687 X .051/.080 HD ZN/YL9 034280 4 CS .312-18 X .750 HX G5 ZN

10 034272 4 NT .312-18 HX G5 ZN11 036244 2 CS .375-16 X 1.00 HX G5 ZN12 767954 2 FW .406 X .812 X .060 SAE HRD ZN13 111440 1 STEERING HANDLE ZEON14 781260 1 STEERING BAR GRIP15 603415 1 ALL ELECTRIC DECAL

3-10 112480_1111

Control Console—RS

3

4

5

5

6

78

8

9

10

1112 12

13

14

1516

17

18

1

2

1

2

1

2

19

112480_1111 3-11

Control Console—RS

NOTES:


1 602174 4 CS .250-20X1.5 BH ZNYC2 602678 4 FW .281 X .500 X .0933 550522 1 RS FENDER SHELL (WITH DECALS)4 785808 1 KEY ASSEMBLY5 045898 1 IGN SWITCH6 776476 1 PTO SWITCH7 602136 1 DIGITAL DISPLAY8 601982 4 CN .250-20 X .150 MAX THK9 602170 1 INSTRUMENT PANEL DECAL

10 550526 1 CONTROL PANEL (WITH DECAL)11 034280 4 CS .312-18 X.750 HX G5 ZN12 768523 8 FW .343 X .687 X .051/.080 HD ZN/YL13 781260 1 STEERING BAR GRIP14 111440 1 STEERING HANDLE15 767954 2 FW .406 X .812 X .060 SAE HRD ZN16 036244 2 CS .375-16 X 1.00 HX G5 ZN17 034272 4 NT .312-18 HX G5 ZN18 602407 1 ZEON DECAL19 603415 1 ALL ELECTRIC DECAL

3-12 112480_1111

112480_1111 4-1

Section 4

Wheels & Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Drive Wheel Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Front Wheel Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4-2 112480_1111

Wheels & Tires

1

23

4

4

5

6

798

109

11

12 13

82

14

12

15

17

9

9 17

14

112480_1111 4-3

Wheels & Tires

NOTES:

1. Torque to 65–75 ft-lbs.


1 705954 2 CS .500-13 X 1.250 HX G5 ZN2 344267 6 FW .510 X 2.15 X .187 SPL ZN3 712976 2 FW .531 X 1.375 X .125 ZN4 784223 4 BEARING5 784603 2 SPACER6 339689 2 CASTER FORK 7 768044 2 TIRE/WHEEL ASSY 11 X 4-5 RIBBED8 781567 4 NT .500-13 HX G8 ZY NL9 767962 8 FW .531 X 1.063 X .09 SAE HRD ZN

10 306969 2 GAGE WHEEL SPACER11 042630 2 CS .500-13 X 6.50 HX GR5 ZN12 601810 2 TIRE/WHEEL ASSY 18 X 8.5 - 813 061077 8 WHEEL NUT14 788166 2 ANTI-SCALP WHEEL ASSEMBLY15 781708 2 CS .500-13 X 4.250 HX G516 031997 2 ANTI-SCALP WHEEL17 053199 2 NT .500-13 HX JAM ZNYC

4-4 112480_1111

Drive Wheel Breakdown

NOTES:


1 601821 1 TIRE 18 X 8.5 2 601820 1 WHEEL 8 X 6.933 019521 1 TIRE VALVE

1

3

2

112480_1111 4-5

Front Wheel Breakdown

NOTES:


1 772806 2 BEARING CAP2 772814 1 3/4" ROLLER BEARING

2

1

1

4-6 112480_1111

112480_1111 5-1

Section 5

Battery Pack—Lead Acid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Water Refill Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Cable Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Fan/Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Cable Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Charging Circuit, 7A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

5-2 112480_1111

Battery Pack—Lead Acid1

2

34

6

78

10

1

5

9

BATTERIES2

112480_1111 5-3

Battery Pack—Lead Acid

NOTES:

1. Torque to 120 in-lbs.2. Replace all batteries at the same time.


1 086660 1 NT .375-16 HXZY NL2 767954 1 FW .406 X .812 X .060 SAE3 112478 1 HOLD DOWN BAR4 602560 1 SPLASH COVER5 602115 1 NEGATIVE BATTERY HARNESS6 602155 8 NT .375-16 HX LK NY 18-87 602127 8 FW .406X .812 X.060 18-88 602116 3 BATTERY CABLE9 602114 1 POSITIVE BATTERY HARNESS

10 602081 1 BATTERY TRAY

5-4 112480_1111

Water Refill Container

NOTES:


1 602133 1 WATER REFILL CONTAINER

1

112480_1111 5-5

This page intentionally left blank.

5-6 112480_1111

Cable Power

9

32

84

7

13

14

64

5

84

7

6

45

32 10

1112

1

1

1

POSITIVECABLE

112480_1111 5-7

Cable Power

NOTES:

1. Torque to 33 in-lbs.


1 602145 1 SUPPLY BUSS2 017038 4 LW .250 MED SPRING ZN3 044131 4 NT M6-1.00-10-HX ZNYC4 767954 6 FW .406 X .812 X .060 SAE HRD ZN5 005132 2 CS .375-16 X 1.125 HX G5 ZN6 602160 2 CABLE, POWER, DRIVE7 793885 3 LW .375 INT-EXT TOOTH ZN8 054502 3 NT .375-16 HX G5 ZN9 601098 2 CB 10-24 X .500 ZYNC

10 602123 1 CONTACTOR, MAIN ELECT11 035691 2 FW .210 X .500 X .046 ZN12 059832 4 NT #10-24 HX NL ZN13 602161 1 CABLE, POWER, RIGHT TRACTION DRIVE14 602149 1 BUSS, CONTROLLER

5-8 112480_1111

Cable Power

7

8

4

17

15

16

18

17

4

CONTROLLER

TO JUNCTIONBLOCK

TO JUNCTIONBLOCK

TO CONTROLLER

DECK MOTORCONTROLLER

DECK MOTORCONTROLLER

TO

TO BATTERY

12

18

112480_1111 5-9

Cable Power

NOTES:


15 016063 2 MS #10-24 X .750 TH SL ZN16 602154 1 JUNCTION BLOCK17 602153 1 CABLE, GROUND18 602151 2 CABLE, GROUND

5-10 112480_1111

Cable Power

19

20

TRANSAXLE

CONTROLLER

CONTROLLER

112480_1111 5-11

Cable Power

NOTES:


19 602134 1 CABLE, POWER RS DRIVE20 602119 1 CABLE, POWER LS DRIVE

5-12 112480_1111

Fan/Converter

1

4

2

35

7

6

6

112480_1111 5-13

Fan/Converter

NOTES:


1 602163 1 FAN 4IN 12VDC 2 602144 1 DC CONVERTER3 055863 4 NT # 6-32 HX NL ZN4 017954 4 FW .156 X .375 X.049 ZN5 000331 1 WIRE TIE SMALL/SHORT6 000430 2 WIRE TIE SMALL/LONG7 077842 4 MS # 6-32 X1.000 RD SL

5-14 112480_1111

Controller

1

2

1011

5

8

12

4

13

2

3

56

7

9

8 9

15

14

616

131415

POWERCABLE

1

1

POWERCABLE

112480_1111 5-15

Controller

NOTES:



1 112164 1 REAR WELDMENT ZEON CONTROLLER2 602121 2 TRACTION DRIVE CONTROLLER3 602148 1 DECK MOTOR CONTROLLER4 601982 2 CN .250-20 X .150 MAX THK5 063198 8 CS 10-24 X .750 HXFLK ZN6 768515 6 FW .281 X .625 X .051/.080 HD ZN/YL7 056077 4 CS .250-20 X 1.000 HX G5 ZN8 035691 8 FW .210 X .500 X .046 ZN9 059832 8 NT #10-24 HX NL ZN

10 034272 2 NT .312-18 HX G5 ZN11 768523 2 FW .343 X .687 X .051/.080 HD ZN/YL12 016253 2 CB .312-18 X 0.750 FULL ZN13 017079 18 FW .250 X .560 X .04 SAE ZN14 017038 18 LW .250 MED SPRING ZN15 044131 18 NT M6-1.00-10-HX ZNYC16 064329 2 CS .250-20X .625 HX G5 ZN

5-16 112480_1111

Cable Control

1

1

1

1

2

2

2

SeatRight Console

Left Console

2

TRACTION DRIVECONTROLLER


112480_1111 5-17

Cable Control

NOTES:


1 602561 1 MAIN WIRE HARNESS2 000331 8 WIRE TIE, SMALL/SHORT

5-18 112480_1111

Cable Control

1

1

1 1

3

3

4ExistingHardware

GROUND WIREBLACK

SHIELD WIREBLACK/ YELLOW STRIPE

112480_1111 5-19

Cable Control

NOTES:


3 767954 2 FW .406 X .812 X .060 SAE4 054502 1 NT .375-16 HX GR 5 ZNY

5-20 112480_1111

Cable Control

56

7

76

5

8

1

1

8

10

11

12

9

1

LEFT SIDE

RIGHT SIDE

INTERIOR WALL

INTERIOR WALL

RED/

WHITE/RED STRIPE

WHITE/BLACK STRIPE

POSITIVE LEADNEGATIVE LEAD

WHITE

STRIPE

1

11

1415 14

15

13

AIRFLOWCOVER



112480_1111 5-21

Cable Control

NOTES:


5 017921 2 NT .312-18 HX ZNYC6 768523 4 FW .343 X .687 X .051/.080 H7 043646 2 CUSHIONED DOUBLE CLAMP8 034280 2 CS .312-18 X .750 HX G 59 056325 1 CB .250-20 X 1.000 FUL Z

10 042960 1 CLIP CFV-060911 768515 1 FW .281 X .625 X .051/.080 H12 024927 1 NT .250-20 HX GR 5 ZNYC13 601098 2 CB 10-24 X .500 ZYNC14 035691 2 FW .210X .500X.046 ZNYC15 059832 2 NT #10-24 HX NL ZN

5-22 112480_1111

Charging Circuit, 7A

BATTERIESAND CABLES

1

2

EXISTINGHARDWARE

EXISTINGHARDWARE

112480_1111 5-23


NOTES:

1. See the Battery Storage section of your operator’s manual.2. Parts on this page are not available for 929141EX models.


1 602681 1 CHARGE ADAPTER, ZEON2 602557 1 WIRE HARNESS ZEON 7A CHARGING

5-24 112480_1111


2 3

76

4

1

98

5

112480_1111 5-25


NOTES:

3. Parts on this page are not available for 929141EX models.


3 602434 4 CS # 4-40 X .500 FHCS ZN4 112030 1 PLATE, ADAPTER ZEON CHARGING PLUG 7A5 601098 4 CB 10-24 X .500 ZYNC6 602217 4 FW #4 FLAT ZN7 602222 4 NT #4-40 HX ZN8 035691 4 FW .210 X .500 X .046 ZN9 059832 4 NT #10-24 HX NL ZN10 602137 1 CHARGER, 48 VOLT 7 AMP (NOT SHOWN)

5-26 112480_1111

112480_1111 6-1

Section 6

Service Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Deck Lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-2 112480_1111

Service Deck

1

2 34

2 5

112480_1111 6-3

Service Deck

NOTES:


1 550042 1 ZEON 42" DECK (WITH DECALS)2 602578 2 DECK DANGERS DECAL3 601892 1 THROWN OBJECTS LARGE DECAL4 794503 1 STEP TREAD5 601624 1 DISCHARGE CHUTE DECAL

6-4 112480_1111

Deck

1

2

3

7

5

6

6

5

4

8

9

10

1112

13

14

15

16

17 2

118

21

19

19 20

11

112480_1111 6-5

Deck

NOTES:

1. Torque to 17 ft-lbs.2. Torque to 50 ft-lbs.


1 601157 2 MOTOR, DECK 48VDC2 601843 1 PIN, CHUTE SPORT DISCHARGE3 601806 1 DISCHARGE CHUTE4 601824 1 TORSION SPRING5 086660 5 NT .375-16 HX G5 ZN NY6 767954 4 FW .406 X .812 X .060 SAE HRD ZN7 111067 1 CHUTE DECK BRACKET8 112429 1 PLATE, DISCHARGE CHUTE9 025395 4 CB .375-16 X 1.000 STD ZN

10 781567 1 NT .500-13 HX G5 ZN NY11 788166 1 ANTI-SCALP WHEEL ASSEMBLY12 768523 8 FW .343 X .687 X .051/.080 HD ZN/YL13 602629 8 CS .312-24 X 1.25 HX G5 Z14 602462 2 BLADE ADAPTER15 602284 2 BLADE, 20.5"-L-F-CW16 798603 2 FW .530 X 1.65 X .125 HD ZN17 077859 2 CS .500-13X 3.250 HX G5 ZN18 781708 1 CS .500-13 X 4.250 HX G519 767962 2 FW .531 X 1.063 X .090 SAE20 031997 1 ANTI-SCALP WHEEL21 053199 1 NT .500-13 HX JAM ZNYC

6-6 112480_1111

Deck

1

3

22

24 2526

23

112480_1111 6-7

Deck

NOTES:



22 602128 2 POWER DECK CABLE23 602142 1 WIRING HARNESS24 768515 6 FW .281 X .625 X .051/.080 HD ZN/YL25 017038 6 LW .250 MED SPRING ZN26 044131 6 NT M6 X 1.00-10-ZN

6-8 112480_1111

Deck Lift

1

3

23

45

64

7

8 63

2

109

14

108

1513

32

12

12

11

13

89

10

13

88

2

3

18

17

13

37

16

122

11

3

11

12

3

88

10

15

112480_1111 6-9

Deck Lift

NOTES:


1 601963 1 PIN, DECK HEIGHT STOP2 054502 8 NT .375-16 HX G5 ZN3 767954 16 FW .406 X .812 X .060 SAE4 769257 2 FW .656 X 1.125 X .250 ZN5 111492 1 TRANSPORT LOCK HANDLE6 348862 2 STEER LEVER BUSHING7 080655 2 CS .375-16 X 1.500 HX G5 ZN8 704643 12 NT .437-14 HX FL ZN9 111458 2 DECK LIFT LINK, REAR

10 055749 6 CS .437-14 X 1.750 HX G5 ZN11 036244 6 CS .375-16 X 1.00 HX G5 ZN12 601839 6 PIVOT SPACER BUSHING13 015495 4 GREASE FITTING STRAIGHT14 111468 1 LIFT PEDAL LINK15 110880 1 DECK LIFT LINK16 110879 2 PULLER STRAP17 602147 1 ZEON HEIGHT INDICATOR DECAL18 550527 1 DECK ADJUSTMENT PLATE (WITH DECAL)

6-10 112480_1111

Deck Lift

8

8

10

10

23

311

112480_1111 6-11

DECK LEVEL ADJUSTMENTS

LEVELING THE DECK MUST BE DONE IN THE FOLLOWING MANNER AND ORDER:1. Check the tire pressures to make certain they are properly inflated before starting to

level the deck. The recommended pressures are as follows:

2. Drive mower onto a hard flat surface.3. Raise and lock the deck into the transport position.

4. Place 3.0" high deck support blocks under the deck at the four corners shown in FIG. 1 (two stacked 2"x4" blocks can be used to create a 3.0" support).

5. Remove the deck stop pin and lower the deck until it rests on the support blocks.6. Loosen the (3) bolts attaching the (3) deck links to the deck.7. Push the lift pedal forward, place the deck stop pin in the indicator hole marked 3.25",

and release the pedal.8. Use a bungee cord to pull the pedal rearward so that the crank lever is held firmly

against the stop pin and play in the pivot joint is removed (FIG. 2).

9. Tighten the (3) deck links to the deck with the flanged nuts clamping on either side of the slot with 48 ft-lbs of torque. Remove the bungee cord and ensure that the deck can be raised and locked into the transport position.

Drive Wheels 8-12 PSIFront Wheels 8-12 PSI

WARNING

Make sure deck clutch switch is in the down (OFF) position. Remove the ignition key. Place the control levers in the brake position before leaving the machine.

FIG. 1

FIG. 2

SPACER BLOCKS

BUNGEE CORD

6-12 112480_1111

112480_1111 7-1

Section 7

Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

ROPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7-2 112480_1111

Seat

1

2

5

34

7

10

16

17

3 6

3

4

3 28

9

810

108

11

12 13

14

15

1310

17

10

1016

18

1

19

112480_1111 7-3

Seat

NOTES:

1. Do not torque, Seat Pan must pivot freely.


1 601807 1 SEAT2 797076 2 CS .437-20 X 1.000 G5 ZN3 017129 4 FW .440 X 1.000 X .083 ZN4 601444 1 SEAT BELT5 112438 1 SEAT BELT CROSS BAR6 704635 2 NT .437-20 HX GR5 ZN7 550524 1 SEAT PAN (WITH DECAL)

8 086660 5 NT .375-16 HX G5 ZN NY9 704726 2 FW .406 X 1.00 X .105 ZNYC

10 767954 13 FW .406 X .812 X .060 SAE HRD ZN11 768523 4 FW .343 X .687 X .051/.080 HD ZN/YL12 034280 4 CS .312-18 X .750 HX G5 ZN13 025395 4 CB .375-16 X 1.000 STD ZN14 601650 2 VIBRATION MOUNT15 112186 1 ZEON SEAT BRACE 16 036244 4 CS .375-16 X 1.00 HX G5 ZN17 054502 6 NT .375-16 HX G5 ZN18 601815 1 BATTERY WARNINGS DECAL19 793315 1 SEAT SWITCH

7-4 112480_1111

ROPS

1

1

2

5

3

4

6

6

7

7

8

89

9

4 9

10

1

112480_1111 7-5

ROPS

NOTES:

1. Torque to 85 ft-lbs.


1 603472 1 ROPS KIT (WITH SEAT BELT & HARDWARE)2 077859 1 CS .500-13X 3.250 HX G5 ZN3 602647 1 ROPS STOP4 023317 6 NT .500-13 UNT LK G8 ZN5 721910 1 CS .500-13 X 2.750 HX GR5 ZN6 601471 2 LYNCH PIN W/ LANYARD7 601470 2 KNOB, HAND FOR ROPS8 602215 4 CS .500-13 X 3.500 HX GR89 767962 8 FW .531 X 1.063 X .09 SAE HRD ZN

10 601635 2 ROPS DECAL

7-6 112480_1111

112480_1111 i-1

Numerical IndexPart PageNo. No.

Part PageNo. No.

Part PageNo. No.

Index000331 5-13, 5-17000430 5-13005132 5-7007567 3-5015495 6-9016063 5-9016253 3-5, 5-15016774 3-5017038 3-3, 5-7, 5-15, 6-7017079 3-3, 5-15017129 7-3017921 5-21017954 5-13019521 4-4023317 7-5024927 5-21025296 3-5025395 6-5, 7-3029876 3-5031997 4-3, 6-5034272 3-3, 3-5, 3-9, 3-11,

5-15034280 2-7, 3-9, 3-11, 5-21,

7-3035626 3-5035691 5-7, 5-15, 5-21, 5-25036244 3-9, 3-11, 6-9, 7-3042630 4-3042960 5-21043067 3-3043646 5-21044131 3-3, 5-7, 5-15, 6-7045898 3-11053199 4-3, 6-5054502 5-7, 5-19, 6-9, 7-3055749 6-9055863 5-13055939 2-7056077 5-15056325 5-21058776 3-5059832 5-7, 5-15, 5-21, 5-25061077 4-3063198 5-15064329 5-15077842 5-13077859 6-5, 7-5080655 3-3, 6-9086660 5-3, 6-5, 7-3110063 2-3110737 1-1110879 6-9110880 6-9111067 6-5

111440 3-9, 3-11111458 6-9111468 6-9111492 6-9111570 2-7111600 3-5111613 3-5111632 3-5112030 5-25112164 5-15112186 7-3112377 2-7112400 1-1112429 6-5112438 7-3112478 5-3112479 1-1112844 1-1306969 4-3333724 1-1339689 4-3344267 4-3348862 6-9550042 6-3550520 2-3550521 3-9550522 3-11550523 2-7550524 7-3550525 3-9550526 3-11550527 6-9550539 2-7600221 3-5600928 2-3601069 2-5601087 3-5601098 5-7, 5-21, 5-25601157 6-5601425 3-5601426 3-5601444 7-3601470 7-5601471 7-5601624 6-3601635 7-5601650 7-3601806 6-5601807 7-3601810 4-3601813 2-3601815 7-3601821 4-4601824 6-5

601839 6-9601843 6-5601892 6-3601963 6-9601981 2-3601982 2-5, 2-7, 3-9, 3-11,

5-15601986 2-3601987 2-3602027 3-5602081 5-3602114 5-3602115 5-3602116 5-3602119 5-11602121 5-15602123 5-7602124 3-5602126 3-5602127 5-3602128 6-7602133 5-4602134 5-11602136 3-11602137 5-25602142 6-7602144 5-13602145 5-7602147 6-9602148 5-15602149 5-7602151 5-9602153 5-9602154 5-9602155 5-3602160 5-7602161 5-7602163 5-13602164 3-3602170 3-11602174 3-9, 3-11602177 3-9602215 7-5602217 5-25602222 5-25602266 3-5602284 6-5602406 2-3, 2-7602407 3-9, 3-11602434 5-25602462 6-5602557 5-23602560 5-3602561 5-17

Part PageNo. No.

Part PageNo. No.

Part PageNo. No.

i-2 112480_1111

602562 2-7602578 6-3602629 6-5602647 7-5602678 3-9602681 5-23603084 3-3603415 3-9, 3-11603472 7-5704635 7-3704643 6-9704718 3-3704726 7-3704791 3-5705954 4-3710087 3-3712976 4-3721910 7-5

727172 2-3767954 3-9, 3-11, 5-3, 5-7,

5-19, 6-5, 6-9, 7-3767962 4-3, 6-5, 7-5768044 4-3768515 2-7, 5-15, 5-21, 6-7768523 2-7, 3-3, 3-5, 3-9,

3-11, 5-15, 5-21, 6-5, 7-3

769257 6-9770867 3-5772806 4-5772814 4-5776476 3-11781260 3-9, 3-11781567 4-3, 6-5781708 4-3, 6-5781922 3-5

782573 2-3784066 4-4784223 4-3784603 4-3785808 3-11788166 4-3, 6-5791434 3-5793315 7-3793885 5-7794503 6-3794644 2-3797076 7-3798603 6-5929141 1-1929141EX 1-1929711 1-1

Documents

Hustler Zeon Parts Manual - · PDF file112480_1111 1-1 General Information This Manual covers the Hustler® Zeon model 929141 & 929141EX. Service Literature Options Available From