Hustler 333559 User Manual

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Page 1

36" & 42" Deck

Parts Manual

333559 Rev. 8/06

••••

P.O. Box 7000

•••

Hesston, Kansas

•

67062-2097

Page 2

WARNING:

The engine exhaust from this product

contains chemicals known to the State

of California to cause cancer, birth

defects or other reproductive harm.

IMPORT ANT: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate this engine on any forest-covered, brush-covered, or grass-covered unimproved land. Other states or federal areas may have similar laws.

This spark ignition system complies with Canadian ICES-002.

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, replac e immediately. Replacements may be orde red per the information found in the Product Information sec tion of the

owner’s manual.

Page 3

Chapter 1

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

Chapter 2 Contents

Tractor Frame Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Engine Guard and Anti-rollover Bracket Assemblies . . . . . . . . . . . 2-3

Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Chapter 3 Contents

Battery Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Hydro Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Steering and Brake Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Chapter 4 Contents

Honda 16 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Kohler 15 & 17 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . 4-4

Fuel System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Instrument Panel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Honda 16HP Electrical Schematic (793083). . . . . . . . . . . . . . . . . . 4-10

Kohler 15 & 17 HP Electrical Schematic (793117) . . . . . . . . . . . . . 4-12

Chapter 5 Contents

Front Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Front Wheel Breakdown -768044 . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Drive Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Chapter 6 Contents

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

Deck Pulley Assembly 36" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Deck Assembly 42" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Deck Pulley Assembly 42" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Chapter 7 Contents

Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Belt Routing and Tensioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Seat Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Chapter 8 Contents

Tractor Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

42" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

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

Chapter 9 Contents

Maintenance & Adjustment Safety Precautions . . . . . . . . . . . . . . . .9-2

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

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

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c-2 333559 8/06

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Chapter 1

General Information

This Manual covers “Mini” FasTrak 15/36 model 927343, “Mini” FasTrak 17/42 model 927350, “Mini” FasTrak 16/42 model 927368, & “Mini” FasTrak 16/36 model 927376,

Frequently Ordered Parts

PART NO. DESCRIPTION

793836 Pump Drive Belt 793828 Deck Belt 36" 793893 Deck Belt 42" 068478 Fuel Filter Kohler 785626 Fuel Filter Honda 794370 Air Filter, Kohler 787226 Air Filter, Honda 747303 Engine Oil Filter, Kohler 787234 Engine Oil Filter, Honda 793794 20.50" 42D X 0.631 CW Blade 793802 13.75" 42D X 0.631 CW Blade

Service Literature

PART NO. DESCRIPTION

107612 Common Consumers Owners Manual 794313 Kohler Engine Manual 787242 Honda 16 HP Engine Manual

Options

PART NO. DESCRIPTION

793331 Armrest Kit 338442 Mulch Kit, 36/42"

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.

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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.

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Chapter 2 Contents

Tractor Frame Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Engine Guard and Anti-rollover Bracket Rivet Nuts. . . . . . . . . . . . . . 2-3

Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

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Tractor Frame Rivet Nut Installation

INDEX

NO.

SERVICE

PAR T NO .

1 546911 315440 1 FASTRAK 36 FRAME

546895 320242 1 FASTRAK 42 FRAME

2 N/A 808493 2 3/8-16 THREAD RIVET NUT

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

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Engine Guard and Anti-rollover Bracket Assemblies

INDEX

NO.

10 788166 788166 2 ANTI SCALP WHEEL ASSEMBLY

SERVICE

PAR T NO .

1 316836 316836 1 ENGINE GUARD

2 320580 320580 2 ANTI ROLLOVER BRACKET

3 808493 808493 8 3/8-16 THREAD RIVET NUT

4 781567 781567 2 NT .50-13 HX LK NY ZNYC

5 344267 344267 4 FW .510 X 2.15 X .187SPL ZNYC

6 053199 N/A 2 NT .500-13 HX JAM ZNYC

7 767962 N/A 4 FW .531 X 1.063 X .090 SAE HD ZN

8 031997 N/A 2 ANTI-SCALP WHEEL

9 781708 N/A 2 CS .500-13 X 4.25 HX G5 ZNYC

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Includes items 6 through 9.

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Footrest Assembly

INDEX

NO.

SERVICE

PAR T NO .

1 011320 011320 4 CB .375-16 X .75 STD ZN

2 785485 785485 2 UPPER STEP TREAD

3 793844 793844 2 LOWER STEP TREAD

4 320267 320267 1 FLOOR PLATE 36" MOWERS

316844 316844 1 FLOOR PLATE 42" MOWERS

5 767954 767954 2 FW .406 X .812 X .060 SAE HD ZN

6 076422 076422 2 FW.406X 1.000X.06 ZNYC

7 054502 054502 4 NT .375-16 HX GRD 5 ZNYC

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

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Chapter 3 Contents

Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Hydro Transmission Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Steering and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

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Battery Installation

PART OF WI RE

HARNESS (BLK)

INDEX

NO.

SERVICE

PAR T NO .

1 314989 314989 1 BATTERY CLAMP STRAP

2 024927 024927 3 NT .250-20 HX GR.5 ZNYC

3 055939 055939 2 CS .250-20 X .75 HX G5 ZNYC

4 029868 029868 4 LW .250 INT-EXT TOOTH ZNYC

5 740696 740696 1 BATTERY VU1LH-8

6 771428 771428 1 RED BATTERY CABLE BOOT

7 785063 785063 1 POSITIVE BATTERY CABLE (KOHLER)

786632 786632 1 POSITIVE BATTERY CABLE (HONDA)

8 786640 786640 1 NEGATIVE BATTERY CABLE

9 793489 793489 1 BATTERY CLAMP ROD

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

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Deck Lift Assembly

13 14

INDEX

NO.

10 781229 781229 1 CE .750 X 2.25 X 1.75 HEADLESS

11 015495 015495 3 STRAIGHT GREASE FITTING

12 756270 756270 1 CS .312-18 X 1.50 FLTHR GR5 ZNYC

13 034272 034272 1 NT .312-18 HX G5 ZNYC

14 348458 348458 1 DECK LEVELER YOKE

15 781831 781831 1 CS .437-14 X 1.75 FULTH G5 ZNYC

16 360131 018846 2 DECK LIFTCHAIN

17 767962 767962 2 FW .531 X 1.063 X .090 SAE HD ZN

SERVICE

PAR T NO .

1 348318 348318 1 STOP HANDLE

2 348284 348284 1 HEIGHT ADJUSTMENT STOP

3 793505 793505 1 DECK HEIGHT INDICATOR

4 782995 782995 1 DECK LIFT SPRING

5 055749 055749 2 CS .437-14 X 1.75 HX G5 ZNYC

6 334045 334045 1 DECK LIFT LINK

7 704643 704643 6 NT .437-14 HX FLG ZN

8 025296 025296 4 FW .760 X 1.625 X .08 ZNYC

9 781294 781294 5 E CLIP 1.00 X.625X .050

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Apply grease to zerks (see owners manual).

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Hydro Transmission Installation

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Hydro Transmission Installation

INDEX

NO.

10 794552 794552 1 CS .438-14 X 6.5 HX ZN G5

11 335695 335695 1 SPACER TUBE-EZT MINI FST

12 768523 768523 12 FW .343 X .687 X .051/.080 HD ZNYC

13 034272 034272 8 NT .312-18 HX G5 ZNYC

14 784827 784827 1 4.00"OD, 5/8"ID IDLER PULLEY

15 781153 781153 2 UHMW BUSHING

16 025296 025296 2 FW .760 X 1.625 X .08 ZNYC

17 324046 324046 1 PUMP BELT IDLER ARM

18 061101 061101 1 NT .750-10 HX NL ZN

19 036384 036384 1 IDLER SPRING

20 364315 059931 1 SPRING CHAIN

21 335893 335893 2 BELT DEFLECTOR

SERVICE

PAR T NO .

1 710087 710087 8 CS .312-18 X 2.50 HX G5 ZNYC

2 028118 028118 3 FW .62 X 1.00 X .134 ZNYC

3 794404 794404 1 PULLEY

4 025007 025007 2 CS .625-11 X 1.75 HX G5 ZNYC

5 793836 793836 1 A-SECTION PUMP BELT

6 792911 792911 1 EZT LEFT PUMP/MOTOR COMBO

7 792895 792895 1 EZT RIGHT PUMP/MOTOR COMBO

8 718288 718288 1 FW .516 X .875 X .09 ZNYC

9 035238 035238 1 LW .437 MED SPRING ZNYC

MFG. PART

NO.

QTY. DESCRIPTION

1. Torque to 17 ft.-lbs.

NOTES:

333559 8/06 3-5

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Steering and Brake Assembly

SEE NOTE 3

37 38

321133

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Steering and Brake Assembly

INDEX

NO.

10 797779 797779 8 IGUS® BUSHING

11 041152 041152 12 NT .312-24 HX ZNYC

12 325464 325464 2 STEERING CONTROL ARM

13 768259 768259 8 IGUS® BUSHING

14 718288 718288 2 FW .516 X .875 X .09 ZNYC

15 793059 793059 2 E CLIP .80X.396X.042

16 793646 793646 2 PUMP ROD ADJUSTER ASSEMBLY

17 794396 794396 2 STEERING LINK ROD

18 793612 793612 2 STEERING DRIVE ARM

19 797753 797753 2 STEERING ARM

20 079186 079186 2 CS .312-18 X 1.250 HX G5

21 079186 079186 2 CS .312-18 X 1.25 HX G5 ZNYC

22 768515 768515 2 FW .281 X .625 X .051/.080 HD ZNYC

23 797761 797761 2 STEERING BLOCK

24 781567 781567 2 NT .50-13 HX LK NY ZNYC

25 795625 795625 2 SNAP MOUNT PLUNGER SWITCH

26 796615 796615 2 BALL JOINT LINK

27 793174 793174 2 TOWLINK ROD

28 048553 048553 2 CP .062D X 1.00 LG HML ZN

29 068551 068551 4 NT .250-20 HX NL ZNYC

30 797050 797050 2 BRAKE ACTUATOR ROD

31 795229 795229 2 INLINE BALL JOINT

32 352112 352112 1 L. H. BRAKE PIVOT (SHOWN)

33 352054 352054 1 R. H. BRAKE PIVOT (NOT SHOWN)

34 024927 024927 2 NT .250-20 HX GR.5 ZNYC

35 781211 781211 2 PUSH BUTTON SWITCH, (DELTA)

36 060731 060731 4 CS 10-24 X .500 HXFLK ZNYC

37 315382 N/A 1 LEFT BRAKE PIVOT ARM (SHOWN)

38 315101 N/A 1 RIGHT BRAKE PIVOT ARM (NOT SHOWN)

39 794883 794883 2 COMPRESSION SPRING

40 793182 793182 2 BRAKE ACTUATOR ROD

41 089789 089789 4 FW .266 X .750 X .06 ZNYC

SERVICE

PAR T NO .

1 781260 N/A 2 STEERING BAR GRIP

2 360487 360487 2 STEERING BAR

3 600221 600221 2 CENTERING DAMPER

783696 783696 2 CENTERING DAMPER

4 767954 767954 10 FW .406 X .812 X .060 SAE HD ZN

5 086660 086660 6 NT .375-16 HX LK NY

6 705178 705178 4 CS .375-16 X 1.75 HX G5 ZNYC

7 034272 034272 4 NT .312-18 HX G5 ZNYC

8 768523 768523 20 FW .343 X .687 X .051/.080 HD ZNYC

9 781922 781922 4 DAMPER BALL STUD

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. With Steering Bars in park position, adjust items 24 (795625 Snap Mount Plunger Switch) outboard until switch is activated by items 32/33

333559 8/06 3-7

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(352112/352054 Brake Pivots).

2. Apply grease to items 12 (768259 Igus® Bushings) (see owners manual).

3. Order these parts for mowers with serial number prior to 05040000.

4. Includes Item 1 (781260 Steering Bar Grip).

5. Use on mowers with serial numbers prior to 060171975.

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Chapter 4 Contents

Honda 16 HP Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Kohler 15 & 17 HP Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . 4-4

Fuel System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Instrument Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Honda 16HP Electrical Schematic (793083) . . . . . . . . . . . . . . . . . . 4-10

Kohler 15 & 17 HP Electrical Schematic (793117) . . . . . . . . . . . . . 4-12

333559 8/06 4-1

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Honda 16 HP Engine Installation

PART OF ENGINE

NEGATIVE BATTERY CABLE

FROM RECTIFIER

RED/BLK

POSITIVE BATTERY CABLE

YEL

TO ENGINE (4 WIRES)

PART OF ENGINE

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Honda 16 HP Engine Installation

INDEX

NO.

10 787267 N/A 1 HONDA 16 AMP RECTIFIER

11 794644 794644 1 GM 1.50 X 2.12 X 1.75 X .12

12 706531 706531 1 GM 1.12 X 1.75 X 1.37 X .12

13 330274 330274 1 CLUTCH ANCHOR

14 029876 029876 4 LW .312 INT-EXT TOOTH ZNYC

15 050161 050161 4 CS .312-18 X 1.75 HX G5 ZNYC

16 784918 784918 1 RUBBER BUMPER

17 793760 793760 1 ENGINE-HYDRO DRIVE PULLEY

18 712372 712372 1 KEY 1/4 SQ. X 0.66 LONG

19 784835 784835 1 FASTRAK CLUTCH

20 791251 N/A 1 CLUTCH WIRE HARNESS PIGTAIL

21 736417 736417 1 FW .454 X 1.50 X.250

22 785048 785048 1 CS .437-20 X 3.00 HX G5 ZNYC

23 043570 043570 1 SINGLE HOSE CLIP

24 791608 791608 1 OIL DRAIN VALVE, M16 X 1.5

25 768523 768523 2 FW .343 X .687 X .051/.080 HD ZNYC

26 793125 793125 1 MUFFLER 15,17 KOHLER & 16 HONDA

27 016253 016253 2 CB .312-18 X .750 FUL ZN

28 316836 316836 1 ENGINE GUARD

29 767954 767954 6 FW .406 X .812 X .060 SAE HD ZN

30 052860 052860 6 CS .375-16 X 1.25 HX G5 ZNYC

31 794180 794180 1 1.125" EXHAUST CLAMP

32 793166 793166 1 16 HONDA MID EXHAUST PIPE

33 794172 794172 1 1.25" EXHAUST CLAMP

34 793141 793141 1 16 HONDA MANIFOLD

35 005231 005231 4 NT M6-1.0-10 HX FLG ZN

36 785543 N/A 2 HONDA MUFFLER GASKET

37 793083 793083 1 HONDA WIRE HARNESS

38 104786 104786 1 OIL DRAIN HOSE (NOT SHOWN)

SERVICE

PAR T NO .

1 785394 785394 1 HONDA 16HP ENGINE (USED ON 927368 & 927376)

2 739144 792796 3 CS M 6-1.0 X 12 10.9 HXFL ZN

3 378273 378273 1 16HP EXHAUST HEAT SHIELD

4 034272 034272 6 NT .312-18 HX G5 ZNYC

5 712927 712927 4 FW .344 X 1.00 X .12 HRD ZNYC

6 782664 782664 1 NT M8-1.25 HX STAINLESS STEEL

7 024927 024927 2 NT .250-20 HX GR.5 ZNYC

8 768515 768515 4 FW .281 X .625 X .051/.080 HD ZNYC

9 056077 056077 2 CS .250-20 X 1.00 HX G5 ZNYC

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Part of item (793083 Honda Wire Harness).

2. Torque to 48-45 ft-lb.

3. Engine oil capacity; 1.37 US qts. (with filter), 1.22 US qts. (w/o filter).

4. Engine speed; 3550±50 RPM.

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Kohler 15 & 17 HP Engine Installation

TTO

TO STARTER SELENOID

FROM NEGATIVE

BATTERY TEMINAL

RED

PUR

TO BATTERY

RED/BLK

YEL

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Kohler 15 & 17 HP Engine Installation

INDEX

NO.

10 030817 030817 1 STARTER SOLENOID

11 792762 792762 1 BATTERY CABLE

12 056077 056077 2 CS .250-20 X 1.00 HX G5 ZNYC

13 330274 330274 1 CLUTCH ANCHOR

14 793885 793885 1 LW .375 INT-EXT TOOTH

15 036244 792788 4 CS .375-16X1.000 HX G5

16 784918 784918 1 RUBBER BUMPER

17 793760 793760 1 ENGINE-HYDRO DRIVE PULLEY

18 712372 712372 1 KEY 1/4 SQ. X 0.66 LONG

19 784835 784835 1 FASTRAK CLUTCH

20 791251 N/A 1 CLUTCH WIRE HARNESS PIGTAIL

21 763417 763417 1 FW .454 X 1.50 X.250

22 785048 785048 1 CS .437-20 X 3.00 HX G5 ZNYC

23 316836 N/A 1 ENGINE GUARD

24 767954 767954 6 FW .406 X .812 X .060 SAE HD ZN

25 052860 052860 6 CS .375-16 X 1.25 HX G5 ZNYC

26 768523 768523 2 FW .343 X .687 X .051/.080 HD ZNYC

27 016253 016253 2 CB .312-18 X .750 FUL ZN

28 793125 793125 1 MUFFLER 15,17 KOHLER & 16 HONDA

29 796516 796516 1 3/8-18 OIL DRAIN VALVE

30 034272 034272 2 NT .312-18 HX G5 ZNYC

31 794180 794180 2 1.125" EXHAUST CLAMP

32 793158 793158 1 KOHLER 15 & 17 HP MID EXHAUST PIPE

33 793117 793117 KOHLER WIRE HARNESS

35 104786 104786 1 OIL DRAIN HOSE (NOT SHOWN)

SERVICE

PAR T NO .

1 792945 792945 1 KOHLER 15 HP ENGINE SV470S

792952 792952 1 KOHLER 17 HP ENGINE SV530S

2 793133 793133 1 KOHLER 15 & 17 HP EXHAUST MANIFOLD

3 739144 792796 1 CS M 6-1.0 X 12 10.9 HX

4 024927 024927 4 NT .250-20 HX GR 5 ZNYC

5 768515 768515 6 FW .281 X .625 X .051/.080 HD ZNYC

6 706531 706531 1 GM 1.12 X 1.75 X 1.37 X .12

7 794644 794644 1 GM 1.50 X 2.12 X 1.75 X .12

8 771428 771428 1 RED BATTERY CABLE BOOT

9 044255 044255 1 NT #10-32 HX ZN

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Supplied with engine.

2. Part of item 30 (793117 Kohler Wire Harness).

3. Torque to 48-45 ft.-lbs.

4. Engine oil capacity; 1.6 US qts.

5. Engine speed; 2450±50 RPM.

6. Coat ID with anti seize.

7. Torque to 33-37 ft.-lbs. Do not reuse factory installed screw when performing service to mower requiring removal of engine, replace with 3/8-16 X 1.0 long grade 5 cap screw.

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Fuel System Installation

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Fuel System Installation

INDEX

NO.

10 000331 000331 2 SMALL, SHORT WIRE TIE

11 015818 015818 1 FUEL LINE, 26.25" LONG

12 015818 015818 1 FUEL LINE, 16.25" LONG (HONDA)

13 015818 015818 1 FUEL LINE, 8.5" LONG

14 781880 781880 2 BUMPER, .500X 1.00X .312 X.188

SERVICE

PAR T NO .

1 779306 779306 2 3.5" FUEL CAP

2 792978 792978 1 36/42 LEFT SIDE FUEL TANK

3 792960 792960 1 36/42 RIGHT SIDE FUEL TANK

4 000323 000323 6 CLIP

5 745059 745059 1 3-WAY FUEL VALVE

6 767954 767954 10 FW .406 X .812 X .060 SAE HD ZN

7 055822 055822 8 CS .375-16 X .75 HX G5 ZNYC

8 054502 054502 2 NT .375-16 HX GRD 5 ZNYC

9 333526 333526 1 HEAT SHIELD

015818 015818 1 FUEL LINE, 14.00" LONG (KOHLER)

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Torque to 20 ft.-lbs.

2. Supplied with new fuel tank.

3. Service parts (not shown) for fuel system:

799221 SUCTION HOSE ASSY

794081 FUEL FILTER SCREEN

785295 FUEL GROMMET

792986 SITE-LINE TANKS FUEL FITTING

333559 8/06 4-7

Page 26

Instrument Panel Installation

10a

FUSE SIZE AND LOCATION

20a

4-8 333559 8/06

Page 27

Instrument Panel Installation

INDEX

NO.

10 026237 N/A 2 RELAY

11 793810 793810 1 THROTTLE CABLE (HONDA)

12 055947 055947 3 CS .250-20X .500 HX G5 ZNYC

13 768515 768515 3 FW .281 X .625 X .051/.080 HD ZNYC

SERVICE

PAR T NO .

1 786657 786657 1 CHOKE CABLE (KOHLER)

785030 785030 1 CHOKE CABLE (HONDA)

2 776476 776476 1 PTO SWITCH

3 712257 712257 1 RED INDICATOR LIGHT

4 083022 N/A 2 IGNITION KEY

785808 785808 1 INDAK COATED KEY

5 045898 045898 1 KEY SWITCH

6 714998 714998 2 MS #10-24 X .625 HX ZN

7 704932 704932 4 FW .219 X .500 X .048 ZNYC

8 059832 059832 4 NT #10-24 HX NL ZN

9 321059 321059 1 INSTRUMENT PANEL

778365 778365 1 THROTTLE CABLE (KOHLER)

MFG. PART

NO.

QTY. DESCRIPTION

NOTES

1. Part of 793117 or 793083 (Tractor Wire Harness).

333559 8/06 4-9

Page 28

Honda 16HP Electrical Schematic (793083)

4-10 333559 8/06

Page 29

Honda 16HP Electrical Schematic (793083)

333559 8/06 4-11

Page 30

Kohler 15 & 17 HP Electrical Schematic (793117)

4-12 333559 8/06

Page 31

Kohler 15 & 17 HP Electrical Schematic (793117)

333559 8/06 4-13

Page 32

4-14 333559 8/06

Page 33

Chapter 5 Contents

Front Wheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Front Wheel Breakdown - 768044 . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Drive Wheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

333559 8/06 5-1

Page 34

Front Wheel Assembly

INDEX

NO.

10 306969 306969 2 GAGE WHEEL SPACER

11 768044 768044 2 TIRE/WHL 11X4-5 RIBBED

SERVICE

PAR T NO .

1 705954 705954 2 CS .500-13 X 1.25 HX G5 ZNYC

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

3 712976 712976 2 FW .531 X 1.375 X .125 ZNYC

4 784223 784223 4 BEARING

5 784603 784603 2 SPACER

6 339689 339689 2 CASTER FORK

7 781567 781567 2 NT .50-13 HX LK NY ZNYC

8 767962 767962 4 FW .531 X 1.063 X .090 SAE HD ZN

9 042630 042630 2 CS .500-13 X 6.50 HX G5 ZNYC

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Apply grease to zerks, see owners manual.

2. Torque to 75 ft.-lbs.

3. Assemble with extended inner race down.

5-2 333559 8/06

Page 35

Front Wheel Breakdown -768044

768044

INDEX

NO.

1 772814 N/A 1 3/4" ROLLER BEARING

2 772806 N/A 2 BEARING CAP

SERVICE

PART NO.

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. Inflate tire to 8-10 psi.

333559 8/06 5-3

Page 36

Drive Wheel Assembly

INDEX

NO.

1 783134 783134 2 WHEEL/TIRE ASSEMBLY 18 X 8.50 (PER 36" MOWER)

2 783142 N/A 1 TIRE 18 X 8.5-8

3 783159 N/A 1 WHEEL ASSY 8.00 X 7.00

4 019521 N/A 1 TIRE VALVE

5 061077 061077 8 WHEEL NUT (PER MOWER)

6 793406 793406 8 SPACER, .375TH X .53 ID X 1.0 0D ZN (PER MOWER)

1 784264 784264 2 WHEEL/TIRE ASSY 18 X 9.50 (PER 42” MOWER)

2 784272 N/A 1 TIRE 18 X 9.5-8

3 784280 N/A 1 WHEEL ASSY 8.00 X 6.32

4 019521 N/A 1 TIRE VALVE

5 061077 061077 8 WHEEL NUT (PER MOWER)

SERVICE

PART NO.

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. Inflate tire to 8-10 psi.

2. Torque to 65 ft.-lb.

3. Used on 36" mowers only (927343 & 927376)

5-4 333559 8/06

Page 37

Chapter 6 Contents

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

Deck Pulley Assembly 36". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Deck Assembly 42" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Deck Pulley Assembly 42". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Blade Spindle Assembly Breakdown. . . . . . . . . . . . . . . . . . . . . . . . 6-14

333559 8/06 6-1

Page 38

Deck Assembly 36"

6-2 333559 8/06

Page 39

Deck Assembly 36"

INDEX

NO.

10 034280 034280 2 CS .312-18 X .75 HX G5 ZNYC 11 546937 315572 1 36" FASTRAK DECK 12 N/A 808485 3 5/16-18 THREAD RIVET NUT 13 034272 034272 2 NT .312-18 HX G5 ZNYC 14 330225 330225 2 PULLBAR 15 781567 781567 1 NT .50-13 HX LK NY 16 053199 N/A 1 NT .500-13 HX JAM ZNYC 17 767962 N/A 2 FW .531 X 1.063 X .090 SAE HD ZN 18 031997 N/A 1 ANTI-SCALP WHEEL 19 781708 N/A 1 CS .500-13 X 4.25 HX G5 ZNYC

SERVICE

PART NO.

1 330399 330399 1 DISCHARGE CHUTE 2 086660 086660 2 NT .375-16 HX LK NY 3 036244 036244 2 CS .375-16 X 1.00 HX G5 ZNYC 4 781880 781880 1 BUMPER, .500X 1.00X .312 X.188 5 054502 054502 2 NT .375-16 HX GRD 5 ZNYC 6 767954 767954 2 FW .406 X .812 X .060 SAE HD ZN 7 352500 352500 1 DISCHARGE CHUTE BASE 8 322974 322974 2 PULLBAR PIN 9 768523 768523 4 FW .343 X .687 X .051/.080 HD ZNYC

788166 788166 1 ANTI SCALP WHEEL ASSY

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Includes items 16 through 19.

2. Do not torque, Item 1 (330399 Discharge Chute) must pivot freely.

333559 8/06 6-3

Page 40

Deck Pulley Assembly 36"

15 16

24 20

6-4 333559 8/06

Page 41

Deck Pulley Assembly 36"

INDEX

NO.

10 364315 059931 1 SPRING CHAIN 11 781302 781302 1 IDLER SPRING 12 786335 786335 1 .03 THICK UHMW 13 321398 321398 1 RIGHT PULLEY COVER 14 330324 330324 1 LEFT PULLEY COVER 15 781872 781872 4 CS .625-11 X 1.25 HX G5 ZNYC 16 782474 782474 4 CW .631 2.250 X .187 PNT 17 793786 793786 1 DECK PULLEY (FASTRAK 36") 18 793778 793778 1 DECK PULLEY (FASTRAK 36"/42") 19 054502 054502 8 NT .375-16 HX GRD 5 ZNYC 20 767954 767954 16 FW .406 X .812 X .060 SAE HD ZN 21 064006 064006 4 CS .312-18 X .625 HX G5 ZNYC 22 768523 768523 10 FW .343 X .687 X .051/.080 HD ZNYC 23 058776 058776 6 NT .312-18 HX NL ZNYC 24 783506 783506 2 BLADE SPINDLE ASSEMBLY 25 005116 005116 8 CS .375-16 X 1.375 HX G5 ZNYC 26 793794 793794 1 20.50" 42D X 0.631 CW BLADE 27 793802 793802 1 13.75" 42D X 0.631 CW BLADE 28 079186 N/A 6 CS .312-18 X 1.25 HX G5

29 712927 N/A 6 FW .344 X 1.00 X .12 HRD ZN

30 785832 N/A 2 DECK IDLER UHMW CLAMP

31 787069 N/A 2 DECK IDLER UHMW RISER

32 017129 N/A 6 FW .440 X 1.000 X .083 ZNYC

SERVICE

PART NO.

1 793828 793828 1 A-SECTION BELT (FASTRAK 36") 2 025007 025007 2 CS .625-11 X 1.75 HX G5 ZNYC 3 046821 046821 2 FW .656 X 2.00 X .078 ZNYC 4 797449 797449 2 FW .650 X 1.00 X .180 ZNYC G5 5 784504 784504 2 IDLER PULLEY, 5.00"OD, 5/8"ID 6 797910 797910 6 CS .312-18 X 1.50 FLT SH ZY 7 600189 600189 1 RS UHMW IDLER SLIDE 8 600171 600171 1 LS UHMW IDLER SLIDE 9 321877 321877 1 DECK IDLER

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Torque to 118 ft. lbs.

2. See “Belt Routing and Tensioning” on page 7-3 for belt tensioning

3. Deck belt tensioning idler for mowers with serial numbers prior to 06010082 (see FIG 6-1).

333559 8/06 6-5

Page 42

FIG. 6-1

6-6 333559 8/06

Page 43

This page intentionally left blank.

333559 8/06 6-7

Page 44

Deck Assembly 42"

6-8 333559 8/06

Page 45

Deck Assembly 42"

INDEX

NO.

10 034280 034280 2 CS .312-18 X .75 HX G5 ZNYC 11 546929 316919 1 42" FASTRAK DECK 12 N/A 808485 3 5/16-18 THREAD RIVET NUT 13 034272 034272 2 NT .312-18 HX G5 ZNYC 14 330225 330225 2 PULLBAR 15 781567 781567 1 NT .50-13 HX LK NY 16 053199 N/A 1 NT .500-13 HX JAM ZNYC 17 767962 N/A 2 FW .531 X 1.063 X .090 SAE HD ZN 18 031997 N/A 1 ANTI-SCALP WHEEL 19 781708 N/A 1 CS .500-13 X 4.25 HX G5 ZNYC

SERVICE

PART NO.

788166 788166 1 ANTI SCALP WHEEL ASSY

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Includes items 16 through 19.

2. Do not torque, Item 1 (330399 Discharge Chute) must pivot freely.

333559 8/06 6-9

Page 46

Deck Pulley Assembly 42"

3 4

4 5

6-10 333559 8/06

Page 47

Deck Pulley Assembly 42"

INDEX

NO.

10 364315 364315 1 SPRING CHAIN 11 781302 059931 1 IDLER SPRING 12 786335 786335 1 .03 THICK UHMW 13 321398 321398 1 RIGHT PULLEY COVER 14 321042 321042 1 LEFT PULLEY COVER 15 781872 781872 2 CS .625-11 X 1.25 HX G5 ZNYC 16 782474 782474 4 CW .631 2.250 X .187 PNT 17 793778 793778 2 DECK PULLEY (FASTRAK 36"/42") 18 054502 054502 8 NT .375-16 HX GRD 5 ZNYC 19 767954 767954 16 FW .406 X .812 X .060 SAE HD ZN 20 064006 064006 4 CS .312-18 X .625 HX G5 ZNYC 21 768523 768523 10 FW .343 X .687 X .051/.080 HD ZNYC 22 058776 058776 6 NT .312-18 HX NL ZNYC 23 783506 783506 2 BLADE SPINDLE ASSEMBLY 24 005116 005116 8 CS .375-16 X 1.375 HX G5 ZNYC 25 793794 793794 2 20.50" 42D X 0.631 CW BLADE 26 781872 781872 2 CS .625-11 X 1.25 HX G5 ZNYC 27 079186 N/A 6 CS .312-18 X 1.25 HX G5 28 712927 N/A 6 FW .344 X 1.00 X .12 HRD ZN 29 785832 N/A 2 DECK IDLER UHMW CLAMP 30 787069 N/A 2 DECK IDLER UHMW RISER 31 017129 N/A 6 FW .440 X 1.000 X .083 ZNYC

SERVICE

PART NO.

1 793893 793893 1 A-SECTION BELT (FASTRAK 42") 2 025007 025007 2 CS .625-11 X 1.75 HX G5 ZNYC 3 046821 046821 2 FW .656 X 2.00 X .078 ZNYC 4 797449 797449 2 FW .650 X 1.00 X .180 ZNYC G5 5 784504 784504 2 IDLER PULLEY, 5.00"OD, 5/8"ID 6 797910 797910 6 CS .312-18 X 1.50 FLT SH ZY 7 600189 600189 1 RS UHMW IDLER SLIDE 8 600171 600171 1 LS UHMW IDLER SLIDE 9 321877 321877 1 DECK IDLER

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Torque to 118 ft. lbs.

2. See “Belt Routing and Tensioning” on page 7-3 for belt tensioning

3. Deck belt tensioning idler for mowers with serial numbers prior to 06010082 (see FIG 6-2).

333559 8/06 6-11

Page 48

FIG. 6-2

6-12 333559 8/06

Page 49

This page intentionally left blank.

333559 8/06 6-13

Page 50

Blade Spindle Assembly Breakdown

INDEX

NO.

SERVICE

PART NO.

1 783548 N/A 1 BLADE SPINDLE RETAINING RING 2 783555 N/A 2 BLADE SPINDLE BEARING 3 783530 N/A 1 BLADE SPINDLE SPACER 4 783514 N/A 1 BLADE SPINDLE HOUSING 5 783522 N/A 1 BLADE SPINDLE SHAFT

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

6-14 333559 8/06

Page 51

Chapter 7 Contents

Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Deck Belt Routing and Tensioning. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

333559 8/06 7-1

Page 52

Deck Installation

INDEX

NO.

SERVICE

PAR T NO .

1 781567 781567 2 NT .500-13 HX GR 8 ZY NL

2 767962 767962 4 FW .531 X 1.063 X .090 SAE HD ZN

3 017616 017616 2 CS .500-13 X 1.75 HX G5 ZNYC

4 704643 704643 5 NT .437-14 HX FLG ZN

5 055749 055749 3 CS .437-14 X 1.75 HX G5 ZNYC

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

7-2 333559 8/06

Page 53

Belt Routing and Tensioning

NOTES:

1. Spring length after tensioning belt–measured from outside of hook to outside of hook.

2. Route belt as shown.

333559 8/06 7-3

Page 54

Seat Installation

INDEX

NO.

SERVICE

PAR T NO .

1 793679 793679 1 STANDARD MICHIGAN SEAT

2 086660 086660 3 NT .375-16 HX LK NY

3 767954 767954 3 FW .406 X .812 X .060 SAE HD ZN

4 320275 320275 1 SEAT PAN

5 052860 052860 2 CS .375-16 X 1.25 HX G5 ZNYC

6 793851 793851 2 COMPRESSION SPRING, 1.25X4.00X.188

7 768523 768523 4 FW .343 X .687 X .051/.080 HD ZNYC

8 034280 034280 4 CS .312-18 X .750 HX G5 ZNYC

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

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Do not torque, Item 4 (320275 Seat Pan) must pivot on these fasteners.

2. Available service parts and options for Michigan Seat:

793331 ARMREST KIT (SQUARE STYLE)

797456 ARMREST KIT (ROUND STYLE)

793315 SEAT SWITCH KIT

7-4 333559 8/06

Page 55

Chapter 8 Contents

Tractor Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

42" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

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

333559 8/06 8-1

Page 56

Tractor Decals

8-2 333559 8/06

Page 57

Tractor Decals

INDEX

NO.

10 793703 793703 1 INSTRUMENT PANEL DECAL

11 793554 793554 1 FASTRAK 36/42 FUEL VALVE DECAL

12 771436 771436 1 STABILIZER DECAL

13 727016 727016 1 BATTERY DECAL

14 788968 788968 1 ENGINE COMPARTMENT DECAL

15 785147 785147 1 SERVICE DECAL

16 600899 600899 1 PUMP BELT WARNING DECAL

SERVICE

PAR T NO .

1 794545 794545 1 DEFLECTOR SHIELD DECAL

2 N/A 083279 1 TURF PROD SERIAL NO PLATE

3 784710 784710 1 FASTRAK DECAL

4 782573 782573 1 FIRST ZERO TURN DECAL

5 793547 793547 1 FASTRAK OPERATION DECAL

6 793588 793588 1 HUSTLER NAME PLATE

7 794305 794305 1 DECK HEIGHT DECAL

8 785139 785139 1 FASTRAK LEFT SIDE STEERING DECAL

9 785220 785220 1 FASTRAK RIGHT SIDE STEERING DECAL

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

333559 8/06 8-3

Page 58

42" Deck Decals

INDEX

NO.

SERVICE

PAR T NO .

1 793521 793521 1 42" DECK ID DECAL

2 793687 793687 1 BELT ROUTING DECAL

3 794503 794503 1 STEP TREAD

4 793570 793570 1 DECK WARNING DECAL

5 727172 727172 1 “MADE IN U.S.A.” DECAL

6 794297 794297 1 DISCHARGE CHUTE DECAL

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

8-4 333559 8/06

Page 59

36" Deck Decals

INDEX

NO.

SERVICE

PAR T NO .

1 793513 793513 1 36" DECK ID DECAL

2 793687 793687 1 BELT ROUTING DECAL

3 794503 794503 1 STEP TREAD

4 727172 727172 1 “MADE IN U.S.A.” DECAL

5 793570 793570 1 DECK WARNING DECAL

6 794297 794297 1 DISCHARGE CHUTE DECAL

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

333559 8/06 8-5

Page 60

8-6 333559 8/06

Page 61

333559_0806

Chapter 9 Contents

Maintenance & Adjustments Safety Precautions . . . . . . . . . . . . . . . .9-2

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-12

9-1

Page 62

333559_0806

This safety alert symbol is used to call attention to a message intended to

provide a reasonable degree of PERSONAL SAFETY for operators and other persons during the normal operation and servicing of this equipment.

DANGER – denotes immediate hazards which WILL result in severe personal injury or death.

WARNING - denotes a hazard or unsafe practice which COULD result in severe personal injury or death.

This manual uses two other words to highlight information.

IMPORTANT calls attention to special mechanical information and NOTE: emphasizes general information worthy of special attention.

All operators/mechanics should read this manual, or be instructed about safe operating and maintenance procedures. This is the owner’s responsibility.

Improper use or maintenance by the operator, mechanic, or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert ▲ symbol, which means DANGER or WARNING - “personal safety instructions.” Failure to comply with the instructions may result in personal injury or death.

Incorrect usage of this machine may result in severe injury. Personnel operating and maintaining it should be trained in the proper use and should read the manuals completely and thoroughly before attempting to set-up, operate, adjust, or service this machine.

The Quick Reference Decals, located in front of and to the right of the seat, are designed to give the operator/mechanic brief information needed in the daily operation and service of the machine. These decals are not intended to be used in place of this manual but instead is to be used as an extension of this manual. These decals should not be removed or obliterated. Replace these decals if they become unreadable.

It is the owner’s responsibility to make certain that the operator/mechanic reads and understands this manual and all decals before operating this machine. It is also the owner’s responsibility to make certain that the operator/mechanic is a qualified and physically able individual, properly trained in the operation of this equipment. Local regulations may restrict the age of the operator/mechanic.

The owner should also ensure that the operator/mechanic know that they are responsible for their own safety as well as the safety of other persons within the vicinity. Remember, the operator/mechanic is responsible for accidents or hazards occurring to other people or their property.

Safe Maintenance & Adjustment Practices

This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death.

▲

Unless specifically required, DO NOT have engine running when servicing or making adjustments to tractor. Place control levers in the park brake position, disengage deck clutch, remove ignition switch key and disconnect the negative battery cable. Repairs or maintenance requiring engine power should be performed by trained personnel only. To prevent carbon monoxide poisoning, be sure proper ventilation is available when engine must be operated in an enclosed area.

▲

Follow daily and weekly checklists, making sure hoses are tightly secured and bolts are tightened.

▲

Keep your machine clean and remove any deposits of trash and clippings, which can cause engine fires and hydraulic overheating as

well as excessive belt wear. Clean up oil or fuel spillage. Allow machine to cool before storing.

▲▲

Clean flammable material from machine. Prevent fires by keeping engine compartment, battery, fuel line, fuel tank and operator’s station clean of accumulated trash, grass clippings, and other debris. Always clean up spilled fuel and oil.

▲ Always wear adequate ear protection, such as earplugs, when

operating this equipment as prolonged exposure to uncomfortable or loud noises can cause impairment or loss of hearing. Do not wear radios or music headphones while operating the machinery. Safe operation requires your full attention.

▲

Never put hands or feet under any part of the machine while it is running.

▲

Except when changing or checking belt, always keep belt covers on mower for safety as well as cleanliness.

▲

Stop the engine before removing the grass catcher or unclogging the discharge chute. Never clear the discharge chute with the engine running. Turn off the engine and be sure the blades have stopped before cleaning. Use a stick to clear a plugged discharge area.

Never use your hand!

▲

Exercise caution when loading or unloading the machine onto a trailer or truck.

▲

Always wear safety goggles or safety glasses with side shields when operating the mower.

▲

Never leave machine unattended with ignition key in switch, especially with children present.

▲

Be alert and turn the machine off if children enter the area.

▲

Always wear adequate eye protection when servicing the battery, hydraulic system or when grinding mower blades and removing accumulated debris.

▲

Use extra caution when handling gasoline and other fuels. They are flammable and vapors are explosive.

▲

Never refuel tractor while engine is running; never refuel near an open flame or near devices which can create a spark. Refuel outdoors preferably, or in well ventilated areas.

▲

Never attempt to start engine when there is a strong odor of gasoline fumes present. Locate and correct cause.

▲

Never run the engine in an enclosed area unless exhaust is vented to the outside. Exhaust gases contain carbon monoxide which is odorless and deadly poison.

▲

Never attempt to make any adjustments or repairs to the tractor drive system, mower deck or any attachment while the tractor engine is running or deck clutch is engaged. Repairs or maintenance requiring engine power should be performed by trained personnel only.

▲

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.

▲

Before working on or under the deck, make certain engine cannot be accidentally started. Shut engine off and remove ignition switch key for maximum safety. Repairs or maintenance requiring engine power should be performed by trained personnel only.

▲

Use a stick or similar instrument to clean under the mower making sure that no part of the body, especially arms and hands are under mower.

▲

Exercise caution when working under the deck as the mower blades are extremely sharp. Wearing gloves or wrapping the blade(s) is advisable when working around or with the blades.

▲

Do not touch hot parts of machine.

▲

Keep nuts and bolts tight, especially the blade attachment bolts. Keep equipment in good condition.

▲

Never tamper with safety devices. Check their proper operation regularly.

MAINTENANCE & ADJUSTMENT SAFETY PRECAUTIONS

9-2

Page 63

333559_0806

9-3

▲

Grass collection system components are subject to wear, damage and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check components and replace with manufacturer’s recommended parts, when necessary.

▲

Use only genuine Hustler replacement parts to ensure that original standards are maintained

Using a ramp

▲

Use extreme caution when loading and unloading a unit with a ramp.

▲

Use only a single, full width ramp; do not use individual ramps for each side of the unit. Having a full width ramp provides a surface for the tractor frame to contact if the unit starts to tip backwards. It also reduces the risk of a wheel going off and the machine tipping over.

▲

Do not exceed a 15 degree angle between the ramp and the ground or between the ramp and the trailer or truck.

▲

When on a ramp avoid sudden acceleration

Page 64

333559_0806

Safety and Instruction Decals

▲▲

Specific safety warning decals are located on the equipment near the immediate areas of potential hazards. These decals should not be removed or obliterated. Replace them if they become non-readable.

The following illustrations show the various safety decals that are located on the machine. A brief explanation is shown to help the operator understand the meanings of these decals.

Read Owner’s Manual and Quick Reference Decal before attempting to operate this machine.

Avoid skin contact with battery acid. Always wear eye protection when checking the battery, acid can cause serious injury to skin and eyes. If contact occurs, flush area with clean water and call physician immediately. Acid will also damage clothing. Do not allow open flame near the battery when charging. Hydrogen gas forms inside the battery. This gas is both toxic and flammable and may cause an explosion if exposed to flame. Always remove the negative ground first and replace it last. Do not overfill battery. Electrolyte may overflow and damage paint, wiring or structure. When cleaning the battery, use soap and water. Be careful not to get soap and water into the battery. Use soda mixed in water to clean corrosion off the terminals.

Do not remove or modify stabilizer wheels or rear engine guard or injury can result.

Part Number 793547

Part Number

727016

Part Number 771436

Do not smoke while refueling. Do not fill tank with engine running, or while the engine is hot. Allow engine to cool before storing machine inside a building. Store away from open flame or spark if there is fuel in tank. Clean up any gasoline spills. Do not refuel while in enclosed trailer or other enclosed areas

Part Number

793570

Never operate the mower deck with side deflector removed or in raised position, except when the grass catcher attachment is being used. Stay clear of mower blades as long as engine is running. Keep a safe distance from machine.

Keep shields or covers in place while machine is in operation. Keep hands away from rotating pulleys and belts. Whirling blades! Keep hands and feet away. Beware of thrown objects.

Part Number 794297

Never operate the mower deck with side deflector removed or in raised position, except when the grass catcher attachment is being used.

Stay clear of mower blades as long as engine is running. Beware of thrown objects.

Do not remove or modify stabilizer wheels or injury can occur. Keep a safe distance from machine. When operating on a slope of 15 degrees or more, be aware of any conditions that may cause the tractor drive tires to lose traction resulting in a possible loss of control of the machine.

9-4

If you loose steering control while operating the machine, place the steering control levers in the park brake position immediately. Inspect the machine and involve your Hustler dealer to resolve the problem before continuing to operate.

If pump belt fails, steering control will be lost. Refer to owner’s manual for

inspection and replacement intervals and refer to above paragraph for emergency procedures.

Part Number

600899

ReadOwner’s Manual

HelpAvoid Injury

Operatortraining required. Knowall controls.

Keepshields in place. Maintainall safety devices. Lookbehind before backing. Keepchildren and others away. Stayclear of power driven parts. Donot operate in areas where

machinecould tip.

Refueling

Stop engine and allow engine to cool for2 minutes prior to refueling.

Clean up anygasoline spills. Do not refuel while in enclosed

traileror other enclosed areas .

BeforeStar ting

Steering levers mustbe in park brakeposition.

Deckclutch switch must be in offposition.

Checkperformance of all safety interlock switches daily (including operatorpresence switch).

Avoidquick movements of steering levers. Reduce speed and use extreme

caution when operating on slopes.

Checkmowing area, and remove objects

that could be thrownby blades.

Turnengine off and remove key. Chockmachine when par kedon a slope.

While Operating

Neverperform maneuvers

at high groundspeeds .

Avoidsudden turns.

BeforeLeaving Operating Platform

Place drive/steering

controlsin par k brakeposition.

Place deckclutch switch

in the offposition.

793570

793547

If you lose steering control while operating the machine, place the steering control levers in the park brake position immediately. Inspect the machine and

involve your Hustler dealer to resolve the problem before continuing to operate.

If pump belt fails, steering control will be lost. Refer to owner’s manual for inspection and replacement intervals and refer to above paragraph for emergency procedures.

600899

794297

Page 65

9-5

333559_0806

MAINTENANCE

MAINTENANCE LOCATOR

CHART

1. Engine Oil Fill & Dipstick

2. Fuel Filter 3a. Engine Air Cleaner (Honda) 3b. Engine Air Cleaner (Kohler)

4. Engine Oil Drain Plug

5. Battery

6. Fuel Tanks

7. Gauge Wheel Bearing Zerks (2)

8. Engine Oil Filter

9. Deck Lift Pivot Zerks (3)

10. Park Brake Switch (2)

11. Drive Tire

12. Deck Belt

13. Pump Belt

14. Blades

15. Engine Air Intake Screen

16. Front Gauge Wheel Tires

Figure 9-1

Viewed from top of unit

Page 66

NOTES:

1. Initial oil change is after 5 hours of operation. Thereafter, change

oil after every 40 hours operation. Change more often under dusty or dirty conditions and during hot weather periods.

2. Torque initially and after first 2 hours of operation.

3. Change engine oil filter per the engine manufacturer’s

recommendations. Refer to Engine Owner’s Manual for recommendations and other maintenance items.

4. Service more often under dusty or dirty conditions.

5. Pump drive belt only - Inspect every 6 months or 100 hours and replace if worn or cracking is noticed. Otherwise, replace every 200 hours or 2 years whichever comes first.

6. Check fuel line hoses, fuel valve and grommet for any cracks or

leaks

7. Honda engine only

8. Kohler engine only REFERENCES: a —Refer to Engine Owner’s Manual

NOTE: After completing maintenance cycle (100 hours), repeat cycle.

Introd

uction

Regular maintenance is the best prevention for costly downtime or expensive, premature repair. The following pages contain suggested maintenance information and schedules which the operator/mechanic should follow on a routine basis.

Remain alert for unusual noises, they could be signaling a problem. Visually inspect the machine for any abnormal wear or damage. A good time to detect potential problems is while performing scheduled maintenance service. Correcting the problem as quickly as possible is the best insurance.

Clear away heavy build-up of grease, oil and dirt, especially in the engine and under the seat platform areas; minute dust particle are abrasive to close-tolerance engine and hydraulic assemblies.

Daily inspect mower for grass clippings and wire and string tangles. The underside of the mower deck will collect a build-up of grass clippings and dirt, especially when grass is wet or has high moisture content. This build-up will harden, restricting blade and air movement and will probably show a poorer quality of cutting. Therefore it should be removed routinely.

To do this it will be necessary to raise and block the deck, using jack stands or blocks, in the full up position and scrape the build-up from underneath.

Some repairs require the assistance of a trained service mechanic and should not be attempted by unskilled personnel. Consult your Hustler

service center when assistance is needed.

Torque values

WARNING: Particular attention must be given to tightening

the drive wheel lug nuts and blade spindle bolts. Failure to correctly torque these items may result in the loss of a wheel or blade, which can cause serious damage or personal injury. Torque values given below:

Ft-lbs. Nm

Wheel (lug) nuts . . . . . . . . . . . . . . . . . . . . . . .65-75 . . . . . .88.14-101.7

Blade spindle bolt top . . . . . . . . . . . . . . . . . . .118 . . . . . . . . .160.01

Blade spindle bolt bottom . . . . . . . . . . . . . . . .118 . . . . . . . . .160.01

It is recommended that these be checked after the first 2 hours of operation, initially and every 50 hours following removal for repair or replacement.

For all other torques refer to the torque callout chart located elsewhere in this manual.

For engine torque values, see engine owner’s manual.

Tires

It is important for level mowing that the tires have the same amount of air pressure. The recommended pressures are:

Drive wheels...............................................8-10 psi (55-69 KPa)

Gauge wheels .............................................8-10 psi (55-69 KPa)

Solid fill tires are not recommended for Hustler turf equipment. On any machine, with solid filled tires, the warranty claim will be denied.

WARNING: Explosive separation of a tire and rim can cause serious injury or death. Do not attempt to mount a tire without the proper equipment and experience to perform the task. Always maintain the correct tire pressure and never over inflate. Never weld or heat a wheel and tire assembly as an explosion may occur. Welding can weaken or deform a wheel. When inflating tires stand to one side and not in front of or over the tire assembly. Check tires for low pressure, blemishes, damaged rims or missing lug bolts and nuts.

Lubrication

1. Grease the three (3) deck lift pivots, located to the side of the operator’s footrest per the Maintenance Schedule. Use SAE multi-purpose grease.

2. Grease the front gauge wheel bearings per the Maintenance Schedule. Use SAE multi-purpose grease.

Electrical system

The electrical system is a 12 volt, negative ground. Recommended battery size is a garden tractor BCI group U1R with 225 or better cranking AMP rating. A maintenance-free battery is recommended. Otherwise, follow battery manufacturer’s maintenance, safety, storing and charging specifications.

The battery is located under the seat platform. Fig. 9-2

WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

WARNING: Avoid skin and clothing contact with battery acid. Always wear eye protection when checking the battery, acid can cause serious injury to skin and eyes. If contact occurs, flush area with clean water and call physician immediately. Acid will also damage clothing. Do not drink the battery electrolyte. Do not allow open flame near the battery when charging. Hydrogen gas forms inside the battery. This gas is both toxic and flammable and may cause an explosion if exposed to

WEEKLY OR ANNUALLY OR

SERVICE AT 50 100

INTERVALS INDICATED HOURS HOURS

Verify safety start interlock system Prior to each use

Visually inspect unit for loose hardware

and/or damaged parts Prior to each use

Visually inspect tires Prior to each use

Check oil level, engine (1) Prior to each use or every 4 hrs.

Clean air intake screen (4)(7) Prior to each use or every 4 hrs.

Clean foam element (4)(7) Prior to each use or every 4 hrs.

Check fuel level Prior to each use

Blades - sharpen & securely fastened Prior to each use

Discharge chute - securely in place &

in lowest position Prior to each use

Grease deck height pivots x

Change engine oil & filter (1) (3) x

Clean cylinder and head fins (a) x

Check battery connections x

Check tire pressure with a gauge x

Clean engine exterior (a) x

Replace air cleaner paper element (4) x

Clean and regap spark plugs (a) x

Check pump and deck belt tension

& condition (5) x

Check fuel lines (6) x

Check fuel valve and grommet (6) x

Tighten lug nuts on wheels (2) x

Change fuel filter x

Replace spark plugs x

Check engine valve clearance (a) Every 200 hours or 2 years

Service starter (8)(a) Every 200 hours or 2 years

Replace EZT pump belt Every 200 hours or 2 years

333559_0806

9-6

Page 67

333559_0806 333559_0806

flame. Always remove the negative ground first and replace it last. Do not overfill battery. Electrolyte may overflow and damage paint, wiring or structure. When cleaning the battery, use soap and water. Be careful not to get soap and water into the battery. Clean the battery terminals with a solution of four parts water and one part baking soda when they become corroded.

WARNING: Shorts caused by battery terminals or metal tools touching metal tractor components can cause sparks. Sparks can cause a battery gas explosion which will result in personal injury. Prevent the battery terminals from touching any metal tractor parts when removing or installing the battery. Do not allow metal tools to short between the battery terminals and metal tractor parts.

WARNING: Incorrect battery cable routing could cause damage to the tractor and battery cables. This can cause sparks which can cause a battery gas explosion which will result in personal injury. Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. Always connect the positive (red) battery cable before connecting the negative (black) cable.

Common circuit failures are usually caused by shorting, corroded or dirty terminals; loose connections, defective wire insulation or broken wires. Switches, solenoids and ignition components may also fail, causing a shorted or open circuit.

The electrical system is protected by fuses located on the right fuel tank instrument panel. Fig. 9-3 The fuses are as follows:

Main - 20 amp, blade-type Clutch/Aux - 10 amp, blade-type

Before attempting any failure diagnosis of the electrical system, use a test light or voltmeter to check the battery voltage. If the battery voltage is satisfactory, check the cleanliness and tightness of the terminals and ground connections. A general understanding of electrical servicing and use of basic test equipment is necessary for troubleshooting and repair.

Major overhaul or repair of the starting motor or charging system should be performed by trained technicians only.

Access to integrated pump/motor transmissions

The integrated pump/motor transmissions are accessed by lifting the seat platform. The seat platform is hinged at the front. To raise it, remove the lock nut and flat washer and tilt seat platform up and forward. (Fig. 9-

If the seat is equipped with the optional arm rest kit, make certain to place the control arms in the park brake position and pivot the arm rests upward before placing the seat platform in the full forward position to prevent damage to the arm rests.

Hydraulic system

The FasTrak 36/42 is equipped with two Hydro-Gear EZT integrated

pump/motor transmissions. Fig. 9-5

The EZT integrated pump/motor transmissions are sealed for life and

do not require any scheduled service.

The EZT integrated pump/motor transmissions are filled with 20W50

engine oil. If they ever become low on oil, fill to the level shown in Fig. 9-

WARNING: When washing the mower, direct spray away (especially if using a power washer) from the Hydro-Gear EZT transmission’s seals to prevent water intrusion and to ensure component performance.

9-7

Figure 9-2

Battery

Figure 9-4

Lock nut

Flat washer

Figure 9-3

FFuussee

Figure 9-5

EZT integrated

pump/motor

Page 68

Fuel system

DANGER: Observe usual fuel handling precautions:

Do not smoke while refueling. Do not fill tank with engine running or while engine is hot. Clean up any gasoline spills. Allow engine to cool before storing machine inside a building. Keep fuel away from open flame or spark and store machine away from open flame or spark if there is fuel in the tank. Use extra caution when handling gasoline and other fuels. They are flammable and vapors are explosive. A fire or explosion from gasoline can burn you and others and can damage property. Refuel outdoors preferably, or in well ventilated areas. Never attempt to start engine when there is a strong odor of gasoline fumes present. Locate and correct cause. Store gasoline in an approved container and keep it out of the reach of children. Never buy more than a 30 day supply of gasoline. Always place gasoline containers on the ground away from your vehicle before filling. Do not fill gasoline containers inside a vehicle or on a truck or trailer as interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge. When practical, remove equipment from the truck or trailer and refuel the equipment with its wheels on the ground. If this is not possible, then refuel the equipment on the truck or trailer using a portable container and not a gasoline dispenser nozzle. If a gasoline dispenser nozzle must be used, keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.

WARNING: Gasoline is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness. Avoid prolonged breathing of vapors. Keep face away from nozzle and gas tank or conditioner opening. Keep gas away from eyes and skin.

The fuel tanks are located in the tractor’s fenders. (Fig. 9-7) Total

capacity for the fuel tanks is 6 U.S. gallon (22.71 liter).

IMPORTANT: Do not overfill the fuel tanks. The fuel tanks should

be filled no higher than 2” below the tank’s fill neck.

When filling the fuel tanks disengage deck clutch, place control levers in park brake position, and stop tractor engine. Clean around the fuel tank cap and remove the cap and begin filling. When finished, screw the cap on securely and wipe up any spilled gasoline.

Use regular unleaded gasoline with an octane rating of 87 or higher. IMPORTANT: Never use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with gasoline.

Using a fuel stabilizer/conditioner in the tractor can provide benefits such as:

1. Keeps gasoline fresh during storage of 90 days or less. For longer

storage, drain the fuel tanks.

2. Cleans the engine during operation.

3. Eliminates gum-like varnish buildup in the fuel system.

IMPORTANT: Do not use fuel additives containing methanol or

ethanol.

Add the correct amount of gas stabilizer/conditioner to the gas. Follow

the gas stabilizer/conditioner manufacturer’s directions for best results.

The fuel filter (Fig. 9-8A & 9-8B) is installed in the fuel line between fuel tanks and engine fuel pump. Replace filter annually or after every 100 hours of operation, whichever occurs first. For fuel filter removal refer to the engine owner’s manual

When replacing the fuel filter, check the fuel line hoses and fuel tank fitting grommets for any cracks or leaks. Replace as needed.

A fuel shut-off valve is located to the right rear of the seat. Fig. 9-9 Close this valve (center position) to prevent fuel flow to the engine. Close this valve when transporting the unit on a trailer or truck.

Draining the fuel tank

1. Park the unit on a flat surface. Stop the engine and remove the

Figure 9-8A

Honda

Fuel filter

Inlet hose

Figure 9-6

Figure 9-7

Fuel tank

.75” - 1.50” Depth

at 50

- 100o F

333559_0806

9-8

Page 69

9-9

333559_0806

ignition key. Make sure deck clutch switch is in the down (OFF) position. Place control levers in the park brake position. Disconnect negative battery cable.

2. Close the fuel shut-off valve (center position). Fig. 9-9

3. Disconnect the fuel line from the fuel tank fitting. Place the end of

the hose in an approved container to drain the remaining fuel from the hose.

4. Remove the fuel tank from the tractor. Remove the fuel cap, tip the

tank and drain the fuel into an approved fuel container.

5. When fuel tank is drained, re-attach the fuel tank to the tractor and

re-connect the fuel line to the fuel tank fitting. Make certain hose clamp is properly installed.

6. Fill fuel tank with proper grade of gasoline and open shut-off valve.

Engine oil and filter

Check engine oil daily and after every 4 hours of operation. Crankcase dipstick and oil filler tube are located as shown in Fig. 9-10A & 9-10B. Tractor must be setting level when checking oil. Refer to engine manual and maintenance schedule for oil recommendation and capacities.

Change the engine oil and filter after the first 5 hours of operation, per the engine manufacturer’s recommendations after that. If tractor is being operated in extremely dirty conditions, then it is recommended oil be changed more frequently.

The oil drain and oil filter are located at the rear of the engine. Fig. 910A, 9-10B & 9-10C

Engine mounting bolts

If the original engine mounting bolts are ever removed from the tractor, do not reuse. The original bolts are self-tapping and if they are reused they may try to cut new threads into the engine block mounting holes.

Replace with 3/8”-16 x 1.00” Grade 5 bolts. Apply Loc-Tite 242 to the threads and torque to 30-35 ft.-lbs. Re-use the int/ext tooth lockwashers

Figure 9-9

Fuel shut-off valve

Closed position shown

Right fuel

tank position

Left fuel

tank position

Figure 9-8B

Kohler

Fuel filter

Inlet hose

Figure 9-10A

Engine oil filter

Dipstick

Honda

Engine oil

filler tube

Engine oil drain plug

Figure 9-10B

Kohler

Dipstick &

Engine oil

filler tube

Engine

oil filter

Figure 9-10C

Kohler

Engine oil

drain plug

Page 70

that were factory installed with the original mounting bolts.

Belt replacement

Figures 9-11 and 9-12 show diagrams and descriptions of the unit’s belt

drive systems.

Inspect these belts frequently for wear and serviceability. Replace a belt

that shows signs of severe cuts, tears, separation, weather checking and cracking, or burns caused by slipping. Slight raveling of belt covering does not indicate failure, trim ravelings with a sharp knife.

WARNING: If the pump belt fails, loss of control will occur especially when operating on a slope. If you lose steering

control while operating the machine, place the steering control levers in the park brake position immediately. Inspect the machine and involve your Hustler dealer to resolve the problem before continuing to operate.

Inspect the belt pulley grooves and flanges for wear. A new belt, or one in good condition, should never run against the bottom of the groove. Replace the pulley when this is the case, otherwise belt will lose power and slip excessively.

Never pry a belt to get it on a pulley as this will cut or damage the fibers of the belt covering.

Keep oil and grease away from belts, and never use belt dressings. Any of these will destroy the belt composition in a very short time.

Deck belt replacement

1. Park the unit on a flat surface. Stop the engine and remove the ignition key. Make sure deck clutch switch is in the down (OFF) position. Place control levers in the park brake position. Disconnect negative battery cable.

2. Place the deck in the lowest position.

3. Remove the deck belt covers.

4. Release the deck belt tension by pulling on the belt tension chain and

sliding the chain out of the anchor bracket slot. This will relieve the tension on the deck belt idler spring. Fig. 9-11

5. Push the idler toward the rear of the deck to provide maximum belt clearance.

6. Remove the existing belt and replace with a new belt.

7. Route the new belt per Fig. 9-11.

8. Re-tension the deck belt idler per the Deck drive belt adjustment

section found elsewhere in this manual.

9. Re-install the deck belt covers.

10. Re-attach the negative battery cable.

Integrated pump/motor drive belt replacement

WARNING: This procedure will require that the unit to be

raised and blocked up off of the ground. Use only appropriate vehicle 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.

2. Place the deck in the lowest position.

3. Raise the rear of the tractor and block with certified jack stands.

4. Remove the right rear tire and wheel from the tractor.

5. The deck belt must be removed from the clutch pulley first by

releasing the deck belt tension by pulling on the belt tension chain and sliding the chain out of the anchor bracket slot. This will relieve the tension on the deck belt idler spring. Fig. 9-11

6. Remove the deck drive belt from the electric clutch pulley. This belt does not need to be removed from any of the other pulleys.

7. Release the tension from the integrated pump/motor belt by pulling on the belt tension chain and sliding the chain out of the anchor bracket slot. Fig. 9-14

8. Slide the belt off the engine pulley. The belt will have to be slid above the engine pulley to allow the belt to be removed from the other pulleys. Fig. 9-13

9. Slide the belt over the integrated pump/motor pulleys and fans.

10. The belt can now be removed from above the engine pulley.

11. Install new belt by sliding it up and over the engine pulley. Make

certain it is not in the pulley groove at this time but is above the pulley.

12. Slide the belt over the integrated pump/motor pulleys.

13. Slide the belt onto the engine pulley.

14. Re-attach the spring and chain to the tensioner pulley arm. Pull

chain and slide the chain into the anchor bracket slot. Fig. 9-14

15. Re-install the deck drive belt on the electric clutch pulley and make

sure it is routed properly on all of the deck pulleys.

16. Re-tension the deck belt idler per the Deck drive belt adjustment

Figure 9-11

Deck Belt Drive Layout

1. Spindle drive belt

2. Deck blade spindle pulley

3. Spindle belt tension idler

4. Spindle belt tension idler spring

(7.5" (19.05

CM) at operation)

5. Deck belt idler pulley

6. Idler arm

Figure 9-12

2, 6

1. Pump belt

2. Engine pulley

3. Pump idler pulley

4. Pump idler arm

5. Pump pulley

6. Electric deck clutch

7. Pump idler spring

8. Fixed idler pulley

Viewed from

top of unit

333559_0806

9-10

Page 71

9-11

333559_0806

section found elsewhere in this manual.

17. Re-attach the right rear drive tire and wheel. Torque lug nuts to 65-

75 ft.-lbs. (88.14-101.7 NM).

18. Raise the tractor and remove the jackstands. Lower the tractor.

19. Re-attach the negative battery cable.

Mower blade removal

Use a 15/16" wrench to remove the 5/8" cap screw holding the blade to

the spindle shaft from underneath.

Sharpen the blades on a grinder following pattern as shown (Fig. 9-15).

Touch-up sharpening can be done with a file.

Check the blades for balance following grinding. A commercial

balancing tool is available through most hardware supply stores, or balancing can be done by placing the blade on an inverted line punch or 5/8" bolt. Blade should not lean or tilt. Spin the blade slowly, blade should not wobble. If blade is out of balance, true it up before reinstalling.

Lay the blade on a flat surface and check for distortion (Fig. 9-16 and 9-

17). Replace any distorted blade. Do not re-use spindle bolts which have stripped, worn or undercut

threads. Torque bolts on spindles to 118 foot-pounds (160.01Nm) when reinstalling blades.

IMPORTANT: The blade sail (curved part) must be pointing upward

toward the inside of the deck to ensure proper cutting.

WARNING: When mounting blades, rotate them after installation to ensure blade tips do not touch each other or sides of the mower.

WARNING: Failure to correctly torque the bolt may result in the loss of the blade which can cause serious injury.

WARNING: Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves and use extra caution when servicing them.

Figure 9-13

Engine

pulley

Deck idler pulley

Figure 9-14

Anchor bracket

slot

Spring

Chain

Figure 9-15

Resharpening Pattern

Do not sharpen to original pattern (below). It is easier to get a straight cutting edge following the resharpening pattern shown above.

Original Edge

Warped Blade (Replace)

Straight Blade

Comparison of Warped and Straight Blades

Cutting

Plane

Figure 9-16

Figure 9-17

Twisted Blade Edge

(Replace)

Cutting Edge

Straight Blade Edge

End view of blades, comparing

twisted and straighten blades.

Cutting Plane

Cutting Edge

Page 72

ADJUSTMENTS

Introduction

Your FasTrak 36/42 was adjusted before it left the factory and was checked during predelivery setup. However, after start-up and continued use, a certain amount of break-in wear will cause some adjustments to change.

Clear away heavy build-up of grease, oil and dirt, especially in the engine and under the seat platform areas; minute dust particle are abrasive to close-tolerance engine and hydraulic assemblies.

Some repairs require the assistance of a trained service mechanic and should not be attempted by unskilled personnel. Consult your Hustler service center when assistance is needed.

Park brake adjustment

Occasionally check the park brake adjustment using the following

method:

1. 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. Raise and block the tractor up so the drive wheels are off of the

floor.

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.

3. Remove the drive tires.

4. Push the steering lever inward into the operating position,

disengaging the brake. Only adjust one side at a time.

5. Locate the brake lever arm and brake gear on the EZT transmission.

When the steering lever is in the operating position, the brake arm should have a minimum of 0.06" (1.52

MM) and maximum of 0.125"

(3.18MM) clearance between the teeth of the brake lever arm and the outside diameter of the brake gear. Fig. 9-18

6. If you find that the clearance is not to this specification, then adjust

the position of the brake lever arm by moving the lock nuts on the brake rod accordingly. When adjusting the nuts, the spacing between the inside of the nuts needs to be maintained at 7/8" (2.22

CM) which has been set at the factory. The best way to keep

this spacing is to turn both nuts in the same direction the same number of turns. Fig. 9-19

7. Loosen the jam nut on the brake rod and rotate the adjusting tube

(Fig. 9-20) until the dimensions shown in Fig. 9-18 can be attained. Re-tighten the locknut.

8. After adjustments are made and the proper clearance is restored,

actuate and release the brakes with the steering lever several times. Check to make sure the brake arm on the EZT is engaging and fully disengaging the teeth of the brake gear.

9. Repeat this process for the opposite side if required.

10. Assemble the rear tires and re-torque the lug nuts to 65-75 ft.-lbs.

(88.14-101.7 NM)

11. Raise the rear of the tractor and remove the jack stands. Lower the

tractor.

Steering linkage adjustment

The neutral adjustment has been factory adjusted to eliminate creeping when the control levers are in the neutral position. However, if the steering linkage should ever need adjustment due to the unit creeping when the steering levers are in the neutral position or the EZT’s whining when the

parking brakes are engaged, take the unit to an Authorized Hustler Dealer for adjustment.

WARNING: Only properly trained personnel should attempt to reset the neutral adjustment on the FasTrak 36/42. This procedure requires that the engine be running and the drive wheels rotating during adjustment.

333559_0806

Brake lever arm

Brake gear

.06” - .125” gap

(1.52

MM - 3.18MM)

Figure 9-18

Lock nut

Brake lever arm

Brake gear

7/8”

(2.22CM)

Lock nut

Figure 9-19

Jam nut

Figure 9-20

Adjusting

tube

9-12

Page 73

9-13

333559_0806

WARNING: The adjustable steering rods are located near the EZT integrated pump/motor fans. Make certain the engine is not running when adjusting the steering rods. The neutral adjustment for the control levers in the neutral position is discussed in this section.

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 Maintenance 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 adjustable pump linkage rods. Fig. 9-21

Neutral is properly adjusted when the control levers are in the park brake position and the EZT transmissions do not “whine” .

If this occurs, the control linkage may be adjusted as follows:

1. Raise and block the tractor frame keeping the rear drive tires free

and clear of any obstructions so they are free to rotate. The engine will be running and tires rotating during this operation.

2. Remove the seat pan locknut as shown in Fig. 9-22 Tilt the seat

forward. Temporarily bypass the seat switch.

3. Loosen the front dampener ball stud nut as shown in Fig. 9-21. The

dampener will be adjusted and tightened after neutral is reset.

4. Staying clear of the rear drive tires, start the engine. If the EZT

transmissions whine, then the neutral setting needs to be re-adjusted. In this operation you will need to adjust one side at a time. If either side whines significantly, then the steering lever needs to be pushed into the operating position, disengaging the brake. Most likely when the brake is disengaged, the drive wheel will begin to rotate even though the steering lever is in the neutral position.

5. Shut off the machine. Loosen the jam nuts on each end of the pump

control rod as shown in Figure 9-21.

6. Start the engine. Move the steering lever to just engage the brake

(neutral) slot and hold it in that position (Do not engage the steering lever far enough to engage the brakes in the brake slot).

WARNING: This operation is extremely dangerous. Pay close attention when adjusting the pump control rod so you do not get your fingers, tools, or anything else close to the EZT pump cooling fans.

7. While holding the steering lever position discussed in step 6,

carefully adjust the pump control rod until the rear wheel starts turning forward. Now turn the pump control rod in the opposite direction until the moment when the wheel just stops turning forward. Turn the control rod another 1/2 turn in this direction. Hold the pump rod in this position and actuate the parking brake with steering lever. The EZT should not whine.

8. Hold the pump control rod still and turn off the engine.

9. Tighten the jam nuts on each end of the pump control rod. NOTE:

Do not let pump control rod turn while tightening the jam nuts.

10. Neutral is now set. Start the engine and actuate the brakes a few

times to confirm that the EZT does not whine when the park brake is set.

11. Repeat for the other side.

12. The steering dampener now needs to be adjusted and tightened.

13. Reconnect the seat switch and make sure the seat switch is operating properly per the following procedure:

A. The operator must be on the seat when testing the seat switch. B. Set both control levers in the park brake position.

C. Start the engine and allow it to warm up to operating

temperature.

D. With the deck clutch switch down and the control levers in the

park brake position, slowly raise off of the seat. The engine

should continue to run.

E. With the deck clutch switch up and/or the control levers in the

neutral position, slowly raise off of the seat. The engine should stop.

F. If the engine fails to stop when the deck clutch switch is up or

one or both of the control levers are not in the park brake position and the operator is off the seat, check the function of the seat switch. If the seat switch is not operating properly (is not opening or closing) and if the cause can not be determined, replace the seat switch.

If the problem can not be located, contact your Hustler Dealer.

WARNING: The safety interlock system should always function per steps 4 and 5. If it does not function properly, it should be corrected immediately. Do not operate machine without properly functioning seat safety switch.

WARNING: Do not operate machine without a properly functioning seat safety switch.

Steering dampener adjustment

The steering dampener 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 steering control lever does not return to neutral from reverse then adjust as follows:

To set the steering dampeners in the correct operating position follow these steps:

1. 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. If you have not already done so, loosen the front ball stud that is

attached to the forward dampener socket. Fig. 9-21

Front dampener ball stud

Jam nut

Pump rod

adjuster assembly

Jam nut

Figure 9-21

Figure 9-22

Lock nut

Flat washer

Page 74

3. When the ball stud is loosened, pull out on the ball stud stud end and

release. The dampener will return to the neutral position and come to rest. Re-tighten the front ball stud.

4. Release the park brake and pull the steering lever to the reverse

position and allow the dampener to return the lever to the neutral position. If the steering lever does not return to the neutral position (centered with the brake slot), then either you have not adjusted the dampener correctly, or it is damaged and needs to be replaced.

5. Repeat for the opposite side.

Hydraulic pump belt adjustment

The pump drive belt tension remains constant by means of a tension idler

and spring (Fig. 9-23). There is no tension adjustment of this belt.

NOTE: Inspect the belt every 100 hours and replace as needed. Replace the belt every 200 hours or every two (2) years whichever comes first.

WARNING: If the pump belt fails, loss of control will occur especially when operating on a slope. If you lose steering

Deck drive belt adjustment

The spindle belt tension remains constant by means of a tension idler and spring (Fig. 9-24). 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 belt stretches and wears in, adjustment may become necessary. To increase belt tension, move the spring chain one (or more) link(s) at the anchor bracket (Fig. 9-24). Installed spring length should be 7.50" ± .3" (19.05CM ± .76CM) originally with adjustments of .60" (15.2MM) per chain link. (Fig. 9-25)

IMPORTANT: Do not over tension the spring to compensate for a badly worn belt or pulley.

Engine RPM setting

The FasTrak 36/42 is designed so that the engine will run at 3600 rpm (Kohler) or 3550 rpm (Honda) with integrated pump/motor load only. At this speed the integrated pump/motors are running at their maximum rated speed.

Deck leveling and height adjustment

The mower deck has three areas that may need to be checked and adjusted periodically. Before considering any mower deck leveling adjustments, check that the tire air pressure is within the specified range.

Deck level adjustments

Leveling the deck must be done in the following manner and order:

1. Check tire pressures to make certain they are properly inflated before

starting to level deck. The recommended pressures are as follows:

Drive wheels tire pressure....................8 - 10 psi (55-69

KPa)

Gauge wheels tire pressure...................8 - 10 psi (55-69

KPa)

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

2. Park the unit on a flat surface.

3. Raise deck and place 3" (7.62CM) tall spacer blocks under the edge

of the deck - two in front on each side and two in back on each side (Fig. 9-26). Remove the height adjusting stop and let the deck down so it rests on the 3” (7.62CM) spacer blocks. Make sure the deck is setting on all four blocks. Leave the height adjusting stop out of the square adjusting bar for now. The deck should be leveled before the height is set. Fig. 9-27

4. Loosen the two nuts that hold the deck adjusting bar in position.

Fig. 9-30

5. Loosen the two nuts that hold the right rear deck lifting arm. Fig. 9-

6. Loosen the left rear deck leveling bracket by loosening the flange

nuts. Fig. 5-14

7. Loosen the jam nut and back out the 5/16” bolt on top of the

adjuster. Fig. 9-29

8. Check to make sure the deck is resting firmly on all of the 3”

(7.62

CM) blocks. Check the front right deck chain to be sure it is

taut. Now, screw both nuts finger tight against the square block on the right rear deck lift arm. Tighten these two nuts. Fig. 9-28

9. Tighten the 5/16” bolt on the adjuster until the chain is taut. Tighten

the jam nut against the adjuster. Tighten the two flange nuts. The deck should now be level. Fig. 9-29

10. To adjust the deck height insert the height adjusting stop into the 3-

1/4” (8.26CM) position. (Fig. 9-27) Remember, the blocks are 3” (7.62CM) and the blades are set 1/4” (6.35MM) higher than the front edge of the deck, so the cutting height is currently at 3-1/4” (8.26CM).

11. Tighten the rear nut against the block attached to the deck lifting

pedal as tight as you can by hand. (Fig. 9-30) Make sure the stop handle is pushing firmly against the height adjusting stop so that there is no free play forward or rearward when you shake the adjustment bar. Fig. 9-27

12. Finger tighten the front nut against the block attached to the deck

lifting pedal. Tighten both nuts and check to make sure that all deck

Figure 9-23

Spring

Tension

idler

Pump drive

belt

Figure 9-24

Figure 9-25

1.50”

Spring Extension

7.50”

6.0”

Normal Spring Length

Spring

Tension idler

Chain

Anchor bracket

9-14

333559_0806

Page 75

333559_0806

9-15

Figure 9-27

Height

adjusting

stop

Stop

handle

Deck adjusting bar

Figure 9-26

Blocks

Figure 9-28

Nut

Chain

Deck lift

threaded rod

Nut

Lifting

arm

Block

Figure 9-29

5/16” bolt

Adjuster

Flange nut

Jam nut

Figure 9-30

Foot

pedal

Nuts

Chain

Deck

adjusting

bar

Block

linkage hardware are tight. Fig. 9-30

13. Raise the deck into transport position and remove the blocks from

under the deck corners. The deck should now be level and the deck cutting height properly adjusted.

Page 76

333559_0806

9-16

Page 77

Numerical Index

Part Page No. No.

Index

Part Numbers

000323 4-7 000331 4-7 005116 6-5 005231 4-3 011320 2-4 015495 3-3 015818 4-7 016253 4-3 017129 6-5 017616 7-2 019521 5-4 024927 3-2 025007 3-5 025296 3-3 026237 4-9 028118 3-5 029868 3-2 029876 4-3 030817 4-5 031997 2-3 034272 3-3

034280 6-3 035238 3-5 036244 4-5 036384 3-5 041152 3-7 042630 5-2 043570 4-3 044255 4-5 045898 4-9 046821 6-5 048553 3-7 050161 4-3 052860 4-3 053199 2-3 054502 2-4

055749 3-3 055822 4-7 055939 3-2 055947 4-9 056077 4-3 058776 6-5 059832 4-9 059931 6-5 060731 3-7 061077 5-4 061101 3-5 064006 6-5 068478 1-1

, 6-11

, 4-5 , 6-11

, 3-7, 4-3, 4-5 , 6-5, 6-11 , 3-5

, 6-3, 6-9 , 3-5, 3-7, 4-3,

4-5, 6-3, 6-9

, 6-9, 7-4

, 6-3, 6-9, 7-4

, 6-11

, 4-5, 7-4 , 6-3, 6-9 , 4-7, 6-3, 6-5,

6-9, 6-11

, 7-2

, 4-5 , 6-11

, 6-11

Part Page No. No.

068551 3-7 076422 2-4 079186 3-7 083022 4-9 083279 8-3 086660 3-7 089789 3-7 104786 4-3 107612 1-1 306969 5-2 314989 3-2 315101 3-7 315382 3-7 315440 2-2 315572 6-3 316836 2-3 316844 2-4 320242 2-2 320267 2-4 320275 7-4 320580 2-3 321042 6-11 321059 4-9 321398 6-5 321877 6-5 322974 6-3 324046 3-5 325464 3-7 330225 6-3 330274 4-3 330324 6-5 330399 6-3 333526 4-7 334045 3-3 335695 3-5 335893 3-5 338442 1-1 339689 5-2 344267 2-3 348284 3-3 348318 3-3 348458 3-3 352054 3-7 352112 3-7 352500 6-3 360131 3-3 360487 3-7 364315 3-5 378273 4-3 546895 2-2 546911 2-2 546929 6-9

, 6-5, 6-11

, 6-3, 6-9, 7-4

, 4-5

, 4-3, 4-5

, 6-11 , 6-11 , 6-9

, 6-9 , 4-5

, 6-9

, 5-2

, 6-9

, 6-5, 6-11

Part Page No. No.

546937 6-3 600171 6-5 600189 6-5 600221 3-7 600899 8-3 704643 3-3 704932 4-9 705178 3-7 705954 5-2 706531 4-3 710087 3-5 712257 4-9 712372 4-3 712927 4-3 712976 5-2 714998 4-9 718288 3-5 727016 8-3 727172 8-4 736417 4-3 739144 4-3 740696 3-2 745059 4-7 747303 1-1 756270 3-3 763417 4-5 767954 2-4

767962 2-3

768044 5-2 768259 3-7 768515 3-7 768523 3-5

771428 3-2 771436 8-3 772806 5-3 772814 5-3 776476 4-9 778365 4-9 779306 4-7 781153 3-5 781211 3-7 781229 3-3 781260 3-7 781294 3-3 781302 6-5 781567 2-3

781708 2-3

, 6-11 , 6-11

, 7-2

, 4-5

, 4-5 , 6-5, 6-11

, 3-7

, 8-5

, 4-5

, 3-7, 4-3, 4-5,

4-7, 6-3, 6-5, 6-9, 6-11, 7-4

, 3-3, 5-2, 6-3,

6-9, 7-2

, 4-3, 4-5, 4-9 , 3-7, 4-3, 4-5,

6-3, 6-5, 6-9, 6-11, 7-4

, 4-5

, 6-11 , 3-7, 5-2, 6-3,

6-9, 7-2

, 6-3, 6-9

333559 8/06 i-1

Page 78

Part Page No. No.

781831 3-3 781872 6-5 781880 4-7 781922 3-7 782474 6-5 782573 8-3 782664 4-3 782995 3-3 783134 5-4 783142 5-4 783159 5-4 783506 6-5 783514 6-14 783522 6-14 783530 6-14 783548 6-14 783555 6-14 783696 3-7 784223 5-2 784264 5-4 784272 5-4 784280 5-4 784504 6-5 784603 5-2 784710 8-3 784827 3-5 784835 4-3 784918 4-3 785030 4-9 785048 4-3 785063 3-2 785139 8-3 785147 8-3 785220 8-3 785295 4-7 785394 4-3 785485 2-4 785543 4-3 785808 4-9 785832 6-5 786335 6-5 786632 3-2 786640 3-2 786657 4-9 787069 6-5

, 6-11 , 6-3, 6-9

, 6-11

, 4-5 , 4-5

, 4-5

, 6-11 , 6-11

, 6-11

787226 1-1 787234 1-1 787242 1-1 787267 4-3 788166 2-3 788968 8-3 791251 4-3 791608 4-3 792762 4-5 792788 4-5 792796 4-3 792895 3-5 792911 3-5 792945 4-5 792952 4-5 792960 4-7 792978 4-7 792986 4-7 793059 3-7 793083 4-3 793117 4-5 793125 4-3 793133 4-5 793141 4-3 793158 4-5 793166 4-3 793174 3-7 793182 3-7 793315 7-4 793331 1-1 793406 5-4 793489 3-2 793505 3-3 793513 8-5 793521 8-4 793547 8-3 793554 8-3 793570 8-4 793588 8-3 793612 3-7 793646 3-7 793679 7-4 793687 8-4 793703 8-3 793760 4-3

, 6-3, 6-9

, 4-5

, 7-4

, 8-5

, 4-5

793778 6-5 793786 6-5 793794 1-1 793802 1-1 793810 4-9 793828 1-1 793836 1-1 793844 2-4 793851 7-4 793885 4-5 793893 1-1 794081 4-7 794172 4-3 794180 4-3 794297 8-4 794305 8-3 794313 1-1 794370 1-1 794396 3-7 794404 3-5 794503 8-4 794545 8-3 794552 3-5 794644 4-3 794883 3-7 795229 3-7 795625 3-7 796516 4-5 796615 3-7 797050 3-7 797449 6-5 797456 7-4 797753 3-7 797761 3-7 797779 3-7 797910 6-5 799221 4-7 808485 6-3 808493 2-2 927343 1-1 927350 1-1 927368 1-1 927376 1-1

, 6-11

, 6-5, 6-11 , 6-5

, 6-5 , 3-5

, 6-11

, 4-5 , 8-5

, 8-5

, 4-5

, 6-11

, 6-9 , 2-3

i-2 333559 8/06

Hustler 333559 User Manual

Table of Contents

Chapter 1

General Information

Chapter 2 Contents

Tractor Frame Rivet Nut Installation

Engine Guard and Anti-rollover Bracket Assemblies

Footrest Assembly

Chapter 3 Contents

Battery Installation

Deck Lift Assembly

Hydro Transmission Installation

Steering and Brake Assembly

Chapter 4 Contents

Honda 16 HP Engine Installation

Kohler 15 & 17 HP Engine Installation

Fuel System Installation

Instrument Panel Installation

Honda 16HP Electrical Schematic (793083)

Kohler 15 & 17 HP Electrical Schematic (793117)

Chapter 5 Contents

Front Wheel Assembly

Front Wheel Breakdown -768044

Drive Wheel Assembly

Chapter 6 Contents

Deck Assembly 36"

Deck Pulley Assembly 36"

Deck Assembly 42"

Deck Pulley Assembly 42"

Chapter 7 Contents

Deck Installation

Belt Routing and Tensioning

Seat Installation

Chapter 8 Contents

Tractor Decals

42" Deck Decals

36" Deck Decals

Chapter 9 Contents

MAINTENANCE & ADJUSTMENT SAFETY PRECAUTIONS

MAINTENANCE

ADJUSTMENTS

Index