HUSTLER FasTrak General Service Manual

Hustler® FasTrak

®

General Service Manual

200 South Ridge Road

Hesston, Kansas

67062

121363 REV C

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

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

Federal law and California State law prohibit the following acts or the causing thereof:

1. The removal or rendering inoperative by any person other than for purposes of maintenance,
repair, replacement, of any device or element of design incorporated into any equipment for the
purposes of emissions control prior to or after its sales or delivery to the ultimate purchaser or
while it is in use, or

2. The use of the equipment after such device or element of design has been remov ed or rendered
inoperative by any person.

WARNINGWARNING

The engine exhaust from this product

contains chemicals known to the state

of California to cause cancer, birth

defects or other reproductive harm.

NOTICE OF REQUIREMENT OF SPARK ARRESTER MUFFLER

This equipment may create sparks that can start fires around dry vegetation. California Public Resources Code
Section 4442.6 provides that it is unlawful to use or operate an internal combustion engine on any forest-covered,
brush-covered, or grass-covered land unless the engine is equipped with a spark arrester maintained in effective
working order. A spark arrester is a device constructed of nonflammable materials specifically for the purpose of
removing and retaining carbon and other flammable particles over 0.0232 of an inch in size from the exhaust flow of
an internal combustion engine that uses hydrocarbon fuels or which is qualified and rated by the United States
Forest Service. Other states or federal areas may have similar laws. The Operator Should Contact Local Fire
Agencies For Laws or Regulations Relating to Fire Prevention Requ irement s. THIS EQUIPMENT DOES NOT HAVE
A SPARK ARRESTER AND YOU SHOULD CONTACT YOUR AUTHORIZED DEALER FOR THE PURCHASE OF
A SPARK ARRESTER.

Inspect spark arrester daily; replace every 500 hours or as needed.

REV C 121363

Table of Contents

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

®

Hustler

Maintenance Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Safe Servicing Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Pre-Operation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Operation Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Operate Machine Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

General Maintenance Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Maintenance Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Standard Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Special Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Service Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Power Unit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Steering Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Steering Control Lever Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Hydraulic Pump Belt Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Fluid Changing Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Engine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

General Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Engine Oil and Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Fuel Evaporation System Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Fuel and Evaporative System Line Routings . . . . . . . . . . . . . . . . . . . . . 5-1

Engine RPM Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Deck Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Deck Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Deck Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

121363 toc-1 REV C

Deck Belt Routing & Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Main Electrical Harness Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Main Harness to Fuel Gauge Voltage Convertor Schematic. . . . . . . . . 7-2

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Maintenance Locator Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

REV C toc-2 121363

GENERAL INFORMATION

Hustler® Service Program

This manual is part of a service package for the Hu stler
FasTrak® mowers. Use of this manual in conjunction with
other Hustler

®

mower and component manuals will provide

the information necessary to service and maintain the Hus-

®

tler

FasTrak® mower.

This General Service Manual is a service guide for use by
Service Technicians. It provides the necessary information
needed to perform normal maintenance requirements on
these units.

The Parts Manual provides a complete parts listing for the
unit. Use this manual when ordering parts.

The Operator's Manual provides fundamental operational
information and operational safety that is needed when ope r­ating the mower.

The component manuals are furnished by the various man­ufacturers to be used for the troubleshooting and servicing
of their components.

Maintenance Introduction

Regular maintenance is the best prevention for downtime
or premature failure. 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 compartment and under the seat platform
areas; minute dust particles 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 build­up 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 lesser
quality of cut. 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

®

Turf Equipment service center

when assistance is needed.

Information included in this manual was current at the time
of printing, but subsequent production changes may cause
your machine to vary slightly in detail. Hustler

®

ment 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 ser­vice manual contact the Customer Service Department at
Hustler

®

Turf Equipment for additional information.

Warranty

Warranty repair must be performed by a Hustler® Turf
Equipment Authorized Dealer before warranty credit can be
allowed.

Turf Equip-

121363 1-1 REV C

REV C 1-2 121363

SAFETY

DANGER

WARNING

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.

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

– denotes a hazard or unsafe practice which

COULD result in severe personal injury or death.

Safe Servicing Practices

Refer to the Safety section of this manual for more detailed
service safety information.

Understand Correct Service

 Be sure you understand a service procedure before

you work on the machine.

 Unauthorized modifications to the machine may

impair the function and/or safety and affect machine
life.

 If it is necessary to make checks with the engine run-

ning, always use two people - with the operator at the
controls, able to see the person doing the checking.

Pre-Operation Precautions

Fuel Handling

 To avoid personal injury or property damage, use

extreme care when handling gasoline. Gasoline is
extremely flammable and the vapors are explosive.

• A fire or explosion from gasoline can burn you

and others and can damage property.

 Observe the usual gasoline handling precautions:

• Do not smoke while refueling. Extinguish all ciga­rettes, cigars, pipes and other sources of ignition.

• Do not remove fuel cap or fill tank with engine run-

ning or while engine is hot. Clean up any gasoline

spills.

• If gasoline is spilled, do not attempt to start the
engine but move the machine away from the area
of spillage and avoid creating any source of igni­tion until gasoline vapors have dissipated.

• Keep gasoline away from open flame or spark and
store machine away from open flame or spark or
pilot light such as on a water heater or appli­ances.

• Refuel outdoors. Never refuel or drain the gaso­line from the machine indoors.

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

• Do not fill fuel containers inside a vehicle or on a
truck or trailer bed with interior carpets or plastic
truck bed liners. Always place gasoline contain­ers on the ground away from your vehicle before
filling.

• When practical, remove the machine from the
truck or trailer and refuel the machine with its
wheels on the ground. If this is not possible, then
refuel such machine on the truck or trailer using a
portable container and not a fuel dispenser noz­zle. If a fuel 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. Do not use a nozzle lock-open device.

• Never use gasoline for cleaning parts.

• Read and observe safety precautions elsewhere

in this manual.

 Gasoline is harmful or fatal if swallowed.
 Avoid prolonged breathing of vapors.

• Long-term exposure to vapors can cause serious
injury and illness.

 Keep gasoline away from eyes and skin.

• Keep face away from nozzle and fuel tank or fuel
container opening.

• If gasoline is spilled on clothing, change clothing
immediately.

Understand Machine Operation

 Only qualified and trained personnel should operate

the equipment.

 Carefully read the operator’s manual and all manuals

furnished with the attachments. Learn the location

121363 2-1 REV C

and purpose of all controls, instruments, indicators
and labels.

Wear Protective Clothing

 Do not operate or service the equipment while wearing

sandals, tennis shoes, sneakers, shorts or any type of
loose fitting clothing. Long hair, loose clothing or jew­elry may get tangled in moving parts. Always wear
long pants, safety glasses, ear protection and safety
shoes when operating or servicing this machine.

 Always wear adequate eye protection when servicing

the hydraulic system and battery, or when grinding
mower blades and removing accumulated debris.

 Prolonged exposure to loud noise can cause impair-

ment or loss of hearing.

• 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.

Operation Precautions

Avoid Fire Hazards

 Clean flammable material from machine. Prevent fires by

keeping engine compartment, top of deck, exhaust area,
battery, hydraulic lines, fuel line, fuel tank and operato r’s
station clean of accumulated trash, grass clippings, and
other debris. Always clean up spilled fuel and oil.

Start Engine Safely

 Avoid possible injury or death from machine runaway.
 Do not start engine by shorting across starter termi-

nals.

 Before you start the engine:

• Sit on the operator’s seat.

• Move control levers to the neutral/brake position.

Operate Machine Safely

 Refer to the unit’s operator’s manual for complete

safety information on safe machine operation.

 Always maintain a safe distance from people and pets

when mowing

 Always be aware of what is behind the machine before

backing up.

 Never leave machine unattended with ignition key in

switch, especially with children present.

 Follow daily and weekly checklists, making sure hoses

are tightly secured and bolts are tightened.

 Always keep engine and machine clean, removing

accumulated dirt, trash and other material from
machine.

 Never put hands or feet under any part of the machine

while it is running.

 Never attempt to start engine when there is a strong

odor of gasoline fumes present. Locate and correct
cause.

 Keep all safety shields and covers in place, except for

servicing.

 Do not touch hot parts of machine.

General Maintenance Precautions

 Repairs or maintenance requiring engine power should

be performed by trained maintenance personnel only.

 Never run the engine in an enclosed area unless

exhaust is vented to the outside. Exhaust gases con­tain carbon monoxide which is an odorless and deadly
poison.

 Unless specifically required, DO NOT have the engine

running when servicing or making adjustments to the
mower.

• Park the mower on level ground

• Disengage the deck clutch.

• Place the steering control levers in the park brake

position.

• Lower the deck.

• Stop the engine.

• Remove the ignition key.

• Disconnect the negative battery cable.

• Wait for all movement to stop before adjusting,

cleaning or repairing.

• Repairs or maintenance requiring engine power
should be performed by trained maintenance per­sonnel only.

• To prevent carbon monoxide poisoning, operate
the engine in a well ventilated area only.

• Read and observe all safety warnings in this man­ual.

 Before working on or under the deck, make certain

engine cannot be accidentally started. Shut engine off,
remove ignition switch key and disconnect negative
battery cable for maximum safety.

 Except when changing or checking belt, always keep

belt covers on mower deck for safety as well as clean­liness.

 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.

 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.

REV C 2-2 121363

Clean up oil or fuel spillage. Allow machine to cool
before storing.

 Always wear adequate eye protection when servicing

the hydraulic system and battery, or when grinding
mower blades and removing accumulated debris.

 Never attempt to make any adjustments or repairs to

the mower drive system, mower deck or any attach­ment while the engine is running or deck clutch is
engaged.

 Exercise caution when releasing spring tension from

any of the belt idlers or when working with any of the
deck lift components.

 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.

 Keep nuts and bolts tight, especially the blade attach-

ment bolts. Keep equipment in good working condi­tion.

 Never tamper with safety devices. Check their proper

operation regularly.

 Exercise caution when working under the deck as the

mower blades are extremely sharp. Wrap the blade(s)
or wear gloves and use extra caution when servicing
them.

 Use original Hustler

are equivalent in overall performance.

• The mower may not comply with the appropriate
safety standards if aftermarket parts, accesso­ries, or attachments are used.

®

replacement parts or parts that

Maintenance Precautions

Avoid Fire Hazards

 Be prepared if an accident or fire should occur. Know

where the first aid kit and the fire extinguishers are
located and how to use them.

 Provide adequate ventilation when charging batteries.
 Do not smoke near battery.
 Never check fuel level with an open flame.
 Never use an open flame to look for leaks anywhere on

the equipment.

 Never use an open flame as light anywhere on or

around the equipment.

 When preparing engine for storage, remember that fuel

stabilizer is volatile and therefore dangerous. Seal and
tape openings after adding the inhibitor. Keep con­tainer tightly closed when not in use.

 Inspect electrical wiring for worn or frayed insulation.

Install new wiring if wires are damaged.

Prepare for Emergencies

 Be prepared if a fire starts.
 Keep a first aid kit and fire extinguishers available.
 Keep emergency numbers for doctor, ambulance ser-

vice, hospital, and fire department near the telephone.

Prevent Battery Explosions

 Battery posts, terminals, and related accessories con-

tain lead and lead compounds, chemicals known to the
State of California to cause cancer and reproductive
harm. Wash hands after handling.

 Charge batteries in a well-ventilated open area, away

from sparks and flames. Unplug charger before connect­ing or disconnecting from battery. Wear protective cloth­ing and use insulated tools.

 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 a 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 disconnect
the negative (black) battery cable(s) before dis­connecting the positive (red) cable(s). Always
connect the positive (red) battery cable(s) before
connecting the negative (black) cable(s).

• Do not overfill the battery.

• Electrolyte may overflow and damage paint, wir-

ing 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.

 Shorts caused by battery terminals or metal tools

touching metal mower 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 mower parts when removing or installing
the battery.

• Do not allow metal tools to short between the
battery terminals and metal mower parts.

 Incorrect battery cable routing could cause damage to

the mower and battery cables. This can cause sparks
which can cause a battery gas explosion which will
result in personal injury.

121363 2-3 REV C

• Always disconnect the negative (black) battery
cable(s) before disconnecting the positive (red)
cable(s).

• Always connect the positive (red) battery cable(s)
before connecting the negative (black) cable(s).

Avoid Acid Burns

 Sulfuric acid in battery electrolyte is poisonous. It is

strong enough to burn skin, eat holes in clothing and
cause blindness if splashed in eyes.

Avoid the hazard by:

• Filling batteries in a well-ventilated area.

• Wearing eye protection and rubber gloves.

• Avoiding breathing fumes when electrolyte is

added.

• Avoiding spilling or dripped electrolyte.

If you spill acid on yourself:

• Flush your skin with water.

• Apply baking soda or lime to help neutralize the

acid.

• Flush your eyes with water for 10-15 minutes. Get
medical attention immediately.

If acid is swallowed:

• Drink large amounts of water or milk.

• Then drink milk of magnesia, beaten eggs or veg-

etable oil.

• Get medical attention immediately.

REV C 2-4 121363

TORQUE

WARNING

Standard Torques

The following chart lists the standard torque values for the threaded fasteners found in this manual. Torque all cap screws, nuts

and set screws to these values unless a different torque is shown in the Special Torques section.

Size ft-lbs N•m Size ft-lbs N•m

#10 32.4 IN.-LBS. 3.6 M3 12 IN.-LBS. 1.3
.250 98.4 IN.-LBS. 11.1 M4 26.4 IN.-LBS. 3
.312 204 IN.-LBS. 23 M5 54 IN.-LBS. 6.1
.375 30 40 M6 92.4 IN.-LBS. 10.4
.438 48 65 M8 222 IN.-LBS. 25
.500 73 99 M10 37 50
.562 105 143 M12 64 87
.625 145 200 M14 103 140
.750 260 350 M16 160 215
.875 420 565 M20 320 435

Special Torques

Size ft-lbs N•m

Wheel (lug) nuts

Blade spindle bolt top 70 95

Blade spindle bolt bottom 118 160

Electric Clutch mounting bolt

Front wheel axle bolt Tighten the nut, then back it off

Transaxle hub nut 275 339

Transaxle pump pulley nut 45–55 61–74.6

NOTE:

1. Lug nuts only – It is recommended that these be
checked after the first 2 hours of operation and every
50 hours and following removal for repair or replace­ment.

2. Engine torque values

owner’s manual.

3. If clutch mounting bolt is loosened or removed, do no t
re-use. Replace with a new bolt. Use only hand tools to

install this fastener.

– Refer to the respective engine

1

3

70 95

45–48 61–65

until the wheel spins freely

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.

121363 3-1 REV C

REV C 3-2 121363

POWER UNIT MAINTENANCE

WARNING

WARNING

WARNING

A

B

B

C

Steering Adjustments

Steering Control Lever Neutral Adjustment

The mower’s steering has been factory adjusted to elimi­nate creeping when the steering control levers are in the neu­tral position. However, should the mower begin to creep, the
steering control lever linkage can be adjusted.

Before considering any adjustment, check the tire air pres­sure. Unequal tire pressure will cause the mower to drift to
one side. Refer to the tire pressure information in the Tires
section for detailed information.

NOTE: Proper park brake adjustment must be completed
before the steering control lever neutral adjustment can be
done. Refer to the Park Brake Spring Adjustment section for
detailed information.

Fine adjustment to the unit’s steering is made with the

transmission’s control rod.

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

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

1. Raise the rear of the mower and block with certified
jack stands. The rear wheels need to be able to rotate
freely and clear of all obstructions.

2. Chock the front tires.

3. Unbolt the seat platform from the mow er frame.

• Disconnect the mower harness from the seat

switch.

• Bypass the seat switch by connecting the two

mower harness female spades together.
Figure 4-1

• Re-attach the seat platform to the mower frame.

This procedure will require that the unit to be
raised to allow the drive wheel to rotate.

• Block the mower up off of the ground using
only appropriate vehicle stands (minimum
weight rating of 2000 pound)s. Use in pairs
only. Follow the instructions supplied with
the vehicle stands.

• Do not allow the wheels to come in contact
with the floor or any object that would permit
the unit to propel itself.

• To prevent injury stay clear and exercise cau­tion when rotating the wheels.

Exercise extreme caution when the transmissions
are engaged.

• Keep hands, hair, clothing, etc., clear of the
cooling fans on top of the transaxles to pre­vent entanglement.

Untrained maintenance personnel should never
attempt to make any adjustments or repairs to the
mower’s drive system while the engine is running.

The following procedures should be per formed by
trained maintenance personnel only.

A. Seat switch
B. Female spades

4. Loosen the jam nuts on each end of the steer ing con-

trol rod assemblies. Figure 4-4

5. Set both steering control levers in the park brake posi­tion. Figure 4-2

NOTE: Both steering control levers need to be in the park
brake position when starting the engine but need to be
moved rapidly out of the park brake position once engine
is started so that the brakes do not fight the transmis­sions since they have not yet been adjusted.

C. Mower harness

Figure 4-1

121363 4-1 REV C

Shown with steering control levers in the park brak e

A

A

WARNING

A

B

C

A

D

position

A. Steering control lever

Figure 4-2

6. Start the engine. Move the steering control lever to

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

Shown with steering control levers in the neutral position

A. Steering control lever

Figure 4-3

Shown with steering control lever in the neutral position

This operation is extremely dangerous. Pay close

attention when adjusting the steering control rod
so you do not get your fingers, tools, or anything
else close to the transaxle’s cooling fans.

7. Beginning with the right side of the mower:

• Adjust the steering control rod so that the right

side wheel starts rotating forward while holding
the steering control lever in the neutral position.

• Adjust the steering rod back the opposite direc­tion to the point when the wheel stops rotating.

• From that point, turn the steering rod back again
½ turn. This ensures that the steering rod is
adjusted so that the transmission control arm is
centered in the neutral band of the transmission.
Figure 4-5

• Move the steering control lever forward and back­ward making sure that the wheel rotates forward
and backward correctly.

• Return the steering control lever to neutral and
re-check to make sure the wheel has stopped in
the neutral position.

• Place the steering control lever in the park brake
posi tion. If neutral is set properly, you should not
hear the transmission whine.

8. Repeat steps 4 through 10 for the le ft side.

9. Once both sides are properly adjusted, check them

together to make sure everything is working properly.

A. Steering control lever
B. Jam nuts

C. Steering control rod
D. Transaxle cooling fan

Figure 4-4

10. IMPORTANT: Unbolt the seat platform from the mower

frame.

• Disconnect the two female spade connectors
from each other (from step #3).

• Reconnect them to the seat switch. This must be
completed so that the safety circuit is function­ing properly. Figure 4-1

• Re-attach the seat platform to the mower frame.

REV C 4-2 121363

WARNING

WARNING

Align handles

± .125”

.50" ± .25”

A

B

1.43"–1.48"

C

Do not operate the mower without plugging the
mower’s wiring harness into the seat switch. This
switch is an important part of the safety start
interlock system. Serious injury can result if the
seat switch is not plugged into the mower’s wiring
harness.

Never operate the mower with a non-functioning
seat switch. Always reconnect the seat switch to the
mower harness.

11. The steering control levers should be adjusted so that

they align within ± .125" of each other when in the neu­tral position. Figure 4-5

NOTE: The space between the ends of steering control
levers should be .50” ±.25”. Figure 4-5

12. Check to make sure all tools or obstructions are
removed from under the mower.

13. Raise the rear of the mower and remove the jack
stands. Lower the mower.

14. Remove the chocks from the front wheels .

• Remove the ignition key.

• Disconnect the negative battery cable.

2. On one side measure the park brake spring. It should

be compressed to 1.43"–1.48". If it is not, adjust the
nylock nut until the proper spring compression is
achieved. Figure 4-6

3. Repeat for other side.

4. Reconnect the negative battery cable.

A. Nylock nut

C. Park brake rod

B. Park brake spring

Figure 4-5

Park Brake Spring Adjustment

Occasionally check the park brake spring adjustment using

the following method:

1. This procedure does not require engine power, there­fore:

• Park the mower on level ground

• Disengage the deck clutch.

• Place the steering control levers in the park brake

• Stop the engine.

position.

Figure 4-6

121363 4-3 REV C

Steering Control Lever Stops

WARNING

WARNING

WARNING

A

B

B

C

A

D

B

C

This procedure will require that the unit to be
raised to allow the drive wheel to rotate.

• Block the mower up off of the ground using
only appropriate vehicle stands (minimum
weight rating of 2000 pound)s. Use in pairs
only. Follow the instructions supplied with
the vehicle stands.

• Do not allow the wheels to come in contact
with the floor or any object that would permit
the unit to propel itself.

• To prevent injury stay clear and exercise cau­tion when rotating the wheels.

Exercise extreme caution when the transmissions
are engaged.

• Keep hands, hair, clothing, etc., clear of the
cooling fans on top of the transaxles to pre­vent entanglement.

Untrained maintenance personnel should never
attempt to make any adjustments or repairs to the
mower’s drive system while the engine is running.

The following procedures should be per formed by
trained maintenance personnel only.

IMPORTANT: Make sure the hydraulic system oil is at

operating temperature before beginning this procedure.

1. Raise the rear of the mower and block with certified
jack stands. The rear wheels need to be able to rotate
freely and clear of all obstructions.

2. Chock the front tires.

3. Unbolt the seat platform from the mowe r frame.

• Disconnect the mower harness from the seat

switch.

• Bypass the seat switch by connecting the two

mower harness female spades together.
Figure 4-7

• Re-attach the seat platform to the mower frame.

4. Start the engine. Move both steering control levers for-

ward against the stops located inside the steering cov­ers.

5. Determine if the drive wheels are rotating equally. If
they are equal, go to step 8. If one is rotating faster
than the other proceed to the next step.

6. Return the steering control levers to the park brake
position and shut the engine off.

7. Loosen the side cap screw on the outside of the steer­ing cover on the side that is rotating too fast. Tighten

A. Seat switch

C. Mower harness

B. Female spades

Figure 4-7

the top cap screw to adjust the drive-straight bracket
up. This allows the steering control lever to make con­tact with the drive-straight bracket sooner. Repeat
until both drive wheels are rotating at the same speed.
Figure 4-8

8. Tighten the side cap screws on both the left and right
sides to lock the drive-straight brackets in place. Snug
the top cap screws to prevent loosening during opera­tion. Figure 4-8

A. Top cap screw
B. Side cap screw

C. Drive-straight bracket
D. Steering control lever

Figure 4-8

9. IMPORTANT: Unbolt the seat platform from the mower

frame.

• Disconnect the two female spade connectors

from each other (from step #3).

• Reconnect them to the seat switch. This must be

completed so that the safety circuit is function­ing properly. Figure 4-1

REV C 4-4 121363

• Re-attach the seat platform to the mower frame.

WARNING

WARNING

WARNING

B

A

C

Do not operate the mower without plugging the
mower’s wiring harness into the seat switch. This
switch is an important part of the safety start
interlock system. Serious injury can result if the
seat switch is not plugged into the mower’s wiring
harness.

Never operate the mower with a non-functioning
seat switch. Always reconnect the seat switch to the
mower harness.

Belts

Inspect belts frequently for wear and serviceability.

Replace a belt that shows signs of:

• severe cuts

• tears

• separation

• weather checking

• cracking

• burns caused by slipping.

Slight raveling of belt covering does not indicate failure,

trim ravelings with a sharp knife.

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, the 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.

Hydraulic Pump Belt Adjustment

The transmission drive belt tension remains constant by
means of a tension idler and spring. There is no tension
adjustment of this belt. Figure 4-9

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

Hydraulic System

This mower is equipped with two integrated hydrostatic

transmissions. Figure 4-10

IMPORTANT: Never use hydraulic or automatic transmis­sion fluid in this system; use only the specified motor oil.

If the transmission 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 dealer to resolve the problem.

A. Tension idler
B. Hydraulic pump belt

Remember, dirt is the primary enemy of any hydraulic sys­tem.

Each transaxle has its own hydraulic expansion tank. The
tanks are located in front of the engine and behind the opera­tor’s platform. Figure 4-10

Check the oil level in the hydraulic system after every 50
hours of operation or weekly, whichever occurs first. Check
more often if the system appears to be leaking or otherwise
malfunctioning.

When the hydraulic system oil is cold, the fluid level should
be at the “Full Cold” line on the expansion tank. Use only SAE
20W50 service motor oil.

Initial system oil and filter change must be after the first 75
hours of use or 1 year whichever comes first. Thereafter,
replace filter and oil in each transmission every 2 years or
200 hours, whichever comes first. NOTE: The filter guard
must be removed to access the filter. Figure 4-11

Each transmission’s filter is located per Figure 4-11. A
standard oil filter wrench is used to change the filter. The
threads are right handed. Use a Hustler

ment only.

IMPORTANT: When washing the mower, direct the spray

away (especially if using a power washer) from the transmis­sion’s seals to prevent water intrusion and to ensure compo­nent performance.

C. Spring

Figure 4-9

®

approved filter ele-

Fluid Changing Procedure

1. Park the unit on a le vel surface.

121363 4-5 REV C

A. Expansion tank

A

A

B

B

C

A

A

Figure 4-10

A. Filter B. Filter guard

Figure 4-11

• Place the steering control levers in the park brake

position.

• Disengage the deck clutch.

• Remove the ignition switch key.

• Disconnect the negative battery cable.

2. Remove the three 1/4” filter guard screws and filter

guard. Clean any loose debris from around the filter.
Figure 4-12

3. Place an oil drain pan beneath the o il filter and remove
the oil filter from the transaxle.

4. After the oil has been dr ained, wipe the filter base sur­face off and apply a film of new oil to the gasket of the
new replacement filter.

5. Install the new filter by hand, turn 3/4 to one full turn
after the filter gasket contacts the filter base surface.

A. Screw

C. Filter guard

B. Filter

Figure 4-12

6. Re-install the filter guard with three 1/4” screws.

Torque the screws to 65 in.–lbs. each. Figure 4-12

7. Repeat steps 2–6 for the opposite side tr ansaxle.

8. Drain oil filters of all free flowing oil prior to disposal.

Place used oil in appropriate containers.

9. IMPORTANT: Remove the top port plug from both tran­saxles prior to filling with oil. This will allow the tran­saxles to vent during oil fill. Figure 4-13

10. Remove the cap from the tra nsaxle's expansion tank.

11. Fill with 20W50 motor oil until oil just appears at the

bottom of each transaxles top port (approximately 2
qts. per transaxle). Install the top port plug into each
transaxle. Torque plugs to 180 in.–lbs. Clean up any
oil that leaked from the ports. Figure 4-13

12. Continue to fill the transaxles through the expansion
tank until the “Full Cold” line is reached on the expan­sion tank.

13. Re-install the expansion tank cap by hand. Be careful
not to overtighten.

14. Proceed to the purge procedure.

IMPORTANT: Purging procedures must be followed after

changing the oil and filter. Refer to the Purging Procedure sec­tion for detailed information.

IMPORTANT: When washing the mower, direct the spray
away (especially if using a power washer) from the transaxle’s
seals to prevent water intrusion and to ensure component per­formance.

Purging Procedure

Due to the effects air has on efficiency in hydrostatic drive

applications, it is critical that air is purged from the system.

REV C 4-6 121363

A. Top port plug

A

WARNING

WARNING

WARNING

A

B

B

C

Figure 4-13

Air creates inefficiency because its compression and
expansion rate is higher than that of the oil approved for use
in hydrostatic drive systems.

These purge procedures should be implemented any time a
hydrostatic system has been opened to facilitate mainte­nance or the oil has been changed.

The resulting symptoms in hydrostatic systems may be:

1. Noisy operation.

2. Lack of power or drive a fter short term opera tion.

3. High operation temperature and exces sive expansion

of oil.

Before starting, make sure the transaxle is at the proper oil
level. If it is not, fill to the specifications outlined in this man­ual.

The following procedures are best performed first with the
vehicle drive wheels off the ground and then repeated under
normal operating conditions. If this is not possible, then the
procedure should be performed in an open area free of any
objects or bystanders.

1. Raise the rear of the mower and block with certified
jack stands. The rear wheels need to be able to rotate
freely and clear of all obstructions.

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.

• Use only certified jack stands. Use only
appropriate jack stands, with a minimum
weight rating of 2000 pounds (907 kg) to
block the unit up.

• Use in pairs only.

• Follow the instructions supplied with the

jack stands.

• The jack stands should not allow the
machine to move when the engine is running
and the drive wheels are rotating.

• Do not allow the wheels to come in contact
with the floor or any object that would permit
the unit to propel itself.

• To prevent injury stay clear and exercise cau­tion when rotating the wheels.

Untrained maintenance personnel should never
attempt to make any adjustments or repairs to the
mower’s drive system while the engine is running.

The following procedures should be performed by
trained maintenance personnel only.

• Bypass the seat switch by connecting the two

mower harness female spades together.
Figure 4-14

• Re-attach the seat platform to the mower frame.

121363 4-7 REV C

Exercise extreme caution when the transmissions
are engaged.

• Keep hands, hair, clothing, etc., clear of the
cooling fans on top of the transmissions to
prevent entanglement.

2. Chock the front tires.

3. Unbolt the seat platform from the mowe r frame.

• Disconnect the mower harness from the seat

switch.

A. Seat switch
B. Female spades

4. Start the engine.

C. Mower harness

Figure 4-14

5. Position the steering control lever in the neutral posi-

A

A

B

WARNING

WARNING

tion.
IMPORTANT: Make sure the deck clutch switch is in

the “OFF” (disengaged) position. Figure 4-15

Shown with steering control levers in the neutr al position

A. Steering control lever

Figure 4-15

6. With the bypass valve open and the engine running,

slowly move the steering control lever in both forward
and reverse directions (5 or 6 times). Figure 4-16

7. With the bypass valve closed and the engine running,
slowly move the steering control lever in both forward
and reverse directions (5 or 6 times). Check the oil
level, and add oil as required after stopping the engine.

8. It may be necessary to repeat Steps 6 and 7 until all
the air is completely purged from the system. When
the transaxle operates at normal noise levels and

moves smoothly forward and reverse at normal
speeds, then the transaxle is considered purged.

A. Bypass valve rod B. Transaxle

Figure 4-16

9. Unbolt the seat platform from the mow er frame.

• Disconnect the two female spade connectors

from each other (from step #3).

• Reconnect them to the seat switch. This must be
completed so that the safety circuit is function­ing properly. Figure 4-14

• Re-attach the seat platform to the mower frame.

Do not operate the mower without plugging the
mower’s wiring harness into the seat switch. This
switch is an important part of the safety start
interlock system. Serious injury can result if the
seat switch is not plugged into the mower’s wiring
harness.

Never operate the mower with a non-functioning
seat switch. Always reconnect the seat switch to the
mower harness.

Tires

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

Drive wheels . . . . . . . . . . . . . . . . . . 8–12 psi (55–83 KPa)

REV C 4-8 121363

Front wheels . . . . . . . . . . . . . . . . . . 8–12 psi (55–83 KPa)

If you wish to use non-pneumatic tires on your Hustler
mower, the tire must be a Hustler® approved tire. Warranty
claims will be denied on any mower equipped with unap­proved non-pneumatic tires.

®

ENGINE MAINTENANCE

WARNING

A

A

General Engine Maintenance

Detailed instructions and recommendations for break-in
and regular maintenance are specified in the Engine Owner’s
Manual. Please refer to this manual for engine servicing,
lubricating oil levels with quality and viscosity recommenda­tions, bolt torques, etc. The engine warranty is backed by the
manufacturer. Special attention should be paid to applicable
data which will not be duplicated here.

Engine Oil and Filter

Allow the engine to cool before changing the
engine oil. If the engine has been running, use cau­tion when changing the engine oil as it will be very
hot. You should wear the appropriate protective
gear to avoid being burned or exposed to engine
oil.

A. Oil drain valve

Figure 5-1

Check the engine oil daily and after every 4 hours of opera­tion. The mower must be level when checking the oil. Refer to
the Engin e Owner’s Manual and maintenance schedule for oil
recommendation and capacities.

Change the engine oil and filter after the first 5 hours of
operation and per the engine manufacturer’s recommenda­tions after that. Change the engine oil more frequently if
operating in extremely dirty conditions.

IMPORTANT: After the new oil filter has been installed,
clean up any oil which may have spilled onto the engine
plate, engine exhaust system, and muffler guard.

Draining the Engine Oil:

1. Locate the oil drain valve on the engine. Figure 5-1

2. Position a suitable oil drain container under the

machine below the oil drain valve.

3. Twist the valve counterclockwise to open the valve.
Allow 10 minutes for engine oil to adequately drain.

4. After oil is drained, close the valve by twisting it clock­wise.

5. Once the valve is closed, clean up any spilled oil.
IMPORTANT: All oil drips or spills must be cleaned off

of the engine plate, engine exhaust system, and muf­fler guard before operating the machine.

Engine Air Filter

Perform engine air filter maintenance per the Maintenance

Schedule shown elsewhere in this manual.

Fuel Evaporation System Filter

Hustler® FasTrak® mowers have a fuel evaporation system
filter. This filter must be checked and replaced every 300
hours or annually whichever comes first. Figure 5-2

A. Fuel evaporation system filter

Figure 5-2

Fuel and Evaporative System Line Routings

These mowers have a fuel evaporative system installed.
There are two different types of rubber hoses that are
connected to the fuel tank. One is the fuel hose that is part of
the fuel system. The other is the vapor line that is part of the
fuel evaporative system.

121363 5-1 REV C

The fuel hose is connected to the fuel tank as shown. It

A

B

B

A

B

B

B

B

C

B

connects the fuel tank to the engine’s fuel pump. Figure 5-3

A. Fuel tank B. Fuel line

Figure 5-3

The vapor lines are connected to the fuel tank as shown.

They connect the fuel tank to the engine’s vapor port.
Figure 5-4

A. Fuel tank
B. Vapor lines

C. Fuel evaporation system

filter

Figure 5-4

Engine RPM Settings

The engine rpm’s are set at the factory for maximum mowing efficiency. Occasionally it may be necessary to check and adjust the

settings. The idle speeds should be set as follows:

Kawasaki FR691 / FR730

ENGINE SPEEDS

MODEL NO. ENDING WITH: LOW IDLE HIGH IDLE

Model NO. without extension
Model NO. with EX extension

Model NO. with US extension

NOTE: Model numbers may or may not end with an extension after the number. There are several different extensions that may be

shown; i.e. EX, AU or CE.

Example: 922222 (no extension)

922222 EX
922222 CE
922222 US
922222 AU

1900 ± 100 rpm 3600 ± 50 rpm

REV C 5-2 121363

DECK ADJUSTMENTS

WARNING

A

A

A

A

A

A

A

A

Deck Leveling

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 - 12 psi

Gauge wheels tire pressure . . . . . . . . 8 - 12 psi

Stop engine. Make sure the deck clutch switch is in
the down (OFF) position. Place the steering control
levers in the park brake position before leaving the
machine.

2. Park the unit on a hard flat surface.

3. Using the deck lift pedal, raise and lock the deck in the

transport position. Figure 6-3

4. Place 3” (76.2 mm) high deck support blocks (two
stacked 2” x 4” blocks can be used to create a 3”
[76.2 mm] high support) at the four corners of the deck
as shown. NOTE: The back of deck will automatically
be set 1/4” (6.35 mm) higher. Figure 6-1 & Figure 6-2

5. Remove the height adjusting stop pin and lower the
deck until it rests on the support blocks. Figure 6-3

6. Loosen the four flange nuts attaching the four deck
links to the deck. Figure 6-3

7. Push the deck lift pedal forward, place the height
adjusting stop pin in the indicator hole marked 3.25”
(82.6 mm) and release the pedal.

8. Unscrew the nut from the eyebolt and s lide the e yebolt
out of the mount. This removes the tension from the
deck lift assist spring. Figure 6-4

9. Pull the pedal rearward s o that the transport latch is
held firmly against the deck height adjusting stop pin
and the play in the pivot joint is removed; secure the
pedal in this position (a bungee cord may be used).

10.

Tighten the four deck links to the deck with the
flange nuts clamping on either side of the slot with
48 ft-lbs (65

N•m) of torque. Release the deck lift

pedal and ensure that the deck can be raised and
locked into the transport position.

Figure 6-3

Side Discharge Deck Shown

A. Blocks

Figure 6-1

Rear Discharge Deck Shown

A. Blocks

Figure 6-2

11. Reinstall the eye bolt and deck lift assist sp ring. Adjust

the spring tension using the lock nut and nut on the
eyebolt. The spring extension should be 9.50”

121363 6-1 REV C

(241.3 mm) when locked in the transport position.
Figure 6-4

A

B

D

D

F

E

C

G

H

H

B

A

9.50"

C

D

WARNING

WARNING

A. Transport latch
B. Deck lift pedal
C. Deck

D. Deck lift link

E. Eyebolt
F. Deck lift assist spring
G. Height adjusting stop pin
H. Flange nuts

Figure 6-3

Blades

Mower Blade Maintenance

IMPORTANT: Refer to the Safety section of this manual for

blade handling safety information.

Refer to the Mower Blade Replacement section for blade

removal and installation.

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

Check the mower blades daily, they are the key to power
efficiency and well groomed turf. Keep the blades 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.

A. Deck lift ass ist spring
B. Eyebolt

C. Nut
D. Lock nut

Figure 6-4

Always check for blade damage:

• if mower strikes a rock, branch or other for-

eign object during mowing!

• or if an abnormal vibration occurs while oper­ating.

Make all necessary repairs before resuming opera­tion.

Sharpen the blades following the pattern shown. Touch-up

sharpening can be done with a file. Figure 6-5

After grinding the blades, check for balance. Blade balanc­ing can be done by placing the blade on an inverted line
punch or 5/8" bolt. A commercial balancing tool is also avail­able through most hardware supply stores.

The blade should not lean or tilt. When spinning the blade
slowly it should not wobble. Balance the blade before rein­stalling.

Lay the blade on a flat surface and check for distortion.
Replace any distorted blade. Figure 6-6 & Figure 6-7

REV C 6-2 121363

Do not sharpen to original pattern (below). It
is easier to get a straight cutting edge follow-

ing the re-sharpening pattern shown above.

A

B

A

B

C

End view of blades, comparing twisted and straightened blades.

A

C

D

D

B

WARNING

WARNING

A. Re-shar pening pattern
B. Original edge

Comparison of Warped and Straight Blades

Figure 6-5

A. Twisted blade edge —

replace blade

C. Cutting plane
D. Cutting edge

B. Straight blade edge

Figure 6-7

Mower Blade Removal

IMPORTANT: Refer to the Safety section of this manual for

blade handling safety information.

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

A 15/16" wrench is required to remove the 5/8" cap screw
holding the blade to the spindle shaft. NOTE: A blade holding
tool (part number 381442) is available from Hustler
Equipment. It is designed to prevent the blades from rotating
when they are being removed or installed on the spindle. Con­tact your Hustler

®

Dealer for more information.

Do not re-use spindle bolts which have stripped, worn or
undercut threads. Torque bolts on spindles to 118 ft-lbs
(160.0 N•m) when reinstalling blades.

®

Turf

A. Warped blade — replace
B. Straight blade

C. Cutting plane

Figure 6-6

121363 6-3 REV C

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

Properly compressed cup washers maintain the correct
compression load on the blades. Replace the cup washers if
they are cracked or flattened.

IMPORTANT: The blade sail (curved part) must be point­ing upward toward the inside of the deck to ensure proper
cutting.

When mounting blades, rotate them after installation to

C

B

A

B

A

C

WARNING

ensure blade tips do not touch each other or sides of the
mower.

Belts

Inspect belts frequently for wear and serviceability.

Replace a belt that shows signs of:

• severe cuts

• tears

• separation

• weather checking

• cracking

• burns caused by slipping.

Slight raveling of belt covering does not indicate failure,

trim ravelings with a sharp knife.

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, the 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 Adjustment

The deck belt tension remains constant by means of a ten­sion idler and spring. There is no tension adjustment of this
belt. Figure 6-8 & Figure 6-9

Rear Discharge Deck Shown

A. Deck belt

C. Tension idler

B. Idler sp ring

Figure 6-9

Deck Belt Installation

When replacing a deck belt use the following procedure:

1. Route the belt around all the pulleys except the left
deck spindle.

2. Grasp the belt at the two locations shown and pull the
belt over the left spindle pulley. Figure 6-10 &
Figure 6-11

3. Release the belt.

Side Discharge Deck Shown

A. Deck belt
B. Idler spring

Figure 6-8

Keep hands clear when pulling belt over the pulley
to prevent pinching. Do not get hand or fingers
between pulley and belt.

C. Tension idler

REV C 6-4 121363

Side Discharge Deck Shown

A

A

Grasp the belt

here and pull

over the pulley.

A

A

Grasp the belt

here and pull

over the pulley.

A. Grasp b elt here

Figure 6-10

Rear Discharge Deck Shown

A. Grasp b elt here

Figure 6-11

121363 6-5 REV C

Deck Belt Routing & Tensioning

The following notes are the same for the different decks that are available.

1. There is no tension adjustment of this belt. 2. Route belt as shown.

Side Discharge Deck Belt Routing

Rear Discharge Deck Belt Routing

Figure 6-12

Figure 6-13

REV C 6-6 121363

Main Electrical Harness Schematic

ELECTRICAL

121363 7-1 REV B

Main Harness to Fuel Gauge Voltage Convertor Schematic

REV B 7-2 114241

MAINTENANCE

Maintenance Schedule

Figure 8-1, Figure 8-2, Figure 8-3 & Figure 8-4

SERVICE AT

INTERVALS INDICATED

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 hours
Clean air intake screen (8) Prior to each use or every 4 hours
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
Clean engine and transaxle compartment Daily
Change transaxle oil and filter (7) Every 200 hours or 2 years
Replace engine air cleaner element (4)(10) As needed
Grease deck height pivots X
Grease front wheel bearings X
Change engine oil and filter (1) (3) X
Clean cylinder and head fins (10) X
Check battery connections X
Check tire pressure with a gauge X
Check hydraulic oil level X
Clean engine exterior (10) X
Clean & regap spark plugs (10) X
Check transacle and deck belt tension and condition (5) X
Check fuel system (6) X
Check hydraulic lines X
Check fuel valve (6) X
Check fuel tank grommet (6) X
Tighten lug nuts on wheels (2) X
Change fuel filter (6) X
Replace spark plugs (10) X
Check ROPS mounting hardware (9) X
Replace fuel evaporation system filter (8) X

WEEKLY

OR 50

HOURS

MONTHLY

OR 100
HOURS

* ANNUALLY

OR 300
HOURS

NOTES:

1. Initial oil change is after 5 hours of operation. Thereafter, change oil after every 40 hours operation. Change mor e o fte n 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. Use caution when servicing to prevent dust contamination in the engine. Do not clean filter
element. Replace with a new one.

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

6. Check fuel system for any crack or leaks including, but not limit to, fuel line hoses, fuel valve, vent line hoses, vent valve, vapor valve, c arbon can­ister, and grommets. Repair as needed.

7. Initial system oil and filter change must be after the first 75 hours of use or 1 year whichever come s first. There after, replace filter and oi l in each
transaxle every 2 years or 200 hours, whichever comes first.

8. More often under dusty or dirty conditions and during hot weather.

9. Inspect ROPS after the first 20 hours of operation and then after every 300 hours of operation or yearly whichever comes first.

10. Refer to engine owner’s manual for engine service information.

* After completing maintenance cycle (300 hours), repeat cycle.

121363 8-1 REV C

Maintenance Locator Chart

1

2

3

4

5

6

7

7

9

9

10

12

12

17

11

11

14

16

16

16

Side Discharge Deck Shown

13

13

8

8

15

Figure 8-1

1. Engine Oil Fill & Dipstick

2. Fuel Filter

3. Engine Air Cleaner

4. Engine Oil Drain Plug

5. Battery

6. Fuel Tank

7. Hydraulic Oil Expansion Tank

8. Hydraulic Oil Filter

9. Front Wheel Bearing Zerks (2)

10. Engine Oil Filter

11. Deck Height Pivot Zerks (4)

12. Park Brake Switch

13. Drive Tire

14. Deck Belt

15. Pump Belt

16. Blades

17. Fuel Evaporation System Filter

Figure 8-2

Figure 8-3

REV C 8-2 121363

Figure 8-4

14

16

16

16

Rear Discharge Deck Shown

1. Engine Oil Fill & Dipstick

2. Fuel Filter

3. Engine Air Cleaner

4. Engine Oil Drain Plug

5. Battery

6. Fuel Tank

7. Hydraulic Oil Expansion Tank

8. Hydraulic Oil Filter

9. Front Wheel Bearing Zerks (2)

10. Engine Oil Filter

11. Deck Height Pivot Zerks (4)

12. Park Brake Switch

13. Drive Tire

14. Deck Belt

15. Pump Belt

16. Blades

17. Fuel Evaporation System Filter

121363 8-3 REV C

REV C 8-4 121363

TROUBLESHOOTING

The majority of operating problems that occur with a system can be traced to improper adjustments or delayed service. A
consistently applied preventative maintenance program will prevent many proble ms. The following chart is designed to help you
locate a problem by suggesting probable causes and the recommended solutions.

SYMPTOMS PROBABLE CAUSES

Starting motor does not
crank

The engine will not start,
starts hard or fails to
keep running

Engine:
Runs with continuous
misfiring or engine runs
unevenly or erratically

Loss of power or system
will not operate in either
direction

Air cooled engine over­heating

Low engine oil pressure Low oil level Add oil

High oil consumption Numerous Contact your Dealer

Steering control levers not
in park brake position or
switch not adjusted

Deck clutch switch
engaged

Weak or dead battery Recharge or replace

Electrical connections are
corroded or loose

Fuse is blown Check fuses – replace

For additional causes See engine manual

No fuel or line plugged Fill tank or replace line

Fuel valve is turned off Open the fuel valve

There is incorrect fuel in
the fuel system

There is dirt in the fuel filter Replace the fuel filter

Dirt, water or stale fuel in
the fuel system

The choke is not on Move the choke lever to ON

Numerous See engine manual

Numerous See engine manual

Restrictions in air cleaner Service air cleaner

Poor compression Contact your Dealer

Steering linkage needs
adjustment

Tow valve open Close tow valve

The traction drive belt is
worn, loose or broken

Air in system Check filter and fittings

For additional causes See engine manual

Air intake screen or clean­ing fins clogged

For additional causes See engine manual

Oil diluted or too light Change oil and check for

Failed oil pump Contact your Dealer

SUGGESTED

REMEDIES

Place steering control
levers in park brake posi­tion or re-adjust switch

Disengage clutch switch

Check the electrical con­nections

blown fuse

(See Fuel System section
for more details)

Drain the tank and replace
the fuel with the proper
type

Contact your Deal er

Adjust linkage

Install a new traction drive
belt

Clean screen and fin

source of contami nation

SYMPTOMS PROBABLE CAUSES

Mower jerky when start­ing or operates in one
direction only

Mower creeps when
steering control levers are
in neutral

Mower circles or veers in
one direction

Mower creeps when park­ing brake engaged

There is abnormal vibra­tion

Blades do not rotate The deck drive belt is worn,

Steering control linkage
needs adjustment

Loose steering linkage Tighten linkage

Transaxle component
faulty

Steering linkage needs
adjustment

Steering linkage needs
adjustment

Loose steering linkage Tighten linkage

Tires improperly inflated Adjust air pressure to 8–12

Transaxle component
faulty

Steering linkage out of
adjustment

Brakes need adjustment Adjust parking brakes

The engine mounting bolts
are loose

The engine pulley, idler pul­ley or blade pulley is loose

The engine pulley is dam­aged

The cutting blade(s) is/are
bent or unbalanced

A blade mounting bolt is
loose

Spindle bearing is worn or
loose

A blade spindle mount is
bent

loose or broken

The deck drive belt is off
the pulley

Electric clutch is not
engaging

SUGGESTED

REMEDIES

Adjust linkage

Contact your Dealer

Adjust linkage

Adjust linkage

psi (55–83 KPa)

Contact your Dealer

Adjust steering linkage

Tighten the engine mount­ing bolts

Tighten the appropriate
pulley

Contact your Dealer

Install new cutting blade(s)

Tighten the blade mount­ing bolt

Replace or tighten spindle
bearing

Contact your Dealer

Install a new deck drive
belt

Install the deck drive belt
and check for a reason

Check and/or replace 15
amp fuse.
Contact your Dealer

121363 9-1 REV C

SYMPTOMS PROBABLE CAUSES

Uneven cutting height The blade(s) are not sharp Sharpen the blades

A cutting blade(s) is/are
bent

The deck is not level Level the deck per the Deck

An anti-scalp wheel is not
set correctly

The underside of the deck
is dirty

Tires improperly inflated Adjust air pressure to 8–12

A blade spindle mount is
bent

SUGGESTED

REMEDIES

Install new cutting blade(s)

leveling and height adjust­ment section of the General

Service Manual

Adjust the height of the
anti-scalp wheel

Clean the underside of the
deck

psi (55–83 KPa)

Contact your Deal er

REV C 9-2 121363

INDEX

PAGE PAGE

Avoid Acid Burns .....................................................2-4

Avoid Fire Hazards
Belts

..................................................................4-5, 6-4

Blades

......................................................................6-2

Deck Belt Adjustment
Deck Belt Installation
Deck Leveling
Draining the Engine Oil
Engine Air Filter
Engine Oil and Filter
Engine RPM Settings
Fluid Changing Procedure
Fuel and Evaporative System Line Routings
Fuel Evaporation System Filter
Fuel Handling

..........................................2-2, 2-3

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

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

..........................................................6-1

..........................................5-1

......................................................5-1

...............................................5-1

..............................................5-2

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

........5-1

..............................5-1

..........................................................2-1

Maintenance Precautions
Maintenance Schedule
Mower Blade Maintenance
Mower Blade Removal
Operate Machine Safely
Operation Precautions
Park Brake Spring Adjustment
Pre-Operation Precautions
Prepare for Emergencies
Prevent Battery Explosions
Purging Procedure

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

Safe Servicing Practices
Service Program

..................................................... 1-1

...................................... 2-3

.......................................... 8-1

.................................... 6-2

........................................... 6-3

........................................ 2-2

........................................... 2-2

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

.................................... 2-1

....................................... 2-3

................................... 2-3

........................................ 2-1

Side Discharge Deck Belt Routing
Special Torques

..................................................... 3-1

........................ 6-6

General Engine Maintenance
General Maintenance Precautions
Hydraulic Pump Belt Adjustment
Hydraulic System

....................................................4-5

Main Electrical Harness Schematic

.................................5-1

........................2-2

...........................4-5

.......................7-1

Main Harness to Fuel Gauge Voltage Convertor
Schematic

Maintenance Introduction
Maintenance Locator Chart

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

.......................................1-1

....................................8-2

Standard Torques
Start Engine Safely
Steering Adjustments

.................................................. 3-1

................................................ 2-2

............................................. 4-1

Steering Control Lever Neutral Adjustment
Tires

........................................................................ 4-8

Understand Correct Service
Understand Machine Operation
Warranty

................................................................. 1-1

Wear Protective Clothing

.................................. 2-1

............................ 2-1

....................................... 2-2

......... 4-1

121363 i-1 REV C