Hustler 365262 User Manual

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Page 1

44" & 52" Deck

Parts Manual

365262 Rev. 6/06

•••••••

Hustler Turf Equipment

•••••

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.

IMPORTANT: 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 enclosed Engine Owner’s Manual is supplied for information regarding the U.S. Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance and warranty.

Keep this Engine Owner’s Manual with your unit. Should the Engine Owner’s Manual become damaged or illegible, replace immediately. Replacements may be ordered per the information found in the Product Information section of this manual.

Page 3

Chapter 1

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

Chapter 2 Contents

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

Idler Plate Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Engine Guard Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Chapter 3 Contents

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

Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

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

Hydro Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Towlink Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Chapter 4 Contents

Honda 18 & 20 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . 4-2

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

Briggs & Stratton 17.5 HP Engine Installation. . . . . . . . . . . . . . . . . 4-6

Kohler 18 & 20 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . 4-8

Fuel System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Instrument Panel Assembly/Installation . . . . . . . . . . . . . . . . . . . . . 4-14

Honda 18 & 20 HP Electrical Schematic (784868) . . . . . . . . . . . . . 4-16

Honda 16 HP Electrical Schematic (786178). . . . . . . . . . . . . . . . . 4-18

Briggs & Stratton Electrical Schematic (786186) . . . . . . . . . . . . . . 4-20

Kohler Electrical Schematic (792754). . . . . . . . . . . . . . . . . . . . . . . 4-22

Chapter 5 Contents

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

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

Drive Wheel Assembly—783134 . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Anti-Rollover Wheel Assembly—Honda and Briggs . . . . . . . . . . . . 5-5

Chapter 6 Contents

52" Deck Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

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

44" Deck Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

365262 6/06 c-1

Page 4

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

Blade Spindle Assembly Breakdown . . . . . . . . . . . . . . . . . . . . . . . 6-13

Chapter 7 Contents

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

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

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

Chapter 8 Contents

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

52" Deck Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

44" Deck Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

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

c-2 365262 6/06

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Chapter 1

General Information

This Manual covers FasTrak 20/52 model 926501, FasTrak 18/44 model 926519, FasTrak 16/44 model 926527, FasTrak 18/52 model 926592, FasTrak 17.5/52 model 926600, FasTrak 17.5/44 model 926774, FasTrak 18/44 model

927442, & Fastrak 20/52 model 927459.

Frequently Ordered Parts

PART NO. DESCRIPTION

784231 Pump Drive A-Section Belt 784249 52" Deck B-Section Belt 784322 44" Deck B- Section, Belt 785626 Fuel Filter 785600 Honda 18 & 20 HP Air Filter 785618 Honda 18 & 20 HP Air Filter Precleaner 785634 Honda 18 & 20 HP Engine Oil Filter 787226 Honda 16 HP Air Filter 787234 Honda 16 HP Engine Oil Filter 786988 Air Cleaner Cartridge, Briggs & Stratton 787002 Oil Filter, Briggs & Stratton Engine 794370 Kohler Paper Air Filter 747303 Kohler Engine Oil Filter 068478 Kohler Fuel Filter In-line 789511 Filter Kit, C-IZT

Service Literature

PART NO. DESCRIPTION

365270 FasTrak Owner’s Manual 785642 Honda 18 & 20 HP Engine Manual 787242 Honda 16 HP Engine Manual 786962 17.5 HP Briggs & Stratton ELS Engine Manual 794313 Kohler Courage Engine Manual

Options

PART NO. DESCRIPTION

365668 52" FasTrak Mulch Kit 365684 44" FasTrak Mulch Kit 785428 16" CW Gator Blade 785436 18" CW Gator Blade 793331 Armrest Kit (Michigan Seat) 784850 Armrest Kit (Milsco Seat) 367425 FasTrak Seat Spring Kit 367656 FasTrak Hour Meter Kit

Note: When ordering parts, you must use the p art numb er a s shown for ea ch 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

365262 6/06 1-1

Page 6

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.

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 torq ue is shown in the Notes section n ext to the fastener

SIZE FT-LBS NM SIZE FT-LBS NM

.250 8.2 11.1 M3 1 1.3 .312 17 23 M4 2.2 3 .375 30 40 M5 4.5 6.1 .438 48 65 M6 7.7 10.4 .500 73 99 M8 18.5 25 .562 105 143 M10 37 50 .625 145 200 M12 64 87 .750 260 350 M16 160 215 .875 420 565 M20 320 435

1.00 625 850 M24 555 750

NOTE:

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

1-2 365262 6/06

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Chapter 2 Contents

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

Idler Plate Rivet Nut Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Engine Guard Rivet Nut Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Footrest Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

365262 6/06 2-1

Page 8

Tractor Frame Rivet Nut Installation

INDEX

NO.

SERVICE

PART NO.

1 N/A 808485 11 RIVET NUT, 5/16-18 THREAD 2 546044 365544 1 44” FASTRAK FRAME

545962 361667 1 52" FASTRAK FRAME

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

2-2 365262 6/06

Page 9

Idler Plate Rivet Nut Installation

INDEX

NO.

SERVICE

PART NO.

1 N/A 808485 3 RIVET NUT, 5/16-18 THREAD 2 363952 363952 1 IDLER PLATE

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

365262 6/06 2-3

Page 10

Engine Guard Rivet Nut Installation

INDEX

NO.

SERVICE

PART NO.

1 364885 364885 1 ENGINE GUARD 2 N/A 808485 2 RIVET NUT, 5/16-18 THREAD

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

2-4 365262 6/06

Page 11

Footrest Assembly

TRACTOR FRAME

INDEX

NO.

SERVICE

PART NO.

1 785493 785493 2 LOWER STEP TREAD 2 785485 785485 2 UPPER STEP TREAD 3 011320 011320 4 CB .375-16 X .750 STD ZN 4 355651 355651 1 FLOOR PLATE 5 054502 054502 4 NT .375-16 HX GRD 5 ZNYC 6 767954 767954 4 FW .406 X .812 X .060 SAE HD ZN

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

365262 6/06 2-5

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2-6 365262 6/06

Page 13

Chapter 3 Contents

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

Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

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

Hydro Transmission Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Towlink Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

365262 6/06 3-1

Page 14

Battery Installation

2 12

IDLER PLATE

TRACTOR FRAME

3-2 365262 6/06

Page 15

Battery Installation

INDEX

NO.

1 2

4 1

3 4

10 771428 771428 1 BATTERY CABLE BOOT-RED 11 034280 034280 5 CS .312-18 X .750 HX G5 ZNYC 12 034272 034272 2 NT .312-18 HX G5 ZNYC 13 364174 364174 1 BATTERY SUPPORT 14 779850 779850 2 CB .312-18 X 3.00 FUL ZN

SERVICE

PART NO.

1 058776 058776 2 NT .312-18 HX NL ZNYC 2 768523 768523 7 FW .343 X .687 X .051/.080 HD ZNYC 3 348417 348417 1 BATTERY CLAMP STRAP 4 055939 055939 2 CS .250-20 X .750 HX G5 ZNYC 5 029868 029868 4 LW .250 INT-EXT TOOTH ZNYC 6 024927 024927 2 NT .250-20 HX GR.5 ZNYC 7 785063 785063 1 POSITIVE BATTERY CABLE 7 786632 786632 1 POSITIVE BATTERY CABLE

793216 793216 1 POSITIVE BATTERY CABLE 8 785071 785071 1 NEGATIVE BATTERY CABLE 8 786640 786640 1 NEGATIVE BATTERY CABLE

795146 795146 1 NEGATIVE BATTERY CABLE 9 740696 740696 1 BATTERY (VU1LH-8)

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Used on mowers with Honda 18 & 20 HP engines.

2. Used on mowers with Briggs & Stratton engines, and Honda 16 HP engines.

3. Used on mowers with Honda 16 HP Engines.

4. Used on mowers with Kohler engines

5. Used on mowers with Briggs & Stratton engines.

365262 6/06 3-3

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Deck Lift Assembly

3-4 365262 6/06

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Deck Lift Assembly

INDEX

NO.

10 781229 781229 1 CE .750 X 2.25 X 1.75 HEADLESS 11 784488 784488 1 DECK LIFT INDICATOR 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 767962 767962 2 FW .531 X 1.063 X .090 SAE HD ZN 16 015495 015495 4 GREASE FITTING STRAIGHT

SERVICE

PART NO.

1 348318 348318 1 STOP HANDLE 2 348284 348284 1 HEIGHT ADJUSTOR STOP 3 781294 781294 7 CLIP E, 1.00 X .625 X .050 4 784686 784686 6 FW .812 X 1.469 X .134 THK ZNYC 5 782995 018846 2 DECK LIFT SPRING 6 055749 055749 3 CS .437-14 X 1.750 HX G5 ZNYC 7 360131 360131 4 DECK LIFT CHAIN 8 704643 704643 8 NT .437-14 HX FLG ZN 9 781831 781831 1 CS.437-14 X 1.750 FULTH G5 ZNYC

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

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

365262 6/06 3-5

Page 18

Steering and Brake Assembly

}

3-6 365262 6/06

Page 19

Steering and Brake Assembly

INDEX

NO.

10 362251 362251 2 CRANK PIVOT 11 036236 036236 9 CS .312-18 X 1.000 HX G5 ZNYC 12 034272 034272 12 NT .312-18 HX G5 ZNYC 13 784405 784405 2 FIXED ASSEMBLY PUMP ROD 14 784355 784355 1 LH PUMP ROD ADJUSTER ASSEMBLY 15 784371 784371 1 RH PUMP ROD ADJUSTER ASSEMBLY 16 781211 781211 2 PUSH BUTTON SWITCH 17 063198 063198 4 CS 10-24 X .75 HXFLK ZNYC 18 059832 059832 6 NT #10-24 HX NL ZN 19 770867 770867 8 PLASTIC BUSHING, .750 X 1.00 X .50 20 784439 784439 4 LOCK COLLAR .750" 21 359737 359737 2 BRAKE TUBE 22 359745 359745 2 BRAKE LINK 23 784421 784421 2 BRAKE TENSION SPRING 24 023655 023655 6 NT .312-24 HX NL ZNYC 25 017251 017251 2 CP .156D X 1.000 LG HML ZN 26 785162 785162 2 SB .250 X 1.00 SH #10-24 ZNYC 27 787879 787879 1 LH ROLLER ARM

28 787887 787887 1 RH ROLLER ARM

29 363176 363176 1 LEFT STEER ARM SUPPORT 30 361550 361550 1 RIGHT STEER ARM SUPPORT 31 783696 783696 2 CENTERING DAMPENER 32 781922 781922 4 DAMPER BALL STUD 33 361295 361295 1 PIVOT TUBE

SERVICE

PART NO.

1 781260 N/A 2 STEERING BAR GRIP 2 360487 360487 2 STEERING BAR 3 086660 086660 6 NT .375-16 HX LK NY 4 767954 767954 14 FW .406 X .812 X .060 SAE HD ZN 5 705178 705178 6 CS .375-16 X 1.750 HX G5 ZNYC 6 363812 363812 2 STEER ARM SUPPORT 7 360677 360677 2 STEERCRANK LEVER 8 768523 768523 31 FW .343 X .687 X .051/.080 HD ZNYC 9 768259 N/A 4 INGUS BUSHING, #MFI-0810-05

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Includes two (2) of 768259 (Ingus Bushing, #MFI-0810-05).

2. Includes 078386 FW and 784819 Retaining Ring.

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

365262 6/06 3-7

Page 20

Hydro Transmission Installation

2 3

9 10

PARKING PAWL

13 11

TRACTOR FRAME

3-8 365262 6/06

Page 21

Hydro Transmission Installation

INDEX

NO.

10 050161 050161 1 CS .312-18 X 1.750 HX G5 ZNYC 11 034272 034272 14 NT .312-18 HX G5 ZNYC 12 043067 043067 6 CS .312-18 X 3.00 HX G5 ZNYC 13 768523 768523 14 FW .343 X .687 X .051/.080 HD ZNYC 14 712927 712927 10 FW .344 X 1.00 X .12 HRD ZNYC 15 785113 785113 6 CS .312-18 X 4.250 HX G5 ZNYC 16 361212 361212 1 LOWER MOUNT SUPPORT 17 788067 788067 1 LEFT PUMP/MOTOR COMBO 18 788059 788059 1 RIGHT PUMP/MOTOR COMBO 19 786301 786301 1 IZT BREATHER SLEAVE

SERVICE

PART NO.

1 784231 784231 1 A-SECTION PUMP BELT 2 025007 025007 2 CS .625-11 X 1.750 HX G5 ZNYC 3 028118 028118 2 FW .62 X 1.00 X .134 ZNYC 4 784827 784827 2 4.00"OD, 5/8"ID IDLER PULLEY 5 061101 061101 1 NT .750-10 HX NL ZN 6 025296 025296 1 FW .760 X 1.625 X .08 ZNYC 7 781153 781153 2 UHMW BUSHING 8 363788 363788 1 PUMP IDLER 9 781302 781302 1 IDLER SPRING

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Service parts for Left/Right Pump/Motor Combo:

784306 RIGHT HAND PARKING PAWL 784314 LEFT HAND PARKING PAWL 785725 FAN 785717 PULLEY 785733 SEAL KIT

365262 6/06 3-9

Page 22

To wlink Installation

TRACTOR ASSEMBLY

BYPASS ARM

FOR MOWERS WITH KOHLER ENGINES

BYPASS ARM

FOR MOWERS WITH HONDA ENGINES

INDEX

NO.

1 786269 786269 2 TOW RELEASE LINK 2 066878 066878 2 CP .094 X .500 LG HML ZN 3 794651 794651 1 TOW LINK, LH FST KOH

SERVICE

PART NO.

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

3-10 365262 6/06

Page 23

Chapter 4 Contents

Honda 18 & 20 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . . 4-2

Honda16 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Briggs & Stratton 17.5 HP Engine Installation . . . . . . . . . . . . . . . . . . 4-6

Kohler 18 & 20 HP Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . 4-8

Fuel System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Instrument Panel Assembly/Installation. . . . . . . . . . . . . . . . . . . . . . 4-14

Honda 18 & 20 HP Electrical Schematic (784868) . . . . . . . . . . . . . 4-16

Honda 16 HP Electrical Schematic (786178) . . . . . . . . . . . . . . . . . 4-18

Briggs & Stratton 17.5 HP Electrical Schematic (786186). . . . . . . . 4-20

Kohler 18 & 20 HP Electrical Schematic . . . . . . . . . . . . . . . . . . . . . 4-22

365262 6/06 4-1

Page 24

Honda 18 & 20 HP Engine Installation

BLK

RED/BLK

PA RT OF ENGINE

YEL

24 25

PUR

TAN/RED

BRN

GRA/PUR

PART OF ENGINE

1 2

{

4-2 365262 6/06

Page 25

Honda 18 & 20 HP Engine Installation

INDEX

NO.

10 000398 000398 1 CLAMP 11 784868 784868 1 FASTRAK WIRE HARNESS 12 024927 024927 2 NT .250-20 HX GR 5 ZNYC 13 017038 017038 2 LW .250 MED SPRING ZNYC 14 785477 N/A 1 HONDA 20 AMP RECTIFIER 15 056077 056077 2 CS .250-20 X 1.00 HX G5 ZNYC 16 768515 768515 2 FW .250 X .560 X .04 SAE ZNYC 17 712372 712372 1 KEY 1/4 SQ X 0.66 LONG 18 786616 786616 1 PUMPDRIVE PULLEY 19 784835 784835 1 FASTRAK CLUTCH 20 763417 763417 1 FW .454 X 1.50 X .250 21 785048 785048 1 CS .437-20 X 3.00 HX G5 ZNYC 22 785063 N/A 1 POSITIVE BATTERY CABLE 23 785071 N/A 1 NEGATIVE BATTERY CABLE 24 034272 034272 5 NT .312-18 HX G5 ZNYC 25 768523 768523 3 FW .343 X .687 X .051/.080 HD ZNYC 26 712927 712927 4 FW .344 X 1.00 X .12 HRD ZNYC 27 029876 029876 4 LW .312 INT-EXT TOOTH ZNYC 28 052837 052837 4 CS .312-18 X 1.500 HX G5 ZNYC 29 000331 000331 1 SMALL/SHORT WIRE TIE 30 791251 N/A 1 CLUTCH WIRE HARNESS PIGTAIL 31 784918 784918 1 RUBBER BUMPER

SERVICE

PART NO.

1 784629 784629 1 HONDA 20HP ENGINE

784611 784611 1 HONDA 18HP ENGINE 2 784843 784843 1 18/20 HONDA MUFFLER 3 720177 720177 2 CS M 8-1.25 X 20 10.9 HX FL ZNYC 4 785378 785378 1 EXHAUST PIPE CLAMP 5 784959 784959 1 FASTRAK MUFFLER MANIFOLD 6 785543 N/A 2 HONDA (20) MUFFLER GASKET 7 017004 N/A 4 LW .312 MED SPRING ZNYC 8 782664 N/A 4 NT M8-1.25 HX STAINLESS STEEL 9 050161 050161 1 CS .312-18 X 1.75 HX G5 ZNYC

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Part of Item 11 (784868 FasTrak wire harness).

2. Two wires.

3. Connected to Item 11 (784868 FasTrak wire harness).

4. Torque to 45-48 ft-lb.

5. Engine oil capacity; 2.3 US qts. (with filter), see engine manual.

6. Engine speed; High speed - 3450 ±50 RPM.

365262 6/06 4-3

Page 26

Honda 16 HP Engine Installation

PART OF ENGINE

{

FROM RECTIFIER

PART OF ENGINE

BLK

RED

RED/BLK

YEL

CONNECTED TO ITEM 11

ROUTE CARBURATOR OVERFLOW HOSE AS SHOWN

TO ENGINE (4 WIRES)

4-4 365262 6/06

Page 27

Honda 16 HP Engine Installation

INDEX

NO.

10 712927 712927 4 FW .344 X 1.00 X .12 HRD ZNYC 11 786178 786178 1 FASTRAK 16 HONDA WIRE HARNESS 12 739144 792796 13 786640 N/A 1 NEGATIVE BATTERY CABLE 14 725267 725267 2 FW .318 X .472 X .047 ZN 15 786632 N/A 1 POSITIVE BATTERY CABLE 16 782664 782664 1 NT M8-1.25 HX STAINLESS STEEL 17 768515 768515 2 FW .250 X .560 X .04 SAE ZNYC 18 017038 017038 2 LW .250 MED SPRING ZNYC 19 056077 056077 2 CS .250-20 X 1.00 HX G5 ZNYC 20 024927 024927 2 NT .250-20 HX GR.5 ZNYC 21 787267 N/A 1 HONDA 16 AMP RECTIFIER 22 029876 029876 4 LW .312 INT-EXT TOOTH ZNYC 23 050161 050161 4 CS .312-18X1.750 HX G5 ZNYC 24 712372 712372 1 KEY 1/4 SQ X 0.66 LONG 25 000331 000331 1 SMALL/SHORT WIRE TIE 26 786616 786616 1 PUMPDRIVE PULLEY 27 791251 N/A 1 CLUTCH WIRE HARNESS PIGTAIL 28 784835 784835 1 FASTRAK CLUTCH 29 784918 784918 1 RUBBER BUMPER 30 763417 763417 1 FW .454 X 1.50 X .250 31 785048 785048 1 CS .437-20 X 3.00 HX G5 ZNYC 32 378273 378273 1 16HP EXHAUST HEAT SHIELD 33 043570 043570 1 SINGLE HOSE CLIP

SERVICE

PART NO.

1 785394 785394 1 HONDA 16 HP ENGINE 2 785410 785410 1 16 HONDA MUFFLER 3 034280 034280 2 CS .312-18 X .750 HX G5 ZNYC 4 768523 768523 5 FW .343 X .687 X .051/.080 HD ZNYC 5 785378 785378 1 EXHAUST PIPE CLAMP 6 785543 N/A 2 HONDA MUFFLER GASKET 7 005231 005231 4 NT M6-1.0 X10 HX FLG ZN 8 785402 785402 1 FASTRAK 16 HP MUFFLER MANIFOLD 9 034272 034272 7 NT .312-18 HX G5 ZNYC

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Part of item 11 (786178 FasTrak 16 Honda Wire Harness).

2. Torque to 45-48 ft-lb.

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

4. Engine speed; High speed - 3450 ±50 RPM.

365262 6/06 4-5

Page 28

Briggs & Stratton 17.5 HP Engine Installation

}

PART OF

ENGINE

BLK

30 PUR RED

BRN TAN/RED

PUR

RED/BLK

4-6 365262 6/06

Page 29

Briggs & Stratton 17.5 HP Engine Installation

INDEX

NO.

10 786954 786954 1 FITTING 90, -6MPT/-6FPT 11 771378 771378 1 16.00” PUSHLOC HYDRO HOSE 12 029876 029876 4 LW .312 INT-EXT TOOTH ZNYC 13 050161 050161 4 CS .312-18X1.750 HX G5 ZNYC 14 712927 712927 4 FW .344 X 1.00 X .12 HRD ZNYC 15 000331 000331 1 SMALL, SHORT WIRE TIE 16 791251 N/A 1 CLUTCH PIGTAIL WIRE HARNESS 17 712372 712372 1 1/4 SQ X 0.66 LONG KEY 18 786616 786616 1 PUMPDRIVE PULLEY 19 784835 784835 1 FASTRAK CLUTCH 20 784918 784918 1 RUBBER BUMPER 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 785071 N/A 1 NEGATIVE BATTERY CABLE 24 786186 786186 1 FASTRAK 17.5 WIRE HARNESS 25 768820 768820 1 BATTERY CABLE 26 768515 768515 7 FW .281 X .625 X .051/.080HD ZNYC 27 024927 024927 5 NT .250-20 HX GR.5 ZNYC 28 055947 055947 2 CS .250-20 X .500 HX G5 ZNYC 29 044255 044255 1 NT #10-32 HX ZN 30 786632 N/A 1 POSITIVE BATTERY CABLE 31 030817 030817 1 STARTER SOLENOID

SERVICE

PART NO.

1 786004 786004 1 BRIGGS 17.5 HP ELS SINGLE ENGINE 2 780841 780841 1 MUFFLER GASKET 3 786012 786012 1 17.5 HP BRIGGS MUFFLER MANIFOLD 4 016287 016287 2 CS .312-18 X 1.00 HXFLK ZNYC 5 785410 785410 1 MUFFLER 6 034280 034280 2 CS .312-18 X .75 HX G5 ZNYC 7 768523 768523 5 FW .343 X .687 X .051/.080 HD ZNYC 8 785378 785378 1 1.50" MUFFLER CLAMP 9 034272 034272 6 NT .312-18 HX G5 ZNYC

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Part of Item 24 (786186 FasTrak 17.5 HP B & S Wire Harness).

2. Connected to Item 24 (786186 FasTrak 17.5 HP B & S Wire Harness).

3. Torque to 45-48 ft-lb.

4. Engine oil capacity; 1.5 US qts. (see engine manual).

5. Engine speed; High speed - 3450 ±50 RPM.

365262 6/06 4-7

Page 30

Kohler 18 & 20 HP Engine Installation

TO STARTER

FROM NEGATIVE BATTERY TERMINAL

4 5 7

TO STARTER SOLENOID

RED/BLK

FROM POSITIVE BATTERY TERMINAL

YEL

4-8 365262 6/06

Page 31

Kohler 18 & 20 HP Engine Installation

INDEX

NO.

10 793885 793885 4 LW .375 INT-EXT TOOTH 11 036244 792788 4 CS .375-16X1.000 HX G5 ZNYC

12 712372 712372 1 KEY 1/4 SQ X 0.66 LONG 13 786616 786616 1 PUMPDRIVE PULLEY 14 000331 000331 1 SMALL/SHORT WIRE TIE 15 791251 N/A 1 CLUTCH PIGTAIL, WIRE HARNESS 16 784835 784835 1 FASTRAK CLUTCH 17 763417 763417 1 FW .454 X 1.50 X .250 18 785048 785048 1 CS .437-20 X 3.00 HX G5 ZNYC 19 796516 796516 1 VALVE,OIL DRAIN 3/8-18 20 104786 104786 1 OIL DRAIN HOSE 21 768523 768523 9 FW .343 X .687 X .051/.080 HD ZNYC 22 043570 043570 1 SINGLE HOSE CLIP 23 017004 017004 2 LW .312 MED SPRING ZNYC 24 782664 782664 2 NT M8-1.25 HX STAINLESS 25 034272 034272 3 NT .312-18 HX G5 ZNYC 26 792739 792739 1 18/20HP KOHLER COURAGE MANIFOLD 27 792747 792747 1 18/20HP KOHLER COURAGE MUFFLER 28 016253 016253 2 CB .312-18 X .750 FUL ZN 29 794180 794180 1 1.125" EXHAUST CLAMP 30 034280 034280 5 CS .312-18 X .750 HX G5 ZNYC 31 756270 756270 1 CS .312-18 X 1.50 FLTHR GR5 ZNYC 32 337444 337444 1 FST - KOHLER ENGINE GUARD 33 781708 N/A 2 CS .500-13 X 4.25 HX G5 ZNYC 34 767962 N/A 4 FW .531 X 1.063 X .090 SAE HD ZN 35 031997 N/A 2 ANTI-SCALP WHEEL 36 053199 N/A 2 NT .500-13 HX JAM ZNYC 37 344267 344267 4 FW .510 X 2.15 X .187 SPL ZNYC 38 781567 781567 2 NT .50-13 HX LK NY ZNYC

SERVICE

PART NO.

1 792713 792713 1 KOHLER 18 HP SV540S ENGINE

792721 792721 1 KOHLER 20 HP SV600S ENGINE 2 739144 739144 1 CS M 6-1.0 X 12 10.9 HXFL ZN 3 792754 792754 1 FST 44/52 KOHLER WIRE HARNESS 4 055939 055939 2 CS .250-20 X .750 HX G5 ZNYC 5 768515 768515 6 FW .281 X .625 X .051/.080 HD ZNYC 6 044255 044255 1 NT #10-32 HX ZN 7 030817 030817 1 STARTER SOLENOID 8 792762 792762 1 RED 9" BATTERY CABLE 9 024927 024927 4 NT .250-20 HX GR.5 ZNYC

788166 788166 2 ANTI SCALP WHEEL ASSY

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Included with engine.

2. Part of item 3 (792754 FasTrak Kohler wire harness).

3. Torque to 45-48 ft-lb.

4. Engine oil capacity: 1.6 US qts.

5. Engine speed: 3600 ±50 RPM.

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Page 32

6. Includes Items 31 through 33.

7. Torque to 30-35 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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365262 6/06 4-11

Page 34

Fuel System Installation

4-12 365262 6/06

Page 35

Fuel System Installation

INDEX

NO.

10 791277 N/A 2 FUEL TANK 90° FITTING

11 000323 000323 6 CLIP 12 745059 745059 1 FUEL VALVE 3-WAY

SERVICE

PART NO.

1 784181 784181 2 FUEL TANK CAP 2 796318 796318 1 R.S. FUEL TANK 3 796326 796326 1 L.S. FUEL TANK 4 055822 055822 12 CS .375-16 X .750 HX G5 ZNYC 5 712919 712919 12 FW .406 X 1.00 X .12 HRD ZNYC 6 000331 000331 5 SMALL/SHORT WIRE TIE 7 015818 015818 1 FUEL LINE, 33” 8 015818 015818 1 FUEL LINE, 35"

015818 015818 1 FUEL LINE, 21" 015818 015818 1 FUEL LINE, 12"

9 015818 015818 1 FUEL LINE, 14"

MFG. PART

NO.

QTY. DESCRIPTION

3 4 5

NOTES:

1. Torque to 20 ft.-lbs.

2. Supplied with new fuel tank.

3. Length for mowers with Honda engines only.

4. Length for mowers with Briggs & Stratton engines only.

5. Length for mowers with Kohler engines only.

365262 6/06 4-13

Page 36

Instrument Panel Assembly/Installation

RIGHT SIDE FUEL TANK

10a

20a

FUSE SIZE AND LOCATION

4-14 365262 6/06

Page 37

Instrument Panel Assembly/Installation

INDEX

NO.

10 026237 N/A 2 RELAY

11 768879 768879 1 ENGINE CONTROLS CABLE (HONDA 18 & 20, KOHLER AND , & 17.5 BRIGGS)

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

PART NO.

1 785196 785196 1 CHOKE CABLE (HONDA 18 & 20 AND KOHLER ENGINES)

785030 785030 1 CHOKE CABLE (HONDA 16) ENGINE

786657 786657 1 CHOKE CABLE (17.5 BRIGGS, STRATTON ENGINE) 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 365411 365411 1 INSTRUMENT PANEL

787788 787788 1 THROTTLE CABLE ASSEMBLY (HONDA 16 ONLY)

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Part of 784868, 786186, 792754 or 786178 (Tractor Wire Harness).

365262 6/06 4-15

Page 38

Honda 18 & 20 HP Electrical Schematic (784868)

4-16 365262 6/06

Page 39

Honda 18 & 20 HP Electrical Schematic (784868)

365262 6/06 4-17

Page 40

Honda 16 HP Electrical Schematic (786178)

4-18 365262 6/06

Page 41

Honda 16 HP Electrical Schematic (786178)

365262 6/06 4-19

Page 42

Briggs & Stratton Electrical Schematic (786186)

4-20 365262 6/06

Page 43

Briggs & Stratton Electrical Schematic (786186)

365262 6/06 4-21

Page 44

Kohler Electrical Schematic (792754)

4-22 365262 6/06

Page 45

Kohler Electrical Schematic (792754)

365262 6/06 4-23

Page 46

4-24 365262 6/06

Page 47

Chapter 5 Contents

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

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

Drive Wheel Assembly—783134. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Anti-Rollover Wheel Assembly—Honda and Briggs . . . . . . . . . . . . . 5-5

365262 6/06 5-1

Page 48

Front Wheel Assembly

INDEX

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 767962 767962 4 FW .531 X 1.063 X .090 SAE HD ZN 8 781567 781567 2 NT .50-13 HX LK NY ZNYC

9 042630 042630 2 CS .500-13 X 6.50 HX G5 ZNYC 10 306969 306969 2 GAGE WHEEL SPACER 11 768044 768044 2 TIRE/WHL 11 X 4-5 RIBBED

SERVICE

PART NO.

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Apply grease to zerks.

2. Torque to 75 ft.-lbs.

3. Assemble with extended inner race down.

5-2 365262 6/06

Page 49

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.

365262 6/06 5-3

Page 50

Drive Wheel Assembly—783134

INDEX

NO.

SERVICE

PART NO.

1 784264 784264 2 WHEEL/TIRE ASSY 18 X 9.50 (QTY PER 52" TRACTOR) 2 784272 N/A 1 TIRE 18 X 9.5 3 784280 N/A 1 WHEEL 4 019521 N/A 1 TIRE VALVE 5 061077 061077 4 WHEEL NUT (QTY PER WHEEL)

1 783134 783134 2 WHEEL/TIRE ASSY 18 X 8.50 (QTY PER 44" TRACTOR) 2 783142 N/A 1 TIRE 18 X 8.50 3 783159 N/A 1 WHEEL 4 019521 N/A 1 TIRE VALVE

061077 061077 4 WHEEL NUT (QTY PER WHEEL)

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Inflate tire to 8-10 psi.

2. Torque to 65 ft-lbs

5-4 365262 6/06

Page 51

Anti-Rollover Wheel Assembly—Honda and Briggs

TRACTOR FRAME

INDEX

NO.

10 365478 365478 1 MUFFLER GUARD 11 034272 034272 3 NT .312-18 HX G5 ZNYC 12 000398 000398 1 CLAMP

13 378703 378703 1 CHOKE & THROTTLE CABLE BRACKET 14 377242 377242 1 FUEL LINE MOUNTING BRACKET 15 756270 756270 1 CS .312-18 X 1.50 FLTHR GR5 ZNYC 16 043570 043570 1 SINGLE HOSE CLIP

5 6 17

SERVICE

PART NO.

1 364885 N/A 1 ENGINE GUARD 2 768523 768523 12 FW .343 X .687 X .051/.080HD ZNYC 3 034280 034280 9 CS .312-18 X .750 HX G5 ZNYC 4 781567 781567 2 NT .50-13 HX LK NY 5 344267 344267 4 FW .510X 2.15X.187 SPL ZNYC 6 767962 N/A 4 FW .531 X 1.063 X .090 SAE HD ZN 7 053199 N/A 2 NT .500-13 HX JAM ZNYC 8 031997 N/A 2 ANTI-SCALP WHEEL 9 781708 N/A 2 CS .500-13 X 4.250 HX G5 ZNYC

000398 000398 1 CLAMP 788166 788166 2 ANTI SCALP WHEEL ASSEMBLY

MFG. PART

NO.

QTY. DESCRIPTION

365262 6/06 5-5

Page 52

NOTES:

1. Includes Items 6 through 9.

2. Bolts to muffler bracket for 18 & 20 HP Honda engines and to item 10 for 16 HP Honda and 17.5 HP Briggs engines.

3. Used on18 & 20 HP Honda only.

4. Used on 16 HP Honda only..

5. Used on 16 HP Honda only. .

6. Used on 17.5 HP Briggs only.

7. See Kohler engine installation for Kohler configuration.

5-6 365262 6/06

Page 53

Chapter 6 Contents

52" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

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

44" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

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

Blade Spindle Assembly Breakdown. . . . . . . . . . . . . . . . . . . . . . . . 6-13

365262 6/06 6-1

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52" Deck Assembly

6-2 365262 6/06

Page 55

52" Deck Assembly

INDEX

NO.

10 034272 034272 2 NT .312-18 HX G5 ZNYC 11 781880 781880 1 .500X 1.00X .312 X.188 BUMPER 12 781708 N/A 4 CS .500-13 X 4.250 HX G5 ZNYC 13 767962 N/A 12 FW .531 X 1.063 X.090 SAE HD ZN 14 031997 N/A 4 ANTI-SCALP WHEEL 15 053199 N/A 4 NT .50-13 HX JAM ZNYC 16 781567 781567 4 NT .50-13 HX LK NY 17 545970 356212 1 52" FASTRAK DECK

18 055822 055822 2 CS .375-16 X .750 HX G5 ZNYC 19 N/A 808485 4 5/16-18 THREAD RIVET NUT

SERVICE

PART NO.

1 357111 357111 1 FASTRAK DISCHARGE CHUTE 2 063297 063297 2 SB .375 X .500 SH .312-18 TD ZN 3 058776 058776 2 NT .312-18 HX NL ZNYC 4 767954 767954 8 FW .406 X .812 X .060 SAE HD ZN 5 054502 054502 2 NT .375-16 HX GRD 5 ZNYC 6 357103 357103 1 DISCHARGE CHUTE MOUNT BRACKET 7 034280 034280 2 CS .312-18 X .750 HX G5 ZNYC 8 768523 768523 4 FW .343 X .687 X .051/.080HD ZNYC 9 787994 787994 2 DECK PIN & ROD ASSEMBLY

788166 788166 4 ANTI SCALP WHEEL ASSEMBLY

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Factory assembled in top hole for shipping purposes.

2. Includes items 12 through 15.

3. When ordering replacement decks, also order 6 each of Items 6 and 7, 1 each of Item 8, 9, and 12, from Deck Pulley Assembly. Replacement decks include decals, see “52" Deck Decals” on page 8-4.

4. Includes one each of:

784736 DECK PULL ROD ASSY 362988 DECK PIN

365262 6/06 6-3

Page 56

52" Deck Pulley Assembly

52" DECK SHOWN

6-4 365262 6/06

Page 57

52" Deck Pulley Assembly

INDEX

NO.

10 10 10

10 600296 600296 1 SPACER DECK IDLER

11 350884 350884 1 DECK IDLER

12 786335 786335 1 UHMW (.03 THICK)

13 781302 781302 1 IDLER SPRING 14 259812 059931 1 SPRING CHAIN

15 361147 361147 1 R.S. PULLEY COVER 16 361154 361154 1 L.S. PULLEY COVER 17 064006 064006 4 CS .312-18 X .625 HX G5 ZNYC 18 768523 768523 10 FW .343 X.687 X .051/.080HD ZNYC 19 781872 781872 6 CS .625-11 X 1.25 HX G5 ZNYC 20 782474 782474 8 CW .631 2.250 X .187 PNT 21 786889 786889 3 DECK DRIVE 5.25 PULLEY 22 783506 783506 3 BLADE SPINDLE ASSEMBLY 23 783753 783753 3 18" X 2.50 X 0.204 .631 DIA BLADE 24 005116 005116 12 CS .375-16 X 1.375 HX G5 ZNYC 25 767954 767954 24 FW .406 X .812 X .060 SAE HD ZN 26 783738 783738 2 CS .625-11X3.00 FULL HX G5 ZN 27 054502 054502 12 NT .375-16 HX GRD 5 ZNYC 28 058776 058776 6 NT .312-18 HX NL ZNYC 29 079186 079186 6 CS .312-18 X 1.25 HX G5 ZNYC

30 712927 712927 6 FW .344 X 1.00 X.12 HRD ZNYC

31 358317 358317 1 DECK IDLER

32 364315 364315 1 SPRING CHAIN

33 028118 028118 3 FW .62 X 1.00 X.134 ZNYC

34 102970 102970 1 MINI Z IDLER DECK

35 787069 787069 2 UHMW RISER DECK IDLER

36 785832 785832 2 UHMW CLAMP DECK IDLER

8 3

37 017129 017129 6 FW .440 X 1.000 X .083 ZNYC

38 784199 784199 6 CS .312-18 X1.25 FLT SH ZNYC

40 720193 720193 1 FW .656 X 1.125 X .06 ZNYC

SERVICE

PART NO.

1 784249 784249 1 B-SECTION BELT 2 016972 016972 2 NT .625-11 HX G5 ZNYC 3 046821 046821 3 FW .656 X 2.00 X .078 ZNYC 4 797449 797449 3 FW .650X1.00X.180 ZNYCG5 5 784504 784504 3 5.00" OD, 5/8" ID IDLER PULLEY 6 797910 797910 6 CS .312-18X1.50FLT SH ZY 7 600171 600171 1 UHMW DECK IDLER CLAMP 8 600189 600189 1 IDLER SLIDE UHMW RS 9 794446 794446 1 CS .625-11 X 1.50 HX G5 ZNYC

783878 N/A 2 UHMW IDLER CLAMP

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Torque to 118 ft. lbs.

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

3. Used on mowers with serial number prior to 02017202 (FIG. 6-1).

365262 6/06 6-5

Page 58

4. Used on mowers with serial numbers between 02017202 and 05050800 (FIG. 6-1).

FIG. 6-1

5. Used on mowers with serial numbers between 02057459 and 06023383.

6. Used on mowers with serial numbers prior to 02017202 and between 05050880 and 06023383 (FIG. 6-2).

7. Deck tensioning idler and spring chain used on mowers with serial number 05050800 and later.

8. Used on mowers with serial numbers 02017202 and later.

FIG. 6-2

9. Used on mowers with serial numbers 02057459 and later.

10. Used on mowers with serial numbers 06023383 and later.

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365262 6/06 6-7

Page 60

44" Deck Assembly

6-8 365262 6/06

Page 61

44" Deck Assembly

INDEX

NO.

10 034272 034272 2 NT .312-18 HX G5 ZNYC 11 781880 781880 1 .500X 1.00X .312 X.188 BUMPER 12 781708 N/A 3 CS .500-13 X 4.250 HX G5 ZNYC 13 767962 N/A 9 FW .531 X 1.063 X.090 SAE HD ZN 14 031997 N/A 3 ANTI-SCALP WHEEL 15 053199 N/A 3 NT .50-13 HX JAM ZNYC 16 781567 781567 3 NT .50-13 HX LK NY 17 546051 358242 1 44" FASTRAK DECK

18 055822 055822 2 CS .375-16 X .750 HX G5 ZNYC 19 N/A 808485 4 5/16-18 THREAD RIVET NUT

SERVICE

PART NO.

788166 788166 3 ANTI SCALP WHEEL ASSEMBLY

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Factory assembled in top hole for shipping purposes.

2. Includes items 12 through 15.

3. Quantity of 3 on mowers with serial number prior to 05050800.

4. When ordering replacement decks, also order 6 each of Items 6, and 7, and 1 each of Item 8, 9 and 12, from Deck Pulley Assembly. Replacement decks include decals, see “44" Deck Decals” on page 8-5.

5. Includes one each of:

784736 DECK PULL ROD ASSY 362988 DECK PIN

365262 6/06 6-9

Page 62

44" Deck Pulley Assembly

3 4

8 10

44" Deck

6-10 365262 6/06

Page 63

44"Deck Pulley Assembly

INDEX

NO.

10 10 10

10 600296 600296 1 DECK IDLER SPACER

11 350884 350884 1 IDLER DECK

12 786335 786335 1 UHMW (.03 THICK)

13 781302 781302 1 IDLER SPRING 14 364315 059931 1 SPRING CHAIN

15 360792 360792 1 R.S. PULLEY COVER 16 360818 360818 1 L.S. PULLEY COVER 17 064006 064006 4 CS .312-18 X .625 HX G5 ZNYC 18 768523 768523 10 FW .343 X.687 X .051/.080HD ZNYC 19 781872 781872 6 CS .625-11 X 1.25 HX G5 ZNYC 20 782474 782474 8 CW .631 2.250 X .187 PNT 21 792689 792689 3 DECK DRIVE 5.00 PULLEY 22 783506 783506 3 BLADE SPINDLE ASSEMBLY 23 784256 784256 3 15.66"-L-F-CW BLADE 24 005116 005116 12 CS .375-16 X 1.375 HX G5 ZNYC 25 767954 767954 24 FW .406 X .812 X .060 SAE HD ZN 26 783738 783738 2 CS .625-11X3.00 FULL HX G5 ZN 27 054502 054502 12 NT .375-16 HX GRD 5 ZNYC 28 058776 058776 6 NT .312-18 HX NL ZNYC 29 079186 079186 6 CS .312-18 X 1.25 HX G5 ZNYC

30 712927 712927 6 FW .344 X 1.00 X.12 HRD ZNYC

31 358317 358317 1 DECK IDLER

32 364315 364315 1 SPRING CHAIN

33 028118 028118 3 FW .62 X 1.00 X.134 ZNYC

34 102970 102970 1 MINI Z DECK IDLER

35 787069 787069 2 UHMW DECK IDLER RISER

36 785832 785832 2 UHMW DECK IDLER CLAMP

8 3

37 017129 017129 6 FW .440 X 1.000 X .083 ZNYC

38 784199 784199 6 CS .312-18 X 1.25 FLT SH ZNYC

39 720193 720193 1 FW .656 X 1.125 X .06 ZNYC

SERVICE

PART NO.

1 784322 784322 1 B-SECTION BELT 2 016972 016972 2 NT .625-11 HX G5 ZNYC 3 046821 046821 3 FW .656 X 2.00 X .078 ZNYC 4 797449 797449 3 FW .650X1.00X.180 ZNYCG5 5 784504 784504 3 5.00" OD, 5/8" ID IDLER PULLEY 6 797910 797910 6 CS .312-18 X1.25 FLT SH ZNYC 7 600189 600189 2 IDLER SLIDE UHMW RS 8 600171 600171 2 IDLER SLIDE UHMW LS 9 794446 794446 1 CS .625-11 X 1.50 HX G5 ZNYC

783878 N/A 2 UHMW IDLER CLAMP

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Torque to 118 ft. lbs.

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

3. Used on mowers with serial number prior to 02017202 (FIG 6-1).

365262 6/06 6-11

Page 64

4. Used on mowers with serial numbers between 02017202 and 05050800 (FIG. 6-1).

FIG. 6-1

5. Used on mowers with serial numbers between 02057459 and 06023383.

6. Used on mowers with serial numbers prior to 02017202 and between 05050880 and 06023383 (FIG. 6-2).

7. Deck tensioning idler and spring chain used on mowers with serial number 05050800 and later.

8. Used on mowers with serial numbers 02017202 and later.

FIG. 6-2

35 9

9. Used on mowers with serial numbers 02057459 and later.

10. Used on mowers with seial numbers 06023383 and later.

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Page 65

Blade Spindle Assembly Breakdown

INDEX

NO.

SERVICE

PART NO.

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

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

365262 6/06 6-13

Page 66

Chapter 7 Contents

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

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

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

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Deck Installation

TRACTOR ASSEMBLY

INDEX

NO.

1 781567 781567 2 NT .500-13 H8ZY NL 2 767962 767962 4 FW .531 X 1.063 X .090 SAE HD ZN 3 704643 704643 8 NT .437-14 HX FLG ZN 4 055749 055749 4 CS .437-14 X 1.750 HX G5 ZNYC 5 017616 017616 2 CS .500-13 X 1.750 HX G5 ZNYC

SERVICE

PART NO.

MFG. PART

NO.

QTY. DESCRIPTION

DECK ASSEMBLY

NOTES:

7-2 365262 6/06

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Deck 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.

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DECK CLUTCH

Page 69

Seat Installation

SEAT SUPPORT FROM

BOTTOM

INDEX

NO.

1 058776 058776 2 NT .312-18 HX NL ZNYC 2 768523 768523 10 FW .343 X .687 X .051/.080HD ZNYC 3 363507 363507 1 SEAT SUPPORT 4 064014 064014 4 CS .312-18 X .875 HX G5 ZNYC 5 781617 781617 3 RUBBER BUMPER 6 080358 080358 1 GM .50 X 1.00 X .75 X .12 7 047654 047654 2 CLIP 8 792226 792226 1 SEAT 9 034280 034280 4 CS .312-18X .750 HX G5 ZNYC

SERVICE

PART NO.

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Do not torque, Item 3 (363507 Seat Support) must pivot.

2. Service parts (Michigan Seat):

793315 SEAT SWITCH KIT 797464 ARMREST ASSEMBLY L.H. 797472 ARMREST ASSEMBLY R.H. 797480 MOLDED ARMREST KIT

3. Service parts (Milsco Seat):

782177 OPERATOR PRESENCE SWITCH

7-4 365262 6/06

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Chapter 8 Contents

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

52” Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

44" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

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Tractor Decals

8-2 365262 6/06

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Tractor Decals

INDEX

NO.

10 727016 727016 1 BATTERY DECAL 11 788968 788968 1 ENGINE COMPARTMENT DECAL 12 791830 791830 1 FUEL INDICATOR DECAL 13 793588 793588 1 HUSTLER NAME PLATE 14 600899 600899 1 PUMP BELT WARNING DECAL

SERVICE

PART NO.

1 N/A 083279 1 TURF PROD SERIAL NO PLATE 2 784710 784710 1 FASTRAK DECAL 3 788935 788935 1 DECK HEIGHT DECAL 4 785139 785139 1 FASTRAK LEFT SIDE STEERING DECAL 5 785220 785220 1 FASTRAK RIGHT SIDE STEERING DECAL 6 784702 784702 1 INSTRUMENT PANEL DECAL 7 785121 785121 1 OPERATION DECAL 8 785147 785147 1 SERVICE DECAL 9 771436 771436 1 STABILIZER DECAL

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

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52" Deck Decals

INDEX

NO.

1 781419 781419 1 BELT ROUTING DECAL 2 727438 727438 2 WHIRLING BLADES DECAL 3 727420 727420L 1 DEFLECTOR SHIELD DECAL 4 727453 727453 2 BELT & PULLEY DECAL 5 785535 785535 1 52 FASTRAK DECK ID DECAL 6 727172 727172 1 “MADE IN U.S.A.” DECAL 7 785055 785055 1 STEP TREAD

SERVICE

PART NO.

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

8-4 365262 6/06

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44" Deck Decals

INDEX

NO.

SERVICE

PART NO.

1 781419 781419 1 BELT ROUTING DECAL 2 727438 727438 2 WHIRLING BLADES DECAL 3 727420 727420 1 DEFLECTOR SHIELD DECAL 4 727453 727453 2 BELT & PULLEY DECAL 5 784801 784801 1 44 FASTRAK DECK ID DECAL 6 727172 727172 1 “MADE IN U.S.A.” DECAL

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

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8-6 365262 6/06

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Chapter 9 Contents

Maintenance & Adjustments Safety Precautions . . . . . . . . . . . . . . . .9-3

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

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-15

9-1

This spark ignition system complies with Canadian ICES-002.

The enclosed Engine Owner’s Manual is supplied for information regarding the U.S. Enviromental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance and warranty.

The engine exhaust from this product

contains chemicals known to the State

of California to cause cancer, birth

defects or other reproductive harm.

WARNING:

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9-2

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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

9-3

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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.

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

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.

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

727016

Part Number

727420

Part Number

727438

Part Number

727453

Part Number

771436

Keep engine and pump compartment(s) clean (especially in exhaust area) to prevent fire and provide maximum engine and hydraulic cooling.

Part Number

788968

9-4

▲

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

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

Keep engine and pump compartment(s) clean (especially in exhaust area) to prevent fire and provide maximum engine and hydraulic cooling.

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

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MAINTENANCE

MAINTENANCE LOCATOR

CHART

1a. Engine Oil Fill & Dipstick (Honda & Kohler) 1b. Engine Oil Fill & Dipstick (Briggs & Stratton) 2a. Fuel Filter (Honda) 2b. Fuel Filter (Briggs & Stratton)

2c. Fuel Filter (Kohler) 3a. Engine Air Cleaner (Honda) 3b. Engine Air Cleaner (Briggs & Stratton & Kohler) 4a. Engine Oil Drain Plug (Honda & Kohler) 4b. Engine Oil Drain Plug (Briggs & Stratton)

5. Battery

6. Fuel Tanks

7. Gauge Wheel Bearing Zerks (2)

8. Engine Oil Filter

9. Deck Lift Pivot Zerks (4)

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

9-5

365262 6/06

Page 81

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. Change the filter and oil using 20W50 motor oil. REFERENCES: a — Refer to Engine Owner’s Manual

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

Introduction

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

Gauge wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10 psi

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

2. Grease the four deck lift pivots, located to the side of the operator’s footrest 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 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

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) Prior to each use or every 4 hrs.

Clean foam element (4) 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

Grease gauge wheel bearings 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 and hydraulic 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 park brakes x

Change C-IZT pump/motor

transmission oil & filter (7) Every 200 hours or 2 years

9-6

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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 units

The integrated pump/motor units are accessed by lifting the seat platform. The seat platform is hinged at the front. To raise it, remove the two cap screws and tilt seat platform up and forward. (Fig. 9-4)

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 Hustler FasTrak 44/52 is equipped with two Hydro-Gear C-IZT integrated pump/motor transmissions. Fig. 9-5

Units built prior to serial number 03037002 are sealed for life and do not require scheduled service.

Units starting with serial number 03037002 and later have a replaceable filter which will require replacement every 200 hours or 2 years whichever comes first. The required service involves draining the oil and installing a new filter kit (Hustler p/n 789511). Fill with new 20W50 engine oil.

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.

To replace the filter use the following procedure:

1. Raise and block the tractor up so the drive wheels are off the floor. Place the jack stands under the engine guard to support the machine. Fig. 9-6

WARNING: Make sure the transmissions are cool before performing service procedures.

2. Remove the drain plug and filter from the integrated pump/motor transmission and drain the oil into a drain pan. Dispose of the oil in a proper manner. This oil will not be re-used. Fig. 9-7

3. Install a new filter kit into the transmission.

4. Remove the lower side plug and install the magnetic plug included

with the kit. Fig. 9-7

Figure 9-3

Fuse

Figure 9-2

Battery

Figure 9-4

Cap screws

Figure 9-5

C-IZT integrated

pump/motor

9-7

365262 6/06

Page 83

5. Repeat steps 2 through 4 for the other side.

6. Lower the tractor. NOTE: The FasTrak must be level when filling

and checking the oil.

7. Remove the breather hose and nipple from the top of the transmission and fill with new, clean 20W50 engine oil. It will require approximately 2 - 2.46 quarts of oil to fill the transmission. Re-attach the nipple and breather hose. Fig. 9-8

WARNING: Do not overfill. If you overfill the unit while it is “cold”, it may overflow as it reaches normal operating temperatures. The oil level should be within the operating range indicated on the dipstick. This will allow the space needed for the oil to expand as it warms up. Fig. 9-9

8. Start the unit and drive it forward and rearward 5 times approximately 10 - 20 feet each time. If it feels smooth then the unit is ready to operate. If either side moves slower than the other or sluggish then the system will need to be purged. Follow steps 9 through 12 until the air is purged from the system.

9. Raise and block the tractor up so the drive wheels are off the floor.

10. With the bypass valves open (Fig. 9-10), on both transmissions, an

operator on the seat and the engine running at 1/2 throttle, slowly move both control levers forward and rearward 5 to 6 times to allow air to be purged from the system. As this occurs, the oil level will drop.

11. With both bypass valves closed (Fig. 9-11) and the engine running, slowly move both control levers forward and rearward 5 - 6 times. Stop engine and place steering levers in the park brake position. Lower the tractor and check the oil level. Add oil as required.

12. Start the unit and drive it forward and rearward 5 times

approximately 10 - 20 feet each time. If it feels smooth then the unit is ready to operate. If either side moves slower than the other or sluggish then the system will need to be purged again. Follow steps 9 through 12

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

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. 9-12) Total

capacity for the fuel tanks is 12.2 U.S. gallon (46.18 liter).

When filling the fuel tanks disengage deck clutch, place control levers

in park brake position, and stop tractor engine. Clean around the fuel tank

Figure 9-7

Drain plug

& filter

Lower side plug

Figure 9-6

Jack stands

Engine

guard

Figure 9-8

Breather hose

Nipple

9-8

365262 6/06

Page 84

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. 9-13A, 9-13B & 9-13C) is installed in the fuel line between fuel tanks and engine fuel pump on the rear left side of the engine. 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 shutoff valve grommet for any cracks or leaks. Replace as needed.

Fuel Shut-off Valves

On early units a fuel shut-off valve is located on the outlet port of each fuel tank. (Fig. 9-14) Close these valves (turn clockwise) to prevent fuel flow to the engine. To drain a fuel tank equipped with this fuel shut-off

valve use the following method:

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. Close the fuel shut-off valve on both of the fuel tanks.

3. Trace the fuel line from the shut-off valve to the tee. Loosen the

hose clamp and remove the fuel line from the tee.

4. Place the end of the fuel line in a clean certified fuel container and open the fuel shut-off valve to drain the fuel from the fuel tank.

5. When fuel tank is drained re-route the fuel line to the tee and attach to the tee. Clamp fuel line to tee.

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

Current production units have a fuel shut-off valve (Hustler p/n

745059) located behind the seat to the right side of the operator. (Fig. 9-15) Close this valve (center position) to prevent fuel flow to the engine. The valve’s two other positions are front and rear. To drain a fuel tank equipped with this fuel shut-off valve kit use the following method:

2. Turn the fuel valve to the closed position (middle position). Fig. 915

3. Disconnect the tank to fuel valve line from the valve and clamp or cap the end of it.

4. Route the fuel line until it is lower than the fuel tank fitting.

5. Place the end of the fuel line in a clean certified fuel container and

unclamp or uncap the line to permit the fuel to drain from the fuel tank.

6. When fuel tank is drained re-route the fuel line to the shut-off valve and attach it to the tee. Clamp fuel line to shut-off valve.

7. Fill fuel tank with proper grade of gasoline and open shut-off valve (front or rear position).

Figure 9-9

1-1/2”

1-7/8”

Full mark

Dipstick

396242

Acceptable

operating

range

Figure 9-11

Bypass valve rod

(Right rod shown)

Bypass valve rod shown in closed position

Slot

Figure 9-12

Fuel tank

Figure 9-10

Bypass valve rod

(Right rod shown)

Bypass valve rod shown in open position

Slot

9-9

365262 6/06

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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. 9-16A, 9-16B & 916C. 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. 9-

16A, 9-16B & 9-16C

Belt replacement

Figures 9-17 and 9-18 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

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

Fuel shutoff valve

Figure 9-14

Figure 9-13B

Fuel filter

Briggs & Stratton

Figure 9-13A

Fuel filter

Honda

Fuel valve

(shown in closed position)

Figure 9-15

Figure 9-13C

Fuel filter

Kohler

9-10

365262 6/06

Page 86

sliding the chain out of the anchor bracket slot. This will relieve the tension on the deck belt idler spring. Fig. 9-18

5. Pull the idler to the left of the machine to provide maximum belt clearance.

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

7. Route the new belt per Fig. 9-17.

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

section located elsewhere in this manual.

9. Re-install the deck belt covers.

10. Re-attach the negative battery cable.

Integrated pump/motor drive belt replacement

2. Place the deck in the lowest position.

3. 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. 9-17

Figure 9-18

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

Figure 9-17

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" at operation)

5. Deck belt idler pulley

6. Idler arm

Figure 9-16B

Figure 9-16A

Engine oil drain plug

Engine oil filter

Engine oil

filler tube

Dipstick

Engine

oil filter

Dipstick & Engine oil

filler tube

Engine oil drain plug

Briggs & Stratton

Honda

Figure 9-16C

Engine

oil filter

Dipstick & Engine oil

filler tube

Engine oil drain plug

Kohler

9-11

365262 6/06

Page 87

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

5. Release the tension from the integrated pump/motor belt by pulling on the idler pulley (extending spring carefully) and sliding the belt over it. Use caution when releasing the idler pulley as there is still tension on it and it will snap back into position. Fig. 9-18

6. 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. 9-19

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

8. Slide the belt off of the fixed idler pulley.

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

10. 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.

11. Slide the belt over the fixed idler pulley and then over the integrated pump/motor pulleys.

12. Slide the belt onto the engine pulley.

13. Pull the idler pulley over and slide the belt onto it. Make certain to

keep fingers from getting between the belt and the pulley when the pulley is released and tension is re-established.

14. Re-install the deck drive belt on the electric clutch pulley and make sure it is routed properly on all of the deck pulleys.

15. Re-tension the deck belt idler per the Deck drive belt adjustment section located elsewhere in this manual.

16. Re-attach the negative battery cable.

Mower blade maintenance

Check the mower blades daily, they are the key to power efficiency and well groomed turf. Keep them sharp, a dull blade will tear rather than cut the grass, leaving a brown ragged top on the grass within a few hours. A dull blade also requires more power from the engine.

Replace any blade which is bent, cracked or broken.

WARNING: Never attempt to straighten a bent blade by heating, or weld a cracked or broken blade as the blade may break and cause serious injury. Replace worn or damaged blades.

DANGER: Never work with blades while engine is running or deck clutch switch is engaged (on). Always place deck clutch switch in the disengaged position, place control levers in the park brake position and turn engine off and disconnect negative battery cable. Block up mower when you must work under it. Wear gloves when handling blades. Always check for blade damage if mower strikes rock, branch or other foreign object during mowing!

WARNING: Always wear adequate eye protection when grinding mower blades.

Always place deck clutch switch in the disengaged position, place control levers in the park brake position and turn engine off and disconnect negative battery cable. Block up mower when you must work under it. Wear gloves when handling blades. Always check for blade damage if mower strikes rock, branch or other foreign object during mowing!

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. 9-20).

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. 9-21 and 9-

22). 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 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.

Warped Blade (Replace)

Straight Blade

Comparison of Warped and Straight Blades

Cutting

Plane

Figure 9-21

Figure 9-20

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

Engine

pulley

Figure 9-19

Belt

9-12

365262 6/06

Page 88

Figure 9-22

Twisted Blade Edge

(Replace)

Cutting Edge

Straight Blade Edge

End view of blades, comparing

twisted and straighten blades.

Cutting Plane

Cutting Edge

9-13

365262 6/06

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9-14

365262 6/06

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ADJUSTMENTS

Introduction

Your FasTrak 44/52 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.

Seat adjustment

The seat can be adjusted forward and rearward by removing the two cap screws that lock the seat platform in place and pivoting the seat platform up and forward. Then loosen the four cap screws on the underneath side of the operator’s platform. Position the seat where you have the best control of the machine and are the most comfortable and then tighten the cap screws. Fig. 9-23

Control lever adjustment

The control levers can be adjusted for operator comfort. By loosening the cap screws that attaches the upper control lever to the lower lever (Fig. 9-24), the upper control lever can be pivoted to fit the operator’s personal preference.

The control levers can also be adjusted up and down. Remove the cap screws and slide the upper control lever up or down and align the holes in it with the holes in lower lever. Re-install the cap screws and tighten.

The control levers should be adjusted so that they align with each other when in the neutral position.

Steering linkage

The neutral adjustment for the control levers in the neutral position is discussed in this section.

The tractor steering has been factory adjusted to eliminate creeping when the control levers are in the neutral position (Fig. 9-25). However, should the tractor begin to creep, the control lever linkage can be adjusted as follows:

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.

Fine adjustment to the unit’s steering is made with the adjustable pump linkage rods. Fig. 9-26

Neutral is properly adjusted when the control levers are in the neutral position and the drive wheels are not turning.

If the tractor creeps in the neutral position the control linkage may be adjusted as follows:

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

2. Position the control lever in the neutral position. Disengage the deck clutch switch Fig. 9-25.

3. Loosen the nut on the steering dampener’s rear ball stud. Fig. 9-26

4. Remove the cotter key that connects the brake link to the brake

pawl. Remove the brake link from the brake pawl. Fig. 9-30

5. Start the engine and observe which way the wheels are rotating.

6. If wheel(s) are rotating forward, loosen the jam nuts on the pump

linkage rods and rotate the rod to lengthen the steering control linkage until the wheel(s) come to a stop. Fig. 9-26 NOTE: The left linkage controls the left integrated pump/motor and the right linkage controls the right integrated pump/motor. Repeat for the opposite side if necessary.

Figure 9-25

Control lever in the

neutral position

Control

lever

Figure 9-23

Cap screw

Operator’s

platform

9-15

Figure 9-24

Cap screw

Upper

control

lever

Lower control

lever

365262 6/06

Page 91

If wheel(s) are rotating in reverse then loosen the jam nuts on the pump linkage rods and rotate the rod to shorten the steering control linkage until the wheel(s) come to a stop. Fig. 9-26 Repeat for the opposite side if necessary.

7. When both wheels remain in neutral, tighten the jam nuts to lock the pump linkage rod in place.

8. Test again by moving the control levers forward and backward before returning them to the neutral position. If the tires remain in

neutral, the unit is now ready for operation.

9. Shut the engine off. Place the control levers in the neutral position and reconnect the brake link to the brake pawl. Re-insert the cotter key. Fig. 9-30

10. Re-tighten the steering dampener’s rear ball stud after adjusting the dampener per the following instructions:

Steering dampener

The steering dampener (Fig. 9-27) 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 tractor 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. Place the control lever in the neutral position. Fig. 9-25

3. Loosen the steering dampener’s rear ball stud.

4. Pull the dampener spring housing, to the rear, past the point that the

internal spring is engaged.

5. Release the dampener spring housing and allow the internal spring to bring the housing back to the neutral position.

6. Tighten the nut on the steering dampener’s rear ball stud.

7. To check, move the control lever to the reverse position and release.

The control lever should return to the neutral position. If not, repeat steps 1 thru 6.

Figure 9-27

Dampener

spring

housing

Ball stud

Figure 9-28

Brake

switch

Screws

Brake

actuator

lever

Brake

link

Figure 9-30

Cotter

key

Figure 9-29

Nylock

nut

Flat

washer

Spring

Brake

gear

Brake link

Brake

pawl

9-16

Figure 9-26

Pump

linkage rod

Steering

dampener

Ball stud nut

Jam nut

Jam

nut

Jam

nut

365262 6/06

Page 92

Park brake spring adjustment

Occasionally check the park brake spring 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. Position the control lever in the neutral position.

3. Make sure the brake actuator lever and the brake link are all the way

down. Fig. 9-28

4. Tighten the nylock nut on top of the spring assembly until it is touching the top flat washer. Do not compress the spring. Fig. 9-29

5. Place the control lever in the park brake position. The brake pawl should now be activated and engaging the integrated pump/motor brake gear. Fig. 9-30

6. Repeat steps 2 thru 4 for the other side.

Park brake switch adjustment

Occasionally the park brake switch may need adjustment. Use the

following method to adjust the switch:

1. Park the unit on a flat surface. Stop the engine and remove the ignition key. Place control levers in the park brake position.

2. Loosen the screws holding the switch. Fig. 9-28

3. Slide the switch all the way down until it is fully activated (button

pushed in) against the brake actuator lever.

4. Tighten the screws.

Hydraulic pump belt adjustment

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

and spring (Fig. 9-31). 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. 9-32). 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. 9-32). Installed spring length should be 7.50" ± .3" (19.05 cm ± .76 cm) originally with adjustments of .60" (15.2mm) per chain link. (Fig. 9-32 & 9-33)

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

Engine RPM setting

The FasTrak 44/52 is designed so that the engine will run at 3400 rpm with integrated pump/motor load only. At this speed the integrated pump/motors are running at their maximum rated speed.

Figure 9-35

Height

adjusting

stop

Stop

handle

Figure 9-34

Blocks

Figure 9-31

Spring

Tension

idler

Pump drive

belt

Figure 9-32

Spring

Tension idler

Chain

Anchor bracket

Figure 9-33

1.50”

Spring Extension

7.50”

6.0”

Normal Spring Length

9-17

365262 6/06

Page 93

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

Gauge wheels tire pressure.......................................8 - 10 psi

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" of blocking under all 4 corners of the deck

(Fig. 9-34). This will set the cutting height at 3 ¼ ". NOTE: Back of deck will automatically be set ¼" higher.

4. Set cutting height at 3 ¼" in the height indicator by placing the height adjusting stop in the 3" hole, and turning the height stop so that the flat side is against the stop handle. Fig. 9-35

5. Clamp the height adjusting stop against the stop handle (Fig. 9-35). This will assure that the height will not move during the setting process. Otherwise, spring pressure from the deck lift springs will tend to pull the stop away from the handle.

6. Loosen all nuts on the deck lift threaded rods, and the hardware on the adjuster (on the right front), until all the deck lift chains are loose, and the deck is sitting tightly on all four blocks. Fig. 9-36, 937, 9-38

7. Loosen the two nuts on the front of height indicator so that the foot pedal is free. Fig. 9-39

8. Start the leveling process on the left front of the tractor.

9. Set the amount of threads protruding on the deck lift rod from the lift

block at approximately 1". Fig. 9-40

10. Jam both nuts against the block.

11. Push or pull on the deck lift foot pedal until the chain on the left front just becomes tight, making sure that the deck stays tight

against the 3" block.

12. While keeping the chain tight, tighten the nuts against the deck lift block on the height indicator rod. Fig. 9-39

13. Go to the right front of the tractor.

14. Loosen the 5/16" jam nut on the adjuster lift chain (Fig. 9-38), and

back the adjuster bolt out to allow the adjuster to move up and down freely.

15. Be sure that adjuster is free to move up and down.

16. Tighten the adjuster bolt until the chain just becomes tight, making

sure that the deck stays tight against the 3" block.

17. Tighten the adjuster bolt jam nut to prevent the adjuster bolt from moving. Fig. 9-38

18. Tighten the hardware holding the chain and adjuster onto the deck lift arm.

19. Go to the right rear of the tractor.

20. Make sure that there is still slack in the chain. If not, loosen the two

nuts on the block holding the threaded rod until there is slack in the deck lift chain. Fig. 9-38

21. Tighten the appropriate nut until the chain just becomes tight, making sure that the deck stays tight against the 3" block.

22. Tighten the other nut on the opposite side of the block, and jam them tightly together against the block.

23. Go to the left rear of the tractor.

24. Make sure that there is still slack in the chain. If not, loosen the two

nuts on the block holding the threaded rod until there is slack in the deck lift chain. Fig. 9-36

25. Tighten the appropriate nut until the chain just becomes tight.

26. Tighten the other nut on the opposite side of the block, and jam them

tightly together against the block.

27.

Compress the deck lift assist springs so that there is 1” of space between the front nut on the spring and the rear nut on the deck lift block (Fig. 9-40). Typical both sides.

28. When completed, all chains will be tight, and deck cutting height will be set to the deck height indicator.

Figure 9-39

Foot

pedal

Nuts

Figure 9-36

Deck lift threaded rod

NNuutt

Nut

Chains

Figure 9-37

Deck lift

threaded

rod

Nut

NNuutt

Chains

Figure 9-38

5/16” bolt

Adjuster

Hardware

Jam nut

9-18

365262 6/06

Page 94

9-19

Figure 9-40

Lift block

1”

Deck lift rod

1”

Deck lift

assist springs

365262 6/06

Page 95

9-20

365262 6/06

Page 96

Part Number Index

Part Page No. No.

Index

Part Numbers

000323 4-13 000331 4-3

000398 4-3 005116 6-5 005231 4-5 011320 2-5 015495 3-5 015818 4-13 016253 4-9 016287 4-7 016972 6-5 017004 4-3 017038 4-3 017129 6-5 017251 3-7 017616 7-2 018846 3-5 019521 5-4 023655 3-7 024927 3-3 025007 3-9 025296 3-9 026237 4-15 028118 3-9 029868 3-3 029876 4-3 030817 4-7 031997 4-9 034272 3-3

034280 3-3 036236 3-7

036244 4-9 042630 5-2 043067 3-9 043570 4-5 044255 4-7 045898 4-15 046821 6-5 047654 7-4 050161 3-9 052837 4-3 053199 4-9 054502 2-5

055749 3-5 055822 4-13 055939 3-3

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

4-13

, 5-5 , 6-11

, 6-11 , 4-9 , 4-5 , 6-11

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

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

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

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

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

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

, 4-9, 5-5 , 4-9

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

, 6-3, 6-5, 6-9,

6-11

, 7-2

, 6-3, 6-9

, 4-9

Part Page No. No.

055947 4-7 056077 4-3 058776 3-3

059832 3-7 059931 6-5 061077 5-4 061101 3-9 063198 3-7 063297 6-3 064006 6-5 064014 7-4 066878 3-10 068478 1-1 078386 3-7 079186 6-5 080358 7-4 083022 4-15 083279 8-3 086660 3-7 102970 6-5 104786 4-9 259812 6-5 306969 5-2 337444 4-9 339689 5-2 344267 4-9 348284 3-5 348318 3-5 348417 3-3 348458 3-5 350884 6-5 355651 2-5 357103 6-3 357111 6-3 358317 6-5 359737 3-7 359745 3-7 360131 3-5 360487 3-7 360677 3-7 360792 6-11 360818 6-11 361147 6-5 361154 6-5 361212 3-9 361295 3-7 361550 3-7 362251 3-7 362988 6-3 363176 3-7 363507 7-4

, 4-15 , 4-5 , 6-3, 6-5, 6-9,

6-11, 7-4

, 4-15 , 6-11

, 6-9 , 6-11

, 6-11

, 5-2, 5-5

, 6-11 , 6-9

, 6-9 , 6-11

, 6-9

Part Page No. No.

363788 3-9 363812 3-7 363952 2-3 364174 3-3 364315 6-5 364885 2-4 365270 1-1 365411 4-15 365478 5-5 365668 1-1 365684 1-1 367425 1-1 367656 1-1 377242 5-5 378273 4-5 378703 5-5 545962 2-2 545970 6-3 546044 2-2 546051 6-9 600171 6-5 600189 6-5 600296 6-5 600899 8-3 704643 3-5 704932 4-15 705178 3-7 705954 5-2 712257 4-15 712372 4-3 712919 4-13 712927 3-9

712976 5-2 714998 4-15 720177 4-3 720193 6-5 725267 4-5 727016 8-3 727172 8-4 727420 8-4 727438 8-4 727453 8-4 739144 4-5 740696 3-3 745059 4-13 747303 1-1 756270 3-5 763417 4-3 767954 2-5

, 6-11 , 5-5

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

, 7-2

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

6-5, 6-11

, 6-11

, 8-5 , 8-5 , 8-5 , 8-5 , 4-9

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

6-9, 6-11

365262 6/06 i-1

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Part Page No. No.

767962 3-5, 4-9, 5-2, 5-5,

6-3, 6-9, 7-2

768044 5-2 768259 3-7 768515 4-3

768523 3-3

768820 4-7 768879 4-15 770867 3-7 771378 4-7 771428 3-3 771436 8-3 772806 5-3 772814 5-3 776476 4-15 779850 3-3 780841 4-7 781153 3-9 781211 3-7 781229 3-5 781260 3-7 781294 3-5 781302 3-9 781419 8-4 781567 4-9

781617 7-4 781708 4-9 781831 3-5 781872 6-5 781880 6-3 781922 3-7 782177 7-4 782474 6-5 782664 4-3 782995 3-5 783134 5-4 783142 5-4 783159 5-4 783506 6-5 783514 6-13 783522 6-13 783530 6-13 783548 6-13 783555 6-13 783696 3-7 783738 6-5 783753 6-5 783878 6-5 784181 4-13 784199 6-5

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

4-15

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

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

, 6-5, 6-11 , 8-5 , 5-2, 5-5, 6-3,

6-9, 7-2

, 5-5, 6-3, 6-9 , 6-11

, 6-9

, 6-11 , 4-5, 4-9

, 6-11

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

784223 5-2 784231 1-1 784249 1-1 784256 6-11 784264 5-4 784272 5-4 784280 5-4 784306 3-9 784314 3-9 784322 1-1 784355 3-7 784371 3-7 784405 3-7 784421 3-7 784439 3-7 784488 3-5 784504 6-5 784603 5-2 784611 4-3 784629 4-3 784686 3-5 784702 8-3 784710 8-3 784736 6-3 784801 8-5 784819 3-7 784827 3-9 784835 4-3 784843 4-3 784850 1-1 784868 4-3 784918 4-3 784959 4-3 785030 4-15 785048 4-3 785055 8-4 785063 3-3 785071 3-3 785113 3-9 785121 8-3 785139 8-3 785147 8-3 785162 3-7 785196 4-15 785220 8-3 785378 4-3 785402 4-5 785410 4-5 785428 1-1 785436 1-1 785477 4-3 785485 2-5 785493 2-5 785535 8-4

, 3-9 , 6-5

, 6-11

, 6-9

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

, 4-15, 4-16 , 4-5, 4-7

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

, 4-3, 4-7

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

785543 4-3 785600 1-1 785618 1-1 785626 1-1 785634 1-1 785642 1-1 785717 3-9 785725 3-9 785733 3-9 785808 4-15 785832 6-5 786004 4-7 786012 4-7 786178 4-5 786186 4-7 786269 3-10 786301 3-9 786335 6-5 786616 4-3 786632 3-3 786640 4-5 786657 4-15 786889 6-5 786954 4-7 786962 1-1 786988 1-1 787002 1-1 787069 6-5 787226 1-1 787234 1-1 787242 1-1 787267 4-5 787788 4-15 787879 3-7 787887 3-7 787994 6-3 788059 3-9 788067 3-9 788166 4-9 788935 8-3 788968 8-3 789511 1-1 791251 4-3 791277 4-13 791830 8-3 792226 7-4 792689 6-11 792713 4-9 792721 4-9 792739 4-9 792747 4-9 792754 4-9 792762 4-9 792788 4-9

, 4-5

, 6-11

, 4-15 , 4-15

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

, 6-11

, 6-9

, 5-5, 6-3, 6-9

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

i-2 365262 6/06

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793216 3-3 793315 7-4 793331 1-1 793588 8-3 793885 4-9 794180 4-9 794313 1-1 794370 1-1 794446 6-5

, 6-11

794651 3-10 795146 3-3 796318 4-13 796326 4-13 796516 4-9 797449 6-5 797464 7-4 797472 7-4 797480 7-4

, 6-11

797910 6-5 808485 2-2 926501 1-1 926519 1-1 926527 1-1 926592 1-1 926600 1-1 926774 1-1

, 6-11 , 2-3, 2-4, 6-3, 6-9

365262 6/06 i-3

Hustler 365262 User Manual

Table of Contents

Chapter 1

General Information

Chapter 2 Contents

Tractor Frame Rivet Nut Installation

Idler Plate Rivet Nut Installation

Engine Guard Rivet Nut Installation

Footrest Assembly

Chapter 3 Contents

Battery Installation

Deck Lift Assembly

Steering and Brake Assembly

Hydro Transmission Installation

To wlink Installation

Chapter 4 Contents

Honda 18 & 20 HP Engine Installation

Honda 16 HP Engine Installation

Briggs & Stratton 17.5 HP Engine Installation

Kohler 18 & 20 HP Engine Installation

Fuel System Installation

Instrument Panel Assembly/Installation

Honda 18 & 20 HP Electrical Schematic (784868)

Honda 16 HP Electrical Schematic (786178)

Briggs & Stratton Electrical Schematic (786186)

Kohler Electrical Schematic (792754)

Chapter 5 Contents

Front Wheel Assembly

Chapter 6 Contents

52" Deck Assembly

52" Deck Pulley Assembly

44" Deck Assembly

44" Deck Pulley Assembly

Blade Spindle Assembly Breakdown

Chapter 7 Contents

Deck Installation

Deck Belt Routing and Tensioning

Seat Installation

Chapter 8 Contents

Tractor Decals

52" Deck Decals

44" Deck Decals

Chapter 9 Contents

MAINTENANCE

ADJUSTMENTS

Index