Hustler Turf FasTrak 36, FasTrak 42 User Manual

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Hustler FasTrak

36" & 42" Decks

Parts Manual

•••••••

Hustler Turf Equipment

•••••

P.O. Box 7000

•••

Hesston, Kansas

•

67062-2097

IMPORTANT: This engine is not equipped with a spark arr ester muffler. It is a violation of California Public Resource Code Section 4442 to use o r operate this eng i ne on any fo rest-co vered, brush-cover ed, or grass-co ver ed unimproved land . Other states or federal areas may have similar laws.

This spark ign i tion sy stem c ompli es with Can adian ICES -002.

The Eng ine Owne r’s Ma nual provide s info rma tion regarding the U.S. E nvironmenta l Protection Agency (EP A) a nd the California Emission Control Regulation of emission systems, maintenance and warranty.

Keep E ng ine Owner’s Manual with your unit. Sho uld the E ngine Owner’s Manual become damaged or illeg ible, replace i mmediately. Re pl acements may be o rd ered per the information found in th e Produc t In f ormation section of th e

owner’s manual.

The engine exhaust from this product

contains chemicals known to the State

of Calif orn ia to cau se c an cer, birt h

defects or other reproductive harm.

WARNING:

cl-2 333559 9/08

333559 9/08 cl-3

cl-4 333559 9/08

Chapter 1

Chapter 2

Chapter 3

Chapter 4

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

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

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

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

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

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

Hydro Transmission Installation S/N Prior To 07091558 . . . . . . . . 3-4

Hydro Transmission Installation S/N Higher Than 07091558. . . . . 3-6

Steering and Brake Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

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

Kohler 15 & 17 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . 4-6

Fuel System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Instrument Panel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Honda 16HP Electrical Schematic (793083). . . . . . . . . . . . . . . . . . 4-14

Kohler 15 & 17 HP Electrical Schematic (601127& 793117) . . . . . 4-16

Chapter 5

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

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

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

Chapter 6

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

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

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

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

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

Chapter 7

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

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

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

Chapter 8

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

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

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

Chapter 9

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

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20

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

333559 09/08 c-1

c-2 333559 09/08

Chapter 1

General Information

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

Frequently Ordered Parts

PART NO. DESCRIPTION

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

Service Literature

PART NO. DESCRIPTION

601156 Owners Manual 794313 Kohler Engine Manual 787242 Honda 16 HP Engine Manual

Options

PART NO. DESCRIPTION

793331 Armrest Kit 338442 Mulch Kit, 36/42"

Note: When ordering parts, yo u must use the part number as shown for each part, not the index number . Always give the model and serial number to your parts and service represen tative.

Note: Items sold in bulk such as seals and hoses are sold by the foot.

Using this manual

Illustrations used were current at the time of printing, but subsequent production changes may cause your machine to vary slightly in detail. Excel Industries, Inc. reserves the right to redesign and change the machine as deemed nece ssary, 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.

333559 09/08 1-1

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 va lues 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 333559 09/08

Chapter 2 Contents

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

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

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

333559 09/08 2-1

Tractor Frame Rivet Nut Installation

INDEX

NO.

SERVICE

PART NO.

1 546911 315440 1 FASTRAK 36 FRAME

546895 320242 1 FASTRAK 42 FRAME 2 808493 808493 2 3/8-16 THREAD RIVET NUT 3 793869 793869 2 1.5 SQ TUBE PLUG

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

2-2 333559 09/08

Engine Guard and Anti-rollover Bracket Assemblies

INDEX

NO.

10 788166 788166 2 ANTI SCALP WHEEL ASSEMBLY

SERVICE

PART NO.

1 316836 316836 1 ENGINE GUARD 2 320580 320580 2 ANTI ROLLOVER BRACKET 3 808493 808493 8 3/8-16 THREAD RIVET NUT 4 781567 781567 2 NT .50-13 HX LK NY ZNYC 5 344267 344267 4 FW .510 X 2.15 X .187SPL ZNYC 6 053199 N/A 2 NT .500-13 HX JAM ZNYC 7 767962 N/A 4 FW .531 X 1.063 X .090 SAE HD ZN 8 031997 N/A 2 ANTI-SCALP WHEEL 9 781708 N/A 2 CS .500-13 X 4.25 HX G5 ZNYC

1. Includes items 6 through 9.

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

333559 09/08 2-3

Footrest Assembly

INDEX

NO.

SERVICE

PART NO.

1 011320 011320 4 CB .375-16 X .75 STD ZN 2 785485 785485 2 UPPER STEP TREAD 3 793844 793844 2 LOWER STEP TREAD 4 320267 320267 1 FLOOR PLATE 36" MOWERS

316844 316844 1 FLOOR PLATE 42" MOWERS 5 767954 767954 2 FW .406 X .812 X .060 SAE HD ZN 6 076422 076422 2 FW.406X 1.000X.06 ZNYC 7 054502 054502 4 NT .375-16 HX GRD 5 ZNYC

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

2-4 333559 09/08

Chapter 3 Contents

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

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

Hydro Transmission Installation S/N Prior To 07091558. . . . . . . . . . 3-4

Hydro Transmission Installation S/N Higher Than 07091558 . . . . . . 3-6

Steering and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

333559 09/08 3-1

Battery Installation

PART OF WIRE HARNESS (BLK)

INDEX

NO.

SERVICE

PART NO.

1 314989 314989 1 BATTERY CLAMP STRAP 2 024927 024927 3 NT .250-20 HX GR.5 ZNYC 3 055939 055939 2 CS .250-20 X .75 HX G5 ZNYC 4 029868 029868 4 LW .250 INT-EXT TOOTH ZNYC 5 740696 740696 1 BATTERY VU1LH-8 6 771428 771428 1 RED BATTERY CABLE BOOT 7 785063 785063 1 POSITIVE BATTERY CABLE (KOHLER)

786632 786632 1 POSITIVE BATTERY CABLE (HONDA) 8 786640 786640 1 NEGATIVE BATTERY CABLE 9 793489 793489 1 BATTERY CLAMP ROD

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

3-2 333559 09/08

Deck Lift Assembly

INDEX

NO.

10 781229 781229 1 CE .750 X 2.25 X 1.75 HEADLESS 11 015495 015495 3 STRAIGHT GREASE FITTING 12 756270 756270 1 CS .312-18 X 1.50 FLTHR GR5 ZNYC 13 034272 034272 1 NT .312-18 HX G5 ZNYC 14 348458 348458 1 DECK LEVELER YOKE 15 781831 781831 1 CS .437-14 X 1.75 FULTH G5 ZNYC 16 360131 018846 2 DECK LIFTCHAIN 17 767962 767962 2 FW .531 X 1.063 X .090 SAE HD ZN

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

SERVICE

PART NO.

1 348318 348318 1 STOP HANDLE 2 348284 348284 1 HEIGHT ADJUSTMENT STOP 3 793505 793505 1 DECK HEIGHT INDICATOR 4 782995 782995 1 DECK LIFT SPRING 5 055749 055749 2 CS .437-14 X 1.75 HX G5 ZNYC 6 334045 334045 1 DECK LIFT LINK 7 704643 704643 6 NT .437-14 HX FLG ZN 8 025296 025296 4 FW .760 X 1.625 X .08 ZNYC 9 781294 781294 5 E CLIP 1.00 X.625X .050

MFG. PART

NO.

333559 09/08 3-3

QTY. DESCRIPTION

NOTES:

Hydro Transmission Installation S/N Prior To 07091558

3-4 333559 09/08

Hydro Transmission Installation S/N Prior To 07091558

INDEX

NO.

10 794552 794552 1 NT .375-16 HXZY NL 11 335695 335695 1 SPACER TUBE-EZT MINI FST 12 768523 768523 12 FW .343 X .687 X .051/.080 HD ZNYC 13 034272 034272 8 NT .312-18 HX G5 ZNYC 14 784827 784827 1 4.00"OD, 5/8"ID IDLER PULLEY 15 781153 781153 2 UHMW BUSHING 16 025296 025296 2 FW .760 X 1.625 X .08 ZNYC 17 324046 324046 1 PUMP BELT IDLER ARM

18 061101 061101 1 NT .750-10 HX NL ZN 19 036384 036384 1 IDLER SPRING 20 364315 059931 1 SPRING CHAIN 21 335893 335893 2 BELT DEFLECTOR

SERVICE

PART NO.

1 710087 710087 8 CS .312-18 X 2.50 HX G5 ZNYC 2 028118 028118 2 FW .62 X 1.00 X .134 ZNYC 3 794404 794404 1 PULLEY 4 025007 025007 2 CS .625-11 X 1.75 HX G5 ZNYC 5 793836 793836 1 A-SECTION PUMP BELT 6 792911 792911 1 EZT LEFT PUMP/MOTOR COMBO 7 792895 792895 1 EZT RIGHT PUMP/MOTOR COMBO 8 718288 718288 1 FW .516 X .875 X .09 ZNYC 9 035238 035238 1 LW .437 MED SPRING ZYNC

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Torque to 17 ft.-lbs.

2. Install using existing hardware on EZT.

3. Do not torque, item 17 (Pump Belt Idler Arm) must pivot freely .

4. Hydro transmission service parts:

PART NUMBER

PRIOR TO

SERIAL NUMBER

06081543

792013 AXLE NUT 788877 AXLE NUT

794982 FAN, EZT 794974 EZT PULLEY KIT

795005 RIGHT EZ CAP-VENT ASSY 795039 LEFT EZ VENT TUBE ASSY

795013 EZT NUT, SPECIAL 791723f FW .530 X 1.63 X .06 SLO

795021 HUB ASSEMBLY 788232 HUB ASSEMBLY

795047 PARKING PAWL KIT, EZT 798363 PARKING BRAKE GEAR

795054 90 DEG VENT FITTING 795062 RIGJHT EZT VENT HOSE

798371 RETAINING RING 792929 PULLEY/FAN COMBO 36/42

DESCRIPTION

PART NUMBER

SERIAL NUMBER

06081543

DESCRIPTION

333559 09/08 3-5

Hydro Transmission Installation S/N Higher Than 07091558

3-6 333559 09/08

Hydro Transmission Installation S/N Higher Than 07091558

INDEX

NO.

10 335695 335695 1 SPACER TUBE-EZT MINI FST 11 768523 768523 12 FW .343 X .687 X .051/.080 HD ZNYC 12 034272 034272 8 NT .312-18 HX G5 ZNYC 13 784827 784827 1 4.00"OD, 5/8"ID IDLER PULLEY 14 781153 781153 2 UHMW BUSHING 15 025296 025296 2 FW .760 X 1.625 X .08 ZNYC 16 324046 324046 1 PUMP BELT IDLER ARM 17 061101 061101 1 NT .750-10 HX NL ZN 18 036384 036384 1 IDLER SPRING 19 364315 059931 1 SPRING CHAIN 20 335893 335893 2 BELT DEFLECTOR 21 086660 086660 1 NT .375-16 HXZY NL

SERVICE

PART NO.

1 710087 710087 8 CS .312-18 X 2.50 HX G5 ZNYC 2 028118 028118 2 FW .62 X 1.00 X .134 ZNYC 3 601162 601162 1 PULLEY 4 025007 025007 2 CS .625-11 X 1.75 HX G5 ZNYC 5 793836 793836 1 A-SECTION PUMP BELT 6 792911 792911 1 EZT LEFT PUMP/MOTOR COMBO 7 792895 792895 1 EZT RIGHT PUMP/MOTOR COMBO 8 712919 712919 2 FW .516 X .875 X .09 ZNYC 9 721134 721134 1 CS .375-16X8.0 HX.GR5 Z

MFG. PART

NO.

QTY. DESCRIPTION

1. Torque to 17 ft.-lbs.

2. Hydro transmission service parts:

PART NUMBER

PRIOR TO

SERIAL NUMBER

06081543

792013 AXLE NUT 788877 AXLE NUT

794982 FAN, EZT 794974 EZT PULLEY KIT

795005 RIGHT EZ CAP-VENT ASSY 795039 LEFT EZ VENT TUBE ASSY

795013 EZT NUT, SPECIAL 791723f FW .530 X 1.63 X .06 SLO

795021 HUB ASSEMBLY 788232 HUB ASSEMBLY

795047 PARKI NG PAWL KIT, EZT 798363 PARKING BRAKE GEAR

795054 90 DEG VENT FITTING 795062 RIGJHT EZT VENT HOSE

798371 RETAINING RING 792929 PULLEY/FAN COMBO 36/42

DESCRIPTION

NOTES:

PART NUMBER

SERIAL NUMBER

06081543

DESCRIPTION

333559 09/08 3-7

Steering and Brake Assembly

311132

See Note 4

3-8 333559 09/08

Steering and Brake Assembly

333

INDEX

NO.

10 797779 797779 8 IGUS® BUSHING 11 023655 023655 12 NT .312-24 HX ZNYC 12 325464 325464 2 STEERING CONTROL ARM 13 768259 768259 8 IGUS® BUSHING 14 718288 718288 2 FW .516 X .875 X .09 ZNYC 15 793059 793059 2 E CLIP .80X.396X.042 16 793646 793646 2 PUMP ROD ADJUSTER ASSEMBLY 17 794396 794396 2 STEERING LINK ROD 18 793612 793612 2 STEERING DRIVE ARM 19 797753 797753 2 STEERING ARM 20 005108 005108 2 CS .375-16 X 3.50 HX G5 21 079186 079186 2 CS .312-18 X 1.25 HX G5 ZNYC 22 797761 797761 2 STEERING BLOCK 23 781567 781567 2 NT .50-13 HX LK NY ZNYC 24 795625 795625 2 SNAP MOUNT PLUNGER SWITCH 25 796615 796615 2 BALL JOINT LINK 26 793174 793174 2 TOWLINK ROD 27 048553 048553 2 CP .062D X 1.00 LG HML ZN 28 068551 068551 4 NT .250-20 HX NL ZNYC 29 797050 797050 2 BRAKE ACTUATOR ROD 30 795229 795229 2 INLINE BALL JOINT 31 352112 352112 1 L. H. BRAKE PIVOT (SHOWN) 32 352054 352054 1 R. H. BRAKE PIVOT (NOT SHOWN) 33 024927 024927 2 NT .250-20 HX GR.5 ZNYC 34 781211 781211 2 PUSH BUTTON SWITCH, (DELTA) 35 060731 060731 4 CS 10-24 X .500 HXFLK ZNYC 36 315382 N/A 1 LEFT BRAKE PIVOT ARM (SHOWN) 37 315101 N/A 1 RIGHT BRAKE PIVOT ARM (NOT SHOWN) 38 794883 794883 2 COMPRESSION SPRING 39 793182 793182 2 BRAKE ACTUATOR ROD 40 089789 089789 4 FW .266 X .750 X .06 ZNYC 41 029876 029876 2 LW .312 INT-EXT TOOTH Z

SERVICE

PART NO.

1 781260 N/A 2 STEERING BAR GRIP 2 360487 360487 2 STEERING BAR 3 600221 600221 2 CENTERING DAMPER

783696 783696 2 CENTERING DAMPER 4 767954 767954 10 FW .406 X .812 X .060 SAE HD ZN 5 086660 086660 6 NT .375-16 HX LK NY 6 705178 705178 4 CS .375-16 X 1.75 HX G5 ZNYC 7 034272 034272 4 NT .312-18 HX G5 ZNYC 8 768523 768523 22 FW .343 X .687 X .051/.080 HD ZNYC 9 781922 781922 4 DAMPER BALL STUD

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. To adjust park brake safety switch: with Steering Bars in park position, adjust item 24 (795625 Snap Mount Plunger Switch) outboard until

333559 09/08 3-9

switch is activated by items 31/32 (352112/352054 Brake Pivots).

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

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

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

3-10 333559 09/08

Chapter 4 Contents

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

Kohler 15 & 17 HP Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . 4-6

Fuel System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Instrument Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Honda 16HP Electrical Schematic (793083) . . . . . . . . . . . . . . . . . . 4-14

Kohler 15 & 17 HP Electrical Schematic (601127& 793117). . . . . . 4-16

333559 09/08 4-1

Honda 16 HP Engine Installation

NEGATIVE BATTERY CABLE

POSITIVE BATTERY CABLE

RED/BLK

YEL

TO ENGINE (4 WIRES)

13 14 15

21 22

PART OF ENGINE

FROM RECTIFIER

PART OF ENGINE

4-2 333559 09/08

Honda 16 HP Engine Installation

INDEX

NO.

10 787267 N/A 1 HONDA 16 AMP RECTIFIER 11 794644 794644 1 GM 1.50 X 2.12 X 1.75 X .12 12 706531 706531 1 GM 1.12 X 1.75 X 1.37 X .12 13 330274 330274 1 CLUTCH ANCHOR 14 029876 029876 4 LW .312 INT-EXT TOOTH ZNYC 15 050161 050161 4 CS .312-18 X 1.75 HX G5 ZNYC 16 784918 784918 1 RUBBER BUMPER 17 793760 793760 1 ENGINE-HYDRO DRIVE PULLEY 18 712372 712372 1 KEY 1/4 SQ. X 0.66 LONG 19 601325 601325 1 WARNER CLUTCH 20 791251 N/A 1 CLUTCH WIRE HARNESS PIGTAIL 21 763417 763417 1 FW .454 X 1.50 X.250 22 785048 785048 1 CS .437-20 X 3.00 HX G5 ZNYC 23 043570 043570 1 SINGLE HOSE CLIP 24 791608 791608 1 OIL DRAIN VALVE, M16 X 1.5 25 768523 768523 2 FW .343 X .687 X .051/.080 HD ZNYC 26 793125 793125 1 MUFFLER 15,17 KOHLER & 16 HONDA 27 016253 016253 2 CB .312-18 X .750 FUL ZN 28 316836 316836 1 ENGINE GUARD 29 767954 767954 6 FW .406 X .812 X .060 SAE HD ZN 30 052860 052860 6 CS .375-16 X 1.25 HX G5 ZNYC 31 794180 794180 1 1.125" EXHAUST CLAMP 32 793166 793166 1 16 HONDA MID EXHAUST PIPE 33 794172 794172 1 1.25" EXHAUST CLAMP 34 793141 793141 1 16 HONDA MANIFOLD 35 005231 005231 4 NT M6-1.0-10 HX FLG ZN 36 785543 N/A 2 HONDA MUFFLER GASKET 37 793083 793083 1 HONDA WIRE HARNESS 38 104786 104786 1 OIL DRAIN HOSE (NOT SHOWN)

SERVICE

PART NO.

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

2 739144 792796 3 3 378273 378273 1 16HP EXHAUST HEAT SHIELD 4 034272 034272 6 NT .312-18 HX G5 ZNYC 5 712927 712927 4 FW .344 X 1.00 X .12 HRD ZNYC 6 782664 782664 1 NT M8-1.25 HX STAINLESS STEEL 7 024927 024927 2 NT .250-20 HX GR.5 ZNYC 8 768515 768515 4 FW .281 X .625 X .051/.080 HD ZNYC 9 056077 056077 2 CS .250-20 X 1.00 HX G5 ZNYC

MFG.

PART NO.

QTY. DESCRIPTION

927376)

333559 09/08 4-3

NOTES:

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

2. Engine oil capacity:See engine owner’s manual.

3. Engine speed; 3550±50 RPM.

4. Torque to 45-48 ft-lb.

4-4 333559 09/08

.This page intentionally left blank.

333559 09/08 4-5

Kohler 15 & 17 HP Engine Installation

TTO

TO STARTER SOLENOID

6 7

17 18

RED/BLK

FROM NEGATIVE BATTERY TEMINAL

RED PUR

TO BATTERY

4-6 333559 09/08

Kohler 15 & 17 HP Engine Installation

INDEX

NO.

10 771428 771428 1 RED BATTERY CABLE BOOT 11 044255 044255 1 NT #10-32 HX ZN 12 030817 030817 1 STARTER SOLENOID 13 792762 792762 1 BATTERY CABLE 14 056077 056077 2 CS .250-20 X 1.00 HX G5 ZNYC 15 330274 330274 1 CLUTCH ANCHOR 16 793885 793885 1 LW .375 INT-EXT TOOTH 17 036244 792788 4 CS .375-16X1.000 HX G5 18 784918 784918 1 RUBBER BUMPER 19 793760 793760 1 ENGINE-HYDRO DRIVE PULLEY 20 712372 712372 1 KEY 1/4 SQ. X 0.66 LONG 21 601325 601325 1 WARNER CLUTCH 22 791251 N/A 1 CLUTCH WIRE HARNESS PIGTAIL 23 763417 763417 1 FW .454 X 1.50 X.250 24 785048 785048 1 CS .437-20 X 3.00 HX G5 ZNYC 25 316836 N/A 1 ENGINE GUARD 26 767954 767954 6 FW .406 X .812 X .060 SAE HD ZN 27 052860 052860 6 CS .375-16 X 1.25 HX G5 ZNYC 28 768523 768523 2 FW .343 X .687 X .051/.080 HD ZNYC 29 016253 016253 2 CB .312-18 X .750 FUL ZN 30 793125 793125 1 MUFFLER 15,17 KOHLER & 16 HONDA 31 796516 796516 1 3/8-18 OIL DRAIN VALVE 32 034272 034272 2 NT .312-18 HX G5 ZNYC 33 794180 794180 2 1.125" EXHAUST CLAMP 34 793158 793158 1 KOHLER 15 & 17 HP MID EXHAUST PIPE 35 793117 793117 1 KOHLER WIRE HARNESS

SERVICE

PART NO.

1 792945 792945 1 KOHLER 15 HP ENGINE SV470S

792952 792952 1 KOHLER 17 HP ENGINE SV530S 2 793133 793133 1 KOHLER 15 & 17 HP EXHAUST MANIFOLD 3 017004 N/A 2 LW .312 MED SPRING ZNYC 4 704478 N/A 2 CS .312-18 X .75 SKTHD BO 5 739144 792796 1 CS M 6-1.0 X 12 10.9 HX 6 024927 024927 4 NT .250-20 HX GR 5 ZNYC 7 768515 768515 6 FW .281 X .625 X .051/.080 HD ZNYC 8 706531 706531 1 GM 1.12 X 1.75 X 1.37 X .12 9 794644 794644 1 GM 1.50 X 2.12 X 1.75 X .12

601127 601127 1 KOHLER WIRE HARNESS

MFG.

PART NO.

QTY. DESCRIPTION

NOTES:

333559 09/08 4-7

1. Supplied with engine.

2. Part of Kohler Wire Harness item 35 (601127-For S/N higher than 07011902; 793117-For S/N prior to 07011902).

3. Engine oil capacity: See engine owner’s manual.

4. Engine speed; 3600±50 RPM.

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

6. Used on mowers with serial numbers prior to 7020776.

7. Used on mowers with serial numbers after 7020776.

8. Torque to 45-48 ft-lb.

4-8 333559 09/08

This page intentionally left blank.

333559 09/08 4-9

Fuel System Installation

4-10 333559 09/08

Fuel System Installation

INDEX

NO.

1 779306 779306 2 3.5" FUEL CAP 2 792978 792978 1 36/42 LEFT SIDE FUEL TANK 3 792960 792960 1 36/42 RIGHT SIDE FUEL TANK 4 000323 000323 6 CLIP 5 745059 745059 1 3-WAY FUEL VALVE 6 767954 767954 10 FW .406 X .812 X .060 SAE HD ZN 7 055822 055822 8 CS .375-16 X .75 HX G5 ZNYC 8 000331 000331 2 SMALL, SHORT WIRE TIE 9 015818 015818 1 FUEL LINE, 21.00" LONG

10 015818 015818 1 FUEL LINE, 16.25" LONG (HONDA)

11 015818 015818 1 FUEL LINE, 8.5" LONG 12 781880 781880 2 BUMPER, .500X 1.00X .312 X.188

SERVICE

PART NO.

015818 015818 1 FUEL LINE, 12.00" LONG

015818 015818 1 FUEL LINE, 14.00" LONG

MFG.

PART NO.

QTY. DESCRIPTION

(KOHLER)

NOTES:

1. Torque to 20 ft.-lbs.

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

799221 SUCTION HOSE ASSY 794081 FUEL FILTER SCREEN 785295 FUEL GROMMET 792986 SITE-LINE TANKS FUEL FITTING

3. Used on mowers with serial numbers higher than 07110561.

4. Used on mowers with serial numbers prior to 07110561.

333559 09/08 4-11

Instrument Panel Installation

FUSE SIZE

AND LOCATION

20a

10a

4-12 333559 09/08

Instrument Panel Installation

INDEX

NO.

10 026237 N/A 2 RELAY 11 793810 793810 1 THROTTLE CABLE (HONDA)

12 055947 055947 3 CS .250-20X .500 HX G5 ZNYC 13 768515 768515 3 FW .281 X .625 X .051/.080 HD ZNYC

SERVICE

PART NO.

1 786657 786657 1 CHOKE CABLE (KOHLER)

785030 785030 1 CHOKE CABLE (HONDA) 2 776476 776476 1 PTO SWITCH 3 712257 712257 1 RED INDICATOR LIGHT 4 785808 785808 1 KEY ASSEMBLY 5 045898 045898 1 KEY SWITCH 6 714998 714998 2 MS #10-24 X .625 HX ZN 7 704932 704932 4 FW .219 X .500 X .048 ZNYC 8 059832 059832 4 NT #10-24 HX NL ZN 9 321059 321059 1 INSTRUMENT PANEL

778365 778365 1 THROTTLE CABLE (KOHLER)

MFG.

PART NO.

QTY. DESCRIPTION

NOTES

1. Part of 601127, 793117 or 793083 (Tractor Wire Harness).

2. Includes one (1) key and one (1) 083022 metal key.

333559 09/08 4-13

Honda 16HP Electrical Schematic (793083)

4-14 333559 09/08

Honda 16HP Electrical Schematic (793083)

333559 09/08 4-15

Kohler 15 & 17 HP Electrical Schematic (601127& 793117)

4-16 333559 09/08

Kohler 15 & 17 HP Electrical Schematic (601127&793117)

333559 09/08 4-17

This page intentionally left blank.

4-18 333559 09/08

Chapter 5 Contents

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

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

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

333559 08/08 5-1

Front Wheel Assembly

INDEX

NO.

10 306969 306969 2 GAGE WHEEL SPACER

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

1. Apply grease to zerks, see owners manual.

SERVICE

PART NO.

1 705954 705954 2 CS .500-13 X 1.25 HX G5 ZNYC 2 344267 344267 2 FW .510 X 2.15 X .187 SPL ZNYC 3 712976 712976 2 FW .531 X 1.375 X .125 ZNYC 4 784223 784223 4 BEARING 5 784603 784603 2 SPACER 6 339689 339689 2 CASTER FORK 7 781567 781567 2 NT .50-13 HX LK NY ZNYC 8 767962 767962 4 FW .531 X 1.063 X .090 SAE HD ZN 9 042630 042630 2 CS .500-13 X 6.50 HX G5 ZNYC

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

2. Torque to 75 ft.-lbs.

3. Assemble with extended inner race down.

5-2 333559

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 8-12 psi.

333559 08/08 5-3

Drive Wheel Assembly

INDEX

NO.

1 783134 783134 2 WHEEL/TIRE ASSEMBLY 18 X 8.50 (PER 36" MOWER) 2 783142 N/A 1 TIRE 18 X 8.5-8 3 783159 N/A 1 WHEEL ASSY 8.00 X 7.00 4 019521 N/A 1 TIRE VALVE 5 061077 061077 8 WHEEL NUT (PER MOWER) 6 793406 793406 8 SPACER, .375TH X .53 ID X 1.0 0D ZN (PER MOWER)

1 784264 784264 2 WHEEL/TIRE ASSY 18 X 9.50 (PER 42” MOWER) 2 784272 N/A 1 TIRE 18 X 9.5-8 3 784280 N/A 1 WHEEL ASSY 8.00 X 6.32 4 019521 N/A 1 TIRE VALVE 5 061077 061077 8 WHEEL NUT (PER MOWER)

SERVICE

PART NO.

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. Inflate tire to 8-12 psi.

2. Torque to 65-75 ft.-lb.

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

5-4 333559

Chapter 6 Contents

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

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

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

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

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

333559 08/08 6-1

Deck Assembly 36"

6-2 333559 09/08

Deck Assembly 36"

INDEX

NO.

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

SERVICE

PART NO.

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

788166 788166 1 ANTI SCALP WHEEL ASSY

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Includes items 16 through 19.

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

333559 08/08 6-3

Deck Pulley Assembly 36"

6-4 333559 09/08

Deck Pulley Assembly 36"

333

INDEX

NO.

10 781302 781302 1 IDLER SPRING 11 321398 321398 1 RIGHT PULLEY COVER 12 330324 330324 1 LEFT PULLEY COVER 13 781872 781872 4 CS .625-11 X 1.25 HX G5 ZNYC 14 782474 782474 4 CW .631 2.250 X .187 PNT 15 793786 793786 1 DECK PULLEY (FASTRAK 36") 16 793778 793778 1 DECK PULLEY (FASTRAK 36"/42") 17 054502 054502 8 NT .375-16 HX GRD 5 ZNYC 18 767954 767954 16 FW .406 X .812 X .060 SAE HD ZN 19 064006 064006 4 CS .312-18 X .625 HX G5 ZNYC 20 768523 768523 10 FW .343 X .687 X .051/.080 HD ZNYC 21 058776 058776 6 NT .312-18 HX NL ZNYC 22 783506 783506 2 BLADE SPINDLE ASSEMBLY 23 005116 005116 8 CS .375-16 X 1.375 HX G5 ZNYC 24 793794 793794 1 20.50" 42D X 0.631 CW BLADE 25 793802 793802 1 13.75" 42D X 0.631 CW BLADE 28 079186 N/A 6 CS .312-18 X 1.25 HX G5 29 712927 N/A 6 FW .344 X 1.00 X .12 HRD ZN 30 785832 N/A 2 DECK IDLER UHMW CLAMP 31 787069 N/A 2 DECK IDLER UHMW RISER 32 017129 N/A 6 FW .440 X 1.000 X .083 ZNYC

SERVICE

PART NO.

1 793828 793828 1 A-SECTION BELT (FASTRAK 36") 2 025007 025007 2 CS .625-11 X 1.75 HX G5 ZNYC 3 046821 046821 2 FW .656 X 2.00 X .078 ZNYC 4 797449 797449 2 FW .650 X 1.00 X .180 ZNYC G5 5 784504 784504 2 IDLER PULLEY, 5.00"OD, 5/8"ID 6 784199 784199 6 CS .312-18 X 1.25 FLT SH 7 601434 601434 2 UHMW IDLER SLIDE 8 321877 321877 1 DECK IDLER 9 364315 059931 1 SPRING CHAIN

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Torque to 118 ft. lbs.

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

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

333559 08/08 6-5

FIG. 6-1

30 9

6-6 333559 09/08

This page intentionally left blank.

333559 08/08 6-7

Deck Assembly 42"

6-8 333559 09/08

Deck Assembly 42"

INDEX

NO.

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

SERVICE

PART NO.

788166 788166 1 ANTI SCALP WHEEL ASSY

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Includes items 16 through 19.

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

333559 08/08 6-9

Deck Pulley Assembly 42"

6-10 333559 09/08

Deck Pulley Assembly 42"

INDEX

NO.

10 781302 781302 1 IDLER SPRING

11 321398 321398 1 RIGHT PULLEY COVER

12 321042 321042 1 LEFT PULLEY COVER

13 781872 781872 2 CS .625-11 X 1.25 HX G5 ZNYC

14 782474 782474 4 CW .631 2.250 X .187 PNT

15 793778 793778 2 DECK PULLEY (FASTRAK 36"/42")

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

17 767954 767954 16 FW .406 X .812 X .060 SAE HD ZN

18 064006 064006 4 CS .312-18 X .625 HX G5 ZNYC

19 768523 768523 10 FW .343 X .687 X .051/.080 HD ZNYC

20 058776 058776 6 NT .312-18 HX NL ZNYC

21 783506 783506 2 BLADE SPINDLE ASSEMBLY

22 005116 005116 8 CS .375-16 X 1.375 HX G5 ZNYC

23 793794 793794 2 20.50" 42D X 0.631 CW BLADE

24 781872 781872 2 CS .625-11 X 1.25 HX G5 ZNYC

27 712927 N/A 6 FW .344 X 1.00 X .12 HRD ZN

28 785832 N/A 2 DECK IDLER UHMW CLAMP

29 787069 N/A 2 DECK IDLER UHMW RISER

30 017129 N/A 6 FW .440 X 1.000 X .083 ZNYC

SERVICE

PAR T N O.

1 793893 793893 1 A-SECTION BELT (FASTRAK 42")

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

3 046821 046821 2 FW .656 X 2.00 X .078 ZNYC

4 797449 797449 2 FW .650 X 1.00 X .180 ZNYC G5

5 784504 784504 2 IDLER PULLEY, 5.00"OD, 5/8"ID

6 784199 784199 6 CS .312-18 X 1.25 FLT SH ZY

7 601434 601434 2 UHMW IDLER SLIDE

8 321877 321877 1 DECK IDLER

9 259812 059931 1 SPRING CHAIN

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Torque to 118 ft. lbs.

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

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

4. Item 7 (601434) replaces idler slide components 600171, 600189 and 786335 found on mowers with serial numbers prior to 08010000.

333559 08/08 6-11

FIG. 6-2

6-12 333559 09/08

This page intentionally left blank.

333559 08/08 6-13

Blade Spindle Assembly Breakdown

INDEX

NO.

SERVICE

PART NO.

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

MFG. PART

NO.

QTY. DESCRIPTION

6-14 333559 09/08

NOTES:

333559 08/08 6-15

This page intentionally left blank.

6-16 333559 09/08

Chapter 7 Contents

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

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

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

333559 08/08 7-1

Deck Installation

INDEX

NO.

SERVICE

PART NO.

1 781567 781567 2 NT .500-13 HX GR 8 ZY NL 2 767962 767962 4 FW .531 X 1.063 X .090 SAE HD ZN 3 017616 017616 2 CS .500-13 X 1.75 HX G5 ZNYC 4 704643 704643 5 NT .437-14 HX FLG ZN 5 055749 055749 3 CS .437-14 X 1.75 HX G5 ZNYC

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

7-2 333559

Belt Routing and Tensioning

NOTES:

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

2. Route belt as shown.

333559 08/08 7-3

Seat Installation

INDEX

NO.

SERVICE

PART NO.

1 793679 793679 1 STANDARD MICHIGAN SEAT 2 086660 086660 3 NT .375-16 HX LK NY 3 767954 767954 3 FW .406 X .812 X .060 SAE HD ZN 4 320275 320275 1 SEAT PAN 5 052860 052860 2 CS .375-16 X 1.25 HX G5 ZNYC 6 793851 793851 2 COMPRESSION SPRING, 1.25X4.00X.188 7 768523 768523 4 FW .343 X .687 X .051/.080 HD ZNYC 8 034280 034280 4 CS .312-18 X .750 HX G5 ZNYC 9 036244 036244 2 CS .375-16 X 1.00 HX G5 ZNYC

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

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

2. Available service parts and options for Michigan Seat:

797456 ARMREST KIT (ROUND STYLE) 793315 SEAT SWITCH KIT

7-4 333559

Chapter 8 Contents

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

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

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

333559 08/08 8-1

Tractor Decals

8-2 333559

Tractor Decals

INDEX

NO.

10 793703 793703 1 INSTRUMENT PANEL DECAL 11 793554 793554 1 FASTRAK 36/42 FUEL VALVE DECAL 12 771436 771436 1 STABILIZER DECAL 13 727016 727016 1 BATTERY DECAL 14 788968 788968 1 ENGINE COMPARTMENT DECAL 15 785147 785147 1 SERVICE DECAL 16 600899 600899 1 PUMP BELT WARNING DECAL 17 600941 600941 1 PATENT DECAL

SERVICE

PART NO.

1 794545 794545 1 DEFLECTOR SHIELD DECAL 2 N/A 083279 1 TURF PROD SERIAL NO PLATE 3 784710 784710 1 FASTRAK DECAL 4 782573 782573 1 FIRST ZERO TURN DECAL 5 793547 793547 1 FASTRAK OPERATION DECAL 6 793588 793588 1 HUSTLER NAME PLATE 7 794305 794305 1 DECK HEIGHT DECAL 8 785139 785139 1 FASTRAK LEFT SIDE STEERING DECAL 9 785220 785220 1 FASTRAK RIGHT SIDE STEERING DECAL

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

333559 08/08 8-3

42" Deck Decals

INDEX

NO.

SERVICE

PART NO.

1 793521 793521 1 42" DECK ID DECAL 2 793687 793687 1 BELT ROUTING DECAL 3 794503 794503 1 STEP TREAD 4 793570 793570 1 DECK WARNING DECAL 5 727172 727172 1 “MADE IN U.S.A.” DECAL 6 794297 794297 1 DISCHARGE CHUTE DECAL

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

8-4 333559

36" Deck Decals

INDEX

NO.

SERVICE

PART NO.

1 793513 793513 1 36" DECK ID DECAL 2 793687 793687 1 BELT ROUTING DECAL 3 794503 794503 1 STEP TREAD 4 727172 727172 1 “MADE IN U.S.A.” DECAL 5 793570 793570 1 DECK WARNING DECAL 6 794297 794297 1 DISCHARGE CHUTE DECAL

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

333559 08/08 8-5

8-6 333559

Chapter 9 Contents

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

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20

333559 09/08 9-1

Maintenance & Adjustment Safety

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 and mechanics should read this manual, and be instructed about safe operating and maintenance procedures. If the operators or mechanics cannot read and understand English, it is the owner’s responsibility to explain this material to them.

Improper use or maintenance by the operator, mechanic, or owner can result in injury. T o 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 thorou ghly before attempting to set-up, operate, adjust, or service this machine.

The Quick Reference Decals are designed to give the operator 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 operators and mechanics read and understand this manual and all decals before operating this machine. It is also the owner ’s responsibility to make certain that the operators and mechanics area qualified and physically able individuals, properly trained in the operation of this equipment. All operators and mechanics must become familiar with the safe operation of the equipment, operator controls and safety signs before operating the equipment.

Never let children or untrained people operate or service the equipment. Local regulation may restrict the age of the operator.

The owner should also ensure that the operators and mechanics know that they are responsible for their own safety as well as the safety of ot her person s within t he vic inity. Remember, the operator 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. Park

the machine on level ground. Place control levers in the park brake position, disengage deck clutch, lower deck, remove ignition switch key and disconnect the negative battery cable before doing any maintenance. Wait for all movement to stop before adjusting, cleaning or repairing. 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. Read and observe safety warnings in front of manual.

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 spillage. Allow machine to cool before storing.

Clean flammable material from machine. Prevent fires by keeping the top of the deck, engine

compartment, exhaust area, battery, hydraulic lines, fuel line, fuel tank and operator’s station clean of accumulated trash, grass clippings, and other debris. Always clean up spilled fuel and oil.

9-2 333559 09/08

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. 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 remove fuel cap or refuel tractor while engine is running; never refuel near an open flame or near devices

which can create a spark. Refuel outdoors. Never refuel or drain the fuel from the machine indoors.

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 adjustment s o r repairs to the tractor dr ive system, mower deck or an y atta chment 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. Wrap the blade(s) or

wear gloves and use extra caution when servicing them.

Do not touch hot parts of machine. Keep nuts and bolts tight, especially the blade attachment bolts. Keep equipment in good working condition. Never tamper with safety devices. Check their proper operation regularly. 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 onto a truck or trailer 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.

333559 09/08 9-3

Children

Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the mowing activity. Never assume that children will remain where you last saw them.

Never leave machine unattended with ignition key in switch, especially with children present. Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended. Always

disengage deck clutch, place steering control levers in park brake position, stop tractor engine, and remove ignition key when leaving operator’s seat.

Keep children out of the mowing area and under the watchful care of a responsible adult other the operator. Be alert and turn the machine off if children enter the area. Before and while backing, look behind and down for small children. Never carry children, even with the blades off. They may fall off and be seriously injured or interfere with safe

machine operating. Children who have been given rides in the past may suddenly appear in the mowing area for another ride and be run over or backed over the machine.

Never allow children to operate the machine. Use care when approaching blind corners, shrubs, trees, the end of a fence or other objects that may obscure

vision.

Never allow children of others in or on towed equipment.

9-4 333559 09/08

Safety and Instruction Decals

Part Number

727016

Part Number

793547

Part Number

600899

Part Number

793570

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

tion 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.

safety decals that are located on the machine. A brief explana-

Do not remove or modify stabilizer wheels or rear engine guard or

injury can result. When operating on a slope of 15° or more, be aware of any condition that may cause the tractor drive tires to lose traction resulting in a possible loss of control of the machine.

steering control levers in the park brake position immediately. Inspect the machine and involve

If you loose steering control while operating the machine, place the

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.

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 smoke while refueling.

Do not refuel while in enclosed trailer or other enclosed areas. Never operate the mower deck with side deflector damaged, altered, removed or in raised position, except when the entire grass catcher attachment or mulching system is being used. Stay clear of mower blades as long as engine is running.Keep a safe distance from machine. Keep shields or covers in place while machine is in operation. Keep hands away from rotation pulleys and belts.

333559 09/08 9-5

Whirling blades! Keep hands and feet away. Beware of thrown object s. Neve r oper ate the mower

Part Number

794297

Part Number

727453

deck with side deflector damaged, altered, removed or in raised position, except when the entire grass catcher attachment or mulching system is being used.

long as engine is running. Beware of thrown object.

Keep shields or covers in place while machine is in operation. Keep hands away from rotating pulleys and belts.

Stay clear of mower blades as

9-6 333559 09/08

MAINTENANCE LOCATOR

CHART

Viewed from top of unit

1. Engine Oil Fill & Dipstick (Honda & Kohler)

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

4. Engine Oil Drain Plug)

5. Battery

6. Fuel Tanks

7. 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 Tires

Maintenance

333559 09/08 9-7

FIG. 1

SERVICE AT INTERVALS INDICATED

Verify safety start interlock system V isually inspect unit for loose hardware and/or damaged parts Visually inspect tires Check oil level, engine (1) Clean air intake screen (4) Clean Foam element (4) Check fuel level Blades–sharpen & securely fastened Discharge chute–securely in place & in lowest position Grease deck height pivots Grease front wheel bearings Change engine oil & filter (1) (3) Clean cylinder and head fins (a) Check battery connections Check tire pressure with a gauge Clean engine exterior (a) Replace air cleaner paper element (4) Clean and re-gap spark plugs (a) Check pump and deck belt tension & condition (5) Check fuel lines (6) Tighten lug nuts on wheels (2) Change fuel filter Replace spark plugs Check engine valve clearance (a) Service starter (8)(a) Replace EZT pump belt

WEEKLY OR 50

HOURS

Prior to each use Prior to each use

Prior to each use Prior to each use or ever 4 hrs. Prior to each use or ever 4 hrs. Prior to each use or ever 4 hrs.

Prior to each use

X X X X X X X X

Every 200 hours or 2 years Every 200 hours or 2 years Every 200 hours or 2 years

ANNUALLY OF

100 HOURS

X X X X X X

NOTES:

1. Initial oil change is after 5 hours of operation. Thereafter, change oil after ever 40 ho urs. operating. 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 r eplace of wor n or cracking is noticed. Otherwise, replace ever 200 hours or 2 years, whichever comes first.

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

7. Honda engine only.

8. Kohler engine only.

References:

a Refer to Engine Owner’s Manual

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

Introduction

Regular maintenance is the best prevention for costly downtime or expensive, premature repair. The fol-

9-8 333559 09/08

lowing pages contain suggested maintenance information and schedules which the operator 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 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 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 top bolt 118 160 Blade spindle bottom bolt 118 160

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 call out 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:

PSI Drive Tires 8-12 Front Wheels 8-12

Solid fill tires are not recommended for Hustler turf equipment. On any machine , with solid filled ti res, the warranty claim wi ll 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 wheel bearings per the Maintenance Schedule. Use SAE multi-purpose grease.

2. Grease the four deck lif t pivots, located to the side of the operator’s footrest per the Maintenance Schedule. Use SAE multi-purpose grease.

Electrical system

333559 09/08 9-9

The electrical system is a 12 volt, negative ground. Recommended battery size is a garden tractor BCI

BATTERY

group UIR with 225 or better cranking AMP rating . A maint enance-free battery is recommended. Othe rwise, follow battery manufacturer’s maintenance, safety, storing, and charging specification.

The Battery is located under the seat platform (FIG. 2).

WARNING:

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

Battery post, terminals, and related accessories contain lead and lead compounds–

WARNING: Change batteries in an open well ventilated area, away from spark and flames.

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

WARNING: Avoid skin and clothing contact with ba ttery 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. Hydro gen 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. W hen 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.

FIG. 2

WARNING: Shorts caused by battery terminals or metal tools touching metal tractor

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

WARNING: Incorrect battery cable routing could cause damage to the tractor and battery

cables. This can cause sparks which can cause a battery gas explosion which will result in personal injury. Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable.

Common circuit failures are usually caused by shorting, corroded or dirty terminals, loose connection, 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. 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

9-10 333559 09/08

battery voltage. If the battery voltage is satisfactory, check the cleanliness and tigh tness of the terminal s and

FUSES

LOCK NUT FLAT WASHER

ground connections. A general underst a nding of ele ctric al servic ing a nd use o f bas ic tes t equipment is nec es-

sary for troubleshooting and repair.

FIG. 3

Major overhaul or repair of the starting motor or charging system should be performed by trained techni-

cians 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. The seat platform is hinged at the front. To raise it, remove the lock nut and flat washer and tilt seat platform up and forward (FIG. 4).

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

333559 09/08 9-11

FIG. 4

If the seat is equipped with the optional arm rest kit, make certain to place the control arms in the park

The Hustler FasTrak is equipped with two Hydro-Gear EZT integrated pump/motor transmissions (FIG. 5).

EZT INTEGRATED PUMP/MOTOR

FIG. 5

The EZT integrated pump/motor transmission are sealed for life and do not require any scheduled service. The EZT integrated pump/motor transmissions are filled with 20 W50 en gine oil. If they ev er become low on

oil, fill to the level shown in FIG. 6.

Fuel system

FIG. 6

DANGER: Observe usual fuel handling precautio ns : 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 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 spar k and stor e ma chine away fr om ope n flame or spark or pilot light such as on a water heater or other appliances. Use extreme care when handling gasoline and other fuels. They are extremely flammable and vapors are explosive. A fire or from gasoline can burn you and others and can damage property. Never refuel or drain the fuel from the machine indoors. 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 bed with interior carpets or plastic bed liners. Always place gasoline containers on the ground away from your vehicle before filling. When practical, remove gas-powered 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 an 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. Do not use a nozzle lock-open device.

9-12 333559 09/08

WARNING: Gasoline is harmful or fatal if swallow ed. Long-term exposure to vapors can cause

FUEL TANK

serious injury and illness. Avoid prolonged breathing of vapors. Keep face away from nozzl e and gas tank or fuel container opening. Keep gasoline away from eyes and skin. If fuel is spilled on clothing, change clothing immediately.

The fuel tanks are located in the t rac tor’ s fe nder s (FIG. 7). Total capacity for the fuel tanks is 6 U. S. gallons

(22.71 L.).

FIG. 7

IMPORTANT: Do not overfill the fuel tanks.The fuel tanks should be filled no higher than 2” below the tank’s fill neck.When filling the fuel tanks disengage deck clutch, place control levers in park brake position, and stop tractor engine. Clean around the fuel tank cap and remove the cap and begin filling. When finished, screw the cap on securely and wipe up any spilled gasoline.

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

Use regular unleaded gasoline with an octane rating of 87 or higher.

IMPORTANT: Never use methanol, gasoline containing methanol, or gasohol containing more than

10% ethanol because the fuel system could be damaged. Do not mix oil with gasoline.

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

1. Keep s 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 fu el 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. 8, & FIG. 9) is installed in the fuel line between fuel tank s and en gine fuel pump. Re place filter annually or after every 100hours of operation, whichever occurs first. For fuel filter removal refer to the engine owner’s manual.

When replacing the fuel filter, check the fuel line hoses and fuel tank fitting grommets for any cracks or leaks. Replace as needed. A fuel shut-off valve is located to the right rear of the seat (FIG. 10). Close this valve (center position) to prevent fuel flow to the engine. Close this valve when transporting the unit on a trailer or truck.

333559 09/08 9-13

FIG. 8 HONDA FIG. 9 KOHLER

FUEL FILTER

INLET HOSE

FUEL FILTER

INLET HOSE

FUEL SHUT-OFF

VALVE

RIGHT FUEL

TANK POSITION

LEFT FUEL

TANK POSITION

CLOSED POSITION

SHOWN

FIG. 10

DRAINING THE FUEL TANKS

FasTraks have a fuel shut-off valve (Hustler p/n 7480159) located behind the seat to the right side of the

operator (FIG. 10). 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:

1. Park the unit on a flat surface. Stop the engine and remove the ignition key. Make sure deck clutch switch

2. Close fuel shut-off valve (center position) (FIG. 10.

3. Disconnect the fuel line from the fuel tank fitting. Place the end of the hose in an approved container to

4. Remove the fuel tank from the tractor . Remove the fuel cap, tip the t ank and drain the fuel into an approved

5. When fuel tank is drained, re-attach the fuel tank to the tractor andre-connect the fuel line to the fuel tank

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

is IN THE DOWN (OFF) POSITION cable.

drain the remaining fuel from the hose. fuel container. fitting. Make certain hose clamp is properly installed.

. Place control levers in the park position. Disconnect negative battery

Engine oil and filter

9-14 333559 09/08

Check engine oil daily and after every 4 hours of oper ation. Crankcase dipstick and oil filler tube ar located

ENGINE OIL

DRAIN PLUG

ENGINE OIL

FILTER

DIPSTICK &

DIPSTICK & ENGINE

OIL FILLER TUBE

ENGINE OIL

FILLER TUBE

ENGINE OIL

FILTER

ENGINE OIL

DRAIN PLUG

as shown in FIG. 11 & FIG. 12. 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. 11, FIG. 12, & FIG. 13.

FIG. 11 HONDA FIG. 12 KOHLER

FIG. 13 KOHLER

333559 09/08 9-15

Engine mounting bolts

If the original engine mounting bolt s are ever r emoved f r om the trac tor, do not reuse. The original bolts ar e

self-tapping and if they are re-used they may try to cut new treads into the engine block mounting holes. Replace with 3/8"-16 x 1.00 Grade 5 bolts. Apply Loc-Tite® 242 to the treads and torque to 30-35 ft.-lbs. Re-use thin int/ext tooth lockwashers that were factory installed with the original mounting bolts.

Belt replacement

FIG. 14 and FIG. 15 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 c hecking and cra cking, or burns caused by s lipping. Slight raveling of b elt cove ring does not indicate failure, trim ravelling with a sharp knife.

WARNING:

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

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 bolt 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 com-

position in a very short time.

Deck belt replacement

DECK BELT DRIVE LAYOUT

1. SPINDLE DRIVE BELT

2. DECK BLADE SPINDLE PULLEY

3. SPINDLE BELT TENSION IDLER

4. SPINDLE BELT TENSION IDLER SPING (7.5" AT OPERATION)

5. DECK BELT IDLER PULLEY

6. IDLER ARM

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

FIG. 14

battery cable.

2. Place the deck in the lowest position.

3. Remove the deck belt covers.

4. Release the deck belt tension by pulling on the belt tension chain and sliding the chain out of the anchor

9-16 333559 09/08

bracket slot. This will relieve the tension on the deck belt idler spring (FIG. 14.

2 6

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. 14.

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

9. Re-install the deck belt covers.

10. Re-a ttach the ne gative battery cable.

Integrated pump/motor drive replacement

VIEWED FROM

TOP OF UNIT

1. PUMP BELT

2. ENGINE PULLEY

3. PUMP IDLER PULLEY

4. PUMP IDLER ARM

5. PUMP PULLEY

6. ELECTRIC CLUTCH

7. PUMP IDLER SPRING

8. FIXED IDLER PULLEY

FIG. 15

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 lever in the park brake position. Disconnect negative battery cable.

2. Place the deck in the lowest p[osition.

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

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

5. The deck belt must be removed from the clutch pulley first by releasing the deck belt tension by pulling on

the belt tension chain and sliding the chain of the anchor bracket slot. This will relieve the tension on the deck belt idler sprint (FIG. 14).

6. Remove the deck drive belt from the electric clutch pulley. This belt does not need to be remove d from any

of the other pulleys.

7. Release the tension from the integrated pump/motor belt by pulling on the belt tension chain and sliding

the chain out of the anchor bracket slot. (FIG. 17).

8. Slide the belt off the engine pulley The belt will have to be slid above the engine pulley to allow the belt to

be removed from the other pulleys (FIG. 15).

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

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

11. Install new belt by sliding it up and over the engin e pulle y. Make certain it is not in the pulley groove at this

time but is above the pulley.

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

333559 09/08 9-17

13. Slide the belt onto the engine pulley.

ENGINE PULLEY

DECK IDLER

PULLEY

CHAIN

SPRING

ANCHOR

BRACKET

SLOT

14. Slide the belt onto the engine pulley.

FIG. 16 FIG. 17

15. Re-attach the spring and chain to the tensioner pulley arm. Pull chain and slide the chain into the anchor bracket slot.)FIG. 17).

16. Re-install the deck drive belt on the electric clutch pulley and make sure it is routed proper ly on all the deck pulleys.

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

18. Re-attach the right rear drive tire and wheel. Torque lug nuts to 65-75 ft.-lbs. (88.14-101.7 NM).

19. Raise the tractor and remove the jack stands. Lower the tractor.

20. Re-a ttach the ne gative battery cable.

Mower blade maintenance

Use a 15/16" wrench to remove the 5/8" cap screw holding the blade to the spindle shaft from underneath. Sharpen the blades on a grinder following pattern as shown (Fig. 9-15).Touch-up sharpening can be done

with a file.

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

Lay the blade on a flat surface and check for distortion (Fig. 9-16 and 9-17). Replace any distorted blade.

Do not re-use spindle bolts which have st ripped, worn or undercut th reads. Torque bolts on spindles to 118 foot-pounds (160.01Nm) when reinstalling blades.

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

ensure proper cutting.

WARNING:

touch each other or sides of the mower.

WARNING: Failure to correctly torque the bolt ma y 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.

When mounting blades, rotate them after installation to ensure blade tips do not

9-18 333559 09/08

FIG. 18

Re sharpening

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

Original edge

Warped Blade (Replace)

Straight Blade (Replace)

Comparison of Warped and Straight Blades

Cutting

plane

Cutting edge

Twisted Blade Edge

(replace)

Straight Blade Edge

End view of blades, comparing

twisted and straightened blades

Cutting Plane

FIG. 19

FIG. 20

333559 09/08 9-19

Adjustments

Introduction

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

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.

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

Park Brake Adjustment

Occasionally check the park brake adju stment using the following method:

1. Shut engine off, place control levers in the park brake position, disengage deck clutch, remove ignition switch key and disconnect negative battery cable before doing any adjustments.

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

WARNING:

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 of2000 pounds to block the unit up. Use in pairs only. Follow the instructions supplied with the vehicle stands.

3. Remove the drive tires.

4. Push the steering lever inward into the operating position, disengaging the brake. Only adjust one side at a time.

5. Locate the brake lever arm and brake gear on the EZT transmission.When the steering lever is in the operating position, the brake arm should have a minimum of

0.06" (1.52MM) and maximum of 0.125"(3.18MM) clearance between the teeth of the brake lever arm and the outside diameter of the brake gear (FIG. 21).

6. If you find that the clearance is not to this specification, then adjust the position of the brake lever arm by moving the lock nuts on the brake rod according ly. When adjusting the nuts, the spacing between the inside of th e n uts needs to be maintained at 7/8"(2.22CM) which has been set at the factory. The best way to keep this spacing is to turn both nuts in the same direction the same number of turns (FIG. 22).

7. Loosen the jam nut on the brake rod and rotate the adjusting tube (FIG. 23) until the dimensions shown in Fig. 9-18 can be attained.Re-tighten the locknut.

8. After adjustment s are made and the proper clearance is re stored, actuate and release the brakes with the steering lever several times.Check to make sure the brake arm on the EZT is engaging and fully disengaging the teeth of the brake gear.

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

10. Assemble the rear tires and re-torque the lug nuts to 65-75 ft.-lbs.(88.14-101.7 NM)

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

Never work under the machine or attachment unless it is safely supported with jack

Steering linkage adjustment

The neutral adjustment has been factory adjusted to eliminate creeping when the control levers are in the neutral position. However, if the steering linkage should ever need adjustment due to the unit creeping when the steering levers are in the neutral position or the EZT’s whining when the parking brakes are engaged, take the unit to an Authorized Hustler Dealer for adjustment.

9-20 333559 09/08

FIG. 21 FIG. 22

BRAKE

GEAR

.06"-.125"

GAP

BRAKE

LEVER ARM

LOCK

NUT

BRAKE

GEAR

BRAKE

LEVER ARM

7/8"

ADJUSTING

TUBE

JAM

NUT

FIG. 23

WARNING: Only properly trained personnel should attempt to reset the neutral adjustment on

the FasTrak 36/42.This procedure requires that the engine be running and the drive wheels rotating during adjustment.

WARNING: The adjustable steering rods are located near the EZT integrated pump/motor fans.

Make certain the engine is not running when adjusting the steering rod s. The neutral adjustment for the control levers in the neutral position is discussed in this section.

Control lever neutral adjustment

sions do not “whine” .

333559 09/08 9-21

Before considering any adjustment, check the tire air pressure. Unequal tire pressure will cause the tractor to drift to one side. Refer to tire pressure information in the Maintenance section of this manual.

NOTE: Proper park brake adjustment must be completed before the control

lever neutral adjustment can be done. Fine adjustment to the unit’s steering is made with the adjustable pump linkage rods(FIG. 24). Neutral is properly adjusted when the control levers are in the park brake position and the EZT transmis-

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

1. Raise and block the tractor frame keeping the rear drive tires free and clear of any obstructions so they are free to rotate. The engine will be running and tires rotating during this operation.

WARNING:

Never work under the machine or attachment unless it is safely supported with jack

supplied with the vehicle stands.

FRONT DAMPER

BALL STUD

JAM NUT

PUMP ROD

ADJUSTER ASSEMBLY

JAM NUT

2. Remove the seat pan locknut as shown in FIG. 4. Tilt the seat forward. Temporarily bypass the seat switch.

3. Loosen the front dampener ball stud nut as shown in FIG. 24. The dampener will be adjusted and tightened after neutral is reset.

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

5. Shut of f the machine. Loosen the jam nuts on each end of the pump control rod as shown in FIG. 24.

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

FIG. 24

WARNING: This operation is extremely dangerous.

the pump control rod so you do not get your fingers, tools, or anything else close to the EZT pump cooling fans.

Pay close attention when adjusting

7. While holding the steering lever position discussed in step 6,carefully adju st the pu mp control rod until the rear wheel start s turning forward. Now turn the pum p control rod in the opposite direction until the moment when the wheel just stops turning forward. Turn the control rod a nother 1/2 turn in this direction.Hold the pump rod in this position and actuate the parking brake with steering lever. The EZT should not whine.

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

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

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

10. Neutral is now set. St art the engine a nd actuate the br akes a few times to confirm th at the EZT does not whine when the park brake is set.

11. Repeat for the other side.

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

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

A. The operator must be on the seat when testing the seat switch. B. Set both control levers in the park brake position. C. Start the engine and allow it to warm up to operating temperature. D. With the deck clutch switch down and the control le vers in th e park brake position, slowly raise off

of the seat. The engine should continue to run.

E. With the deck clutch switch up and/or the control levers in the neutral position, slowly raise off of

the seat. The engine should stop.

F. If the engine fails to stop when the deck clutch switch is up or one or both of the co ntro l levers a re

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

9-22 333559 09/08

determined, replace the seat switch. If the problem can not be located, contact your Hustler

SPRING

TENSION

IDLER

PUMP DRIVE

BELT

Dealer.

WARNING:

function properly, it should be corrected immediately. Do not operate machine without properly functioning seat safety switch.

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

The safety interlock system should always function per steps 4 and 5. If it does not

Steering dampener adjustment

The steering dampener is spring loaded to return the control leve rs to the neutra l position from the reverse position. This gives the operator a sense of neutral during operation.If the steering control lever does not return to neutral from reverse then adjust as follows:

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

1. Shut engine off, place control levers in the park brake position, disengage deck clutch, remove ignition switch key and disconnect negative battery cable before doing any adjustments.

2. If you have not already done so, loosen the front ball stud that is attached to the forward dampener socket, FIG. 24.

3. When the ball stud is loosened, pull out on the ball stud end and release. The dampener will return to the neutral position and come to rest. Re-tighten the front ball stud.

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

5. Repeat for the opposite side.

Hydraulic pump belt adjustment

The pump drive belt tension remains constant by means of a tension idler and spring (FIG. 25). 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 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 the pump belt fails, loss of control will occur especially when operating on a slope.

FIG. 25

333559 09/08 9-23

Deck drive belt adjustment

TENSION

IDLER

SPRING

CHAIN

ANCHOR

BRACKET

7.50”

1.50”

The spindle belt tension remains constant by means of a tension idler and spring (FIG. 26). The spring ten-

FIG. 26

sion 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. 26). Installed spring length should be 7.50" ± .3) originally with adjustments of .60" per chain link. (FIG. 27).

FIG. 27

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

Engine RPM setting

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

Deck leveling and height adjustment

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

DECK LEVEL ADJUSTMENTS

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

1. Check tire pressures to make certain they are properly inflated before starting to level deck. The recommended pressures are as follows:

PSI Drive Tires 8-12 Front Wheels 8-12

9-24 333559 09/08

WARNING: Stop engine. Make sure deck clutch switch is in the down (OFF) position. Remove

SPACER BLOCKS

HEIGHT ADJUSTING STOP

HEIGHT STOP

HANDLE

ADJUSTING BAR

NUTS

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" tall spacer blocks under the edge of the deck - two in fron t on each side and two in back on each side. (FIG. 28). Remove the height adjusting stop

FIG. 28

and let the deck down so it rests on the 3" spacer blocks. Make sure the deck is setting on all four blocks. Leave the height adjusting stop out of the square adjusting bar for now. The deck should be leveled before the height is set. (FIG. 29)

333559 09/08 9-25

FIG. 29

4. Loosen the two nuts that hold the deck adjusting bar in position. (FIG. 30)

FIG. 30

5. Loosen the two nuts that hold the right rear deck lifting arm. (FIG. 31)

NUTS

DECK LIFTING ARM

5/16" BOLT

FLANGE NUTS

JAM NUT

FIG. 31

6. Loosen the left rear deck leveling bracket by loosening the flange nuts. (FIG. 32)

FIG. 32

7. Loosen the jam nut and back out the 5/16" bolt on top of the adjuster. (FIG. 32)

8. Check to make sure the deck is resting firmly on all of the 3" blocks. Check the front right deck chain to be sure it is taut. Now, screw both nuts finger tight against the square block on the right rear deck lift arm. Tighten these two nuts. (FIG. 31)

9. Tighten the 5/16" bolt on the adjuster until the chain is taut. Tighten the jam nut against the adjuster. Tighten the two flange nuts. (FIG. 32) The deck should now be level.

10. To adjust the deck height insert the height adjusting stop into the 3-1/4" position. (FIG.

29)

1 1. Tighten the rear nut against the block attached to the de ck lif ting pe dal as tight as you

can by hand. (Fig. 3) Make sure the stop handle is pushing firmly against the height adjusting stop so that there is no free play forward or rearward when you shake the adjustment bar. (FIG. 30)

12. Finger tighten the front nut against the block attached to the deck lifting pedal. Tighten both nuts and check to make sure that all deck linkage hardware are tight. (FIG. 30)

13. Raise the deck into transport position and remove the blocks from under the deck corners. The deck should now be level and the deck cutting height properly adjusted.

9-26 333559 09/08

Numerical Index

Part Page No. No.

Index

Part Numbers

000323 4-11 000331 4-11 005116 6-5 005231 4-3 011320 2-4 015495 3-3 015818 4-11 016253 4-3 017004 4-7 017129 6-5 017616 7-2 019521 5-4 024927 3-2 025007 3-5 025296 3-3 026237 4-13 028118 3-5 029868 3-2 029876 3-9 030817 4-7 031997 2-3 034272 3-3

034280 6-3 036244 4-7 036384 3-5 042630 5-2 043570 4-3 044255 4-7 045898 4-13 046821 6-5 048553 3-9 050161 4-3 052860 4-3 053199 2-3 054502 2-4

055749 3-3 055822 4-11 055939 3-2 055947 4-13 056077 4-3 058776 6-5 059832 4-13 059931 6-5 060731 3-9 061077 5-4 061101 3-5 064006 6-5 068478 1-1 068551 3-9

, 6-11

, 4-7 , 6-11

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

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

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

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

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

, 6-11

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

6-11

, 7-2

, 4-7 , 6-11

, 3-7 , 6-11

Part Page No. No.

076422 2-4 079186 3-9 083279 8-3 086660 3-9 089789 3-9 104786 4-3 306969 5-2 314989 3-2 315101 3-9 315382 3-9 315440 2-2 315572 6-3 316836 2-3 316844 2-4 320242 2-2 320267 2-4 320275 7-4 320580 2-3 321042 6-11 321059 4-13 321398 6-5 321877 6-5 322974 6-3 324046 3-5 325464 3-9 330225 6-3 330274 4-3 330324 6-5 330399 6-3 334045 3-3 335695 3-5 335893 3-5 338442 1-1 339689 5-2 344267 2-3 348284 3-3 348318 3-3 348458 3-3 352054 3-9 352112 3-9 352500 6-3 360131 3-3 360487 3-9 364315 3-5 378273 4-3 546895 2-2 546911 2-2 546929 6-9 546937 6-3 600221 3-9 600899 8-3 600941 8-3

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

, 4-3, 4-7

, 6-11 , 6-11 , 6-9 , 3-7

, 6-9 , 4-7

, 6-9 , 3-7

, 3-7

, 5-2

, 6-9

, 3-7, 6-5

Part Page No. No.

601156 1-1 601434 6-5 704478 4-7 704643 3-3 704932 4-13 705178 3-9 705954 5-2 706531 4-3 710087 3-5 712257 4-13 712372 4-3 712919 3-7 712927 4-3 712976 5-2 714998 4-13 718288 3-5 727016 8-3 727172 8-4 739144 4-3 740696 3-2 745059 4-11 747303 1-1 756270 3-3 763417 4-7 767954 2-4

767962 2-3 768044 5-2

768259 3-9 768515 4-3 768523 3-5

771428 3-2 771436 8-3 772806 5-3 772814 5-3 776476 4-13 778365 4-13 779306 4-11 781153 3-5 781211 3-9 781229 3-3 781260 3-9 781294 3-3 781302 6-5 781567 2-3

781708 2-3 781831 3-3

, 7-2

, 4-7 , 3-7

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

, 3-9 , 8-5

, 4-7

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

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

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

6-9, 7-2

, 4-7, 4-13 , 3-7, 3-9, 4-3,

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

, 4-7

, 3-7

, 6-11 , 3-9, 5-2, 6-3,

6-9, 7-2

, 6-3, 6-9

FADFST3642 9/08 i-1

Part Page No. No.

781872 6-5, 6-11 781880 4-11 781922 3-9 782474 6-5 782573 8-3 782664 4-3 782995 3-3 783134 5-4 783142 5-4 783159 5-4 783506 6-5 783514 6-14 783522 6-14 783530 6-14 783548 6-14 783555 6-14 783696 3-9 784223 5-2 784264 5-4 784272 5-4 784280 5-4 784504 6-5 784603 5-2 784710 8-3 784827 3-5 784918 4-3 785030 4-13 785048 4-3 785063 3-2 785139 8-3 785147 8-3 785220 8-3 785295 4-11 785394 4-3 785485 2-4 785543 4-3 785808 4-13 785832 6-5 786632 3-2 786640 3-2 786657 4-13 787069 6-5 787226 1-1 787234 1-1 787242 1-1 787267 4-3 788166 2-3 788232 3-5 788877 3-5

, 6-3, 6-9

, 6-11

, 3-7 , 4-7

, 4-7

, 6-11

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

788968 8-3 791251 4-3 791608 4-3 791723f 3-5 792013 3-5 792762 4-7 792788 4-7 792796 4-3 792895 3-5 792911 3-5 792929 3-5 792945 4-7 792952 4-7 792960 4-11 792978 4-11 792986 4-11 793059 3-9 793083 4-3 793117 4-7 793125 4-3 793133 4-7 793141 4-3 793158 4-7 793166 4-3 793174 3-9 793182 3-9 793315 7-4 793331 1-1 793406 5-4 793489 3-2 793505 3-3 793513 8-5 793521 8-4 793547 8-3 793554 8-3 793570 8-4 793588 8-3 793612 3-9 793646 3-9 793679 7-4 793687 8-4 793703 8-3 793760 4-3 793778 6-5 793786 6-5 793794 1-1 793802 1-1 793810 4-13 793828 1-1

, 4-7 , 3-7

, 3-7

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

, 4-7

, 8-5

, 8-5 , 4-7

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

, 6-5 , 6-5

793836 1-1 793844 2-4 793851 7-4 793869 2-2 793885 4-7 793893 1-1 794081 4-11 794172 4-3 794180 4-3 794297 8-4 794305 8-3 794313 1-1 794370 1-1 794396 3-9 794404 3-5 794503 8-4 794545 8-3 794552 3-5 794644 4-3 794883 3-9 794974 3-5 794982 3-5 795005 3-5 795013 3-5 795021 3-5 795039 3-5 795047 3-5 795054 3-5 795062 3-5 795229 3-9 795625 3-9 796516 4-7 796615 3-9 797050 3-9 797449 6-5 797456 7-4 797753 3-9 797761 3-9 797779 3-9 798363 3-5 798371 3-5 799221 4-11 808485 6-3 808493 2-2 927343 1-1 927350 1-1 927368 1-1 927376 1-1

, 3-5, 3-7

, 6-11

, 4-7 , 8-5

, 8-5

, 4-7 , 3-7

, 3-7 , 3-7 , 3-7 , 3-7 , 3-7 , 3-7 , 3-7 , 3-7

, 6-11

, 3-7 , 3-7

, 6-9 , 2-3

i-2 FADFST3642 9/08

Hustler Turf FasTrak 36, FasTrak 42 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

Chapter 1

General Information

Chapter 2 Contents

Tractor Frame Rivet Nut Installation

Engine Guard and Anti-rollover Bracket Assemblies

Footrest Assembly

Chapter 3 Contents

Battery Installation

Deck Lift Assembly

Hydro Transmission Installation S/N Prior To 07091558

Hydro Transmission Installation S/N Higher Than 07091558

Steering and Brake Assembly

Chapter 4 Contents

Honda 16 HP Engine Installation

Kohler 15 & 17 HP Engine Installation

Fuel System Installation

Instrument Panel Installation

Honda 16HP Electrical Schematic (793083)

Kohler 15 & 17 HP Electrical Schematic (601127& 793117)

Chapter 5 Contents

Front Wheel Assembly

Front Wheel Breakdown -768044

Drive Wheel Assembly

Chapter 6 Contents

Deck Assembly 36"

Deck Pulley Assembly 36"

Deck Assembly 42"

Deck Pulley Assembly 42"

Blade Spindle Assembly Breakdown

Chapter 7 Contents

Deck Installation

Belt Routing and Tensioning

Seat Installation

Chapter 8 Contents

Tractor Decals

42" Deck Decals

36" Deck Decals

Chapter 9 Contents

Maintenance & Adjustment Safety

Maintenance

Adjustments

Index