HUSTLER Truck Engine 108277 Parts Manual
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HUSTLER Truck Engine 108277 Parts Manual

Hustler truck engine parts manual
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Enlarged version
Parts Manual
•••••••
Hustler Turf Equipment
•••••
P.O. Box 7000
•••
Hesston, Kansas
•
67062-2097

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Summary of Contents for HUSTLER Truck Engine 108277

  • Page 1 Parts Manual ••••••• Hustler Turf Equipment ••••• P.O. Box 7000 ••• Hesston, Kansas • 67062-2097...
  • Page 2 WARNING: The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. IMPORTANT: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate this engine on any forest-covered, brush-covered, or grass-covered unimproved land.
  • Page 3 108277 10/08...
  • Page 4 108277 10/08...

  • Page 5: Table Of Contents

    Chapter 1 General Information ........1-1 Chapter 2 Contents Rivet Nut Installation .
  • Page 6 Maintenance & Adjustment Safety ......9-14 Maintenance ......... . 9-18 Adjustment .

  • Page 7: General Information

    General Information This Manual covers Hustler FasTrak models 928267, 928275, 928291, 928502, & 928520 Frequently Ordered Parts PART NO. 600979 791335 789388 785626 068478 785618 785600 780155 601155 772111 772103 794370 785634 772079 747303 600976 601124 601123 Service Literature PART NO. 601156 778423 601158...
  • Page 8 Options Available From Your Dealer PART NO. Hardware Description Codes & Abbreviations The following codes are used throughout this parts manual. Refer to this list when ordering parts. ABBREVIATION DESCRIPTION Carriage Bolt Clevis Pin Cotter Pin Clip Nut Cap Screw Cup Washer FDRW Fender Washer...

  • Page 9: Chapter 2 Contents

    Chapter 2 Contents Rivet Nut Installation ........2-2 Engine Guard and Anti Rollover Wheels .

  • Page 10: Rivet Nut Installation

    Rivet Nut Installation SERVICE INDEX NO. PART NO. 548289 548297 MFG. PART QTY. 107819 54" FASTRAK FRAME 107890 48" FASTRAK FRAME 600994 3/8-16 THREAD RIVET NUT 808493 3/8-16 THREAD RIVET NUT 808485 5/16-18 THREAD RIVET NUT NOTES: DESCRIPTION 108277 10/08...

  • Page 11: Engine Guard And Anti Rollover Wheels

    Engine Guard and Anti Rollover Wheels SERVICE INDEX NO. PART NO. 107840 781708 767962 031997 053199 344267 781567 052860 767954 788166 1. Includes items 2 through 5. 108277 10/08 MFG. PART QTY. 107840 FASTRAK ENGINE GUARD CS .500-13 X 4.25 HX G5 ZNYC FW .531 X 1.063 X .090 SAE ZNYC ANTI-SCALP WHEEL NT .500-13 HX JAM ZNYC...

  • Page 12: Footrest Assembly

    Footrest Assembly SERVICE INDEX NO. PART NO. 107839 785485 785493 011320 767954 054502 MFG. PART QTY. 107839 FLOOR PLATE 785485 UPPER STEP TREAD 785493 LOWER STEP TREAD 011320 CB .375-16 X .750 STD ZNYC 767954 FW .406 X .812 X .060 SAE ZNYC 054502 NT .375-16 HX GRD 5 ZNYC NOTES:...

  • Page 13: Chapter 3 Contents

    Chapter 3 Contents Battery Installation ........3-2 Deck Lift Assembly .

  • Page 14: Battery Installation

    Battery Installation 108277 10/08...
  • Page 15 Battery Installation SERVICE MFG. PART INDEX NO. PART NO. 714618 768523 348417 601062 601312 601063 024927 029868 055939 771428 740696 601069 794644 000331 1. When performing service on mower, disconnect battery ground cable and do not reconnect to battery until engine is ready to be started. See Owners Manual.

  • Page 16: Deck Lift Assembly

    Deck Lift Assembly 108277 10/08...
  • Page 17 Deck Lift Assembly SERVICE INDEX NO. PART NO. 348318 348284 784488 781294 601681 704643 782995 055749 781831 360131 756270 348458 781229 767962 015495 1. Apply grease to zerks. 108277 10/08 MFG. PART QTY. 348318 STOP HANDLE 348284 HEIGHT ADJUSTMENT STOP 784488 DECK LIFT INDICATOR 781294...

  • Page 18: Hydro Transmission Installation

    Hydro Transmission Installation 108277 10/08...
  • Page 19 Hydro Transmission Installation SERVICE INDEX NO. PART NO. 710087 038828 768523 784827 028118 781872 600979 025007 025296 781153 107881 601084 016410 767954 600987 034272 036384 601020 601019 601088 048553 600759 055939 768515 068551 601001 601018 600880 000331 1. Torque to 17 ft-lbs. 2.

  • Page 20: Steering Sub-Assembly

    Steering Sub-Assembly CONNECTS TO PARK BRAKE LINKAGE SERVICE ITEM NO. PART NO. 781260 360487 767954 705178 086660 107843 107842 768523 600991 023655 107848 107847 770867 705178 1. Includes Item 1 (781260 Steering Bar Grip). MFG. PART QTY. STEERING BAR GRIP 360487 STEERING BAR 767954...
  • Page 21 This page intentionally left blank. 108277 10/08...

  • Page 22: Steering And Brake Assembly

    Steering and Brake Assembly See “Steering Sub-Assembly” on page 3-8. ASSEMBLED BRAKE RODS TRACTOR FRAME BRAKE ARM 3-10 BELL CRANK DETAIL HYDRO TRANSAXLE 108277 10/08...
  • Page 23 Steering and Brake Assembly SERVICE INDEX NO. PART NO. 704163 768515 109318 068551 034272 768523 781922 600221 600981 023655 784439 086660 767954 005116 706168 601087 029876 054502 765339 107893 107892 600989 080655 601131 005108 107894 108430 055939 016816 601051 000331 036236 361295 1.
  • Page 24 3-12 108277 10/08...

  • Page 25: Chapter 4 Contents

    Chapter 4 Contents Honda 18 & 20 HP Engine Installation ..... . . 4-2 Kawasaki 19 & 21 HP Engine Installation ..... 4-4 Kohler 19 HP Engine Installation .

  • Page 26: Honda 18 & 20 Hp Engine Installation

    Honda 18 & 20 HP Engine Installation PART OF ENGINE TAN/RED GRA/PUR PART OF ENGINE RED/BLK 108277 10/08...
  • Page 27 Honda 18 & 20 HP Engine Installation SERVICE INDEX NO. PART NO. 784611 784629 601002 601003 785378 785543 017004 782664 016253 768523 034272 787689 050161 043570 785477 768515 056077 601118 712372 799429 784835 763417 785048 784918 791251 000331 070664 058776 600998 601063 029876...

  • Page 28: Kawasaki 19 & 21 Hp Engine Installation

    Kawasaki 19 & 21 HP Engine Installation NEGATIVE BATTERY CABLE PART OF ENGINE TAN/RED POSITIVE BATTERY CABLE RED/BLK 19 HP EXHAUST & CLAMP DETAIL 108277 10/08...
  • Page 29 Kawasaki 19 & 21 HP Engine Installation SERVICE INDEX NO. PART NO. 601082 601081 058776 768523 050161 784918 000331 799429 712372 791251 784835 763417 785048 029876 796524 601341 600999 024927 044818 601118 768515 601062 792762 601319 771428 044255 055939 064329 109338 601429 601429...
  • Page 30 SERVICE MFG. PART INDEX NO. PART NO. 1. Part of Item 16 (600999/601341 FasTrak Kawasaki Wire Harness). 2. Engine oil capacity:See engine manual. 3. Engine speed; High idle—3450 ±50 rpm. 4. Connected to item 16 (600999/601341 FasTrak Kawasaki Wire Harness). 5.
  • Page 31 This page intentionally left blank. 108277 10/08...

  • Page 32: Kohler 19 Hp Engine Installation

    Kohler 19 HP Engine Installation NEGATIVE BATTERY CABLE RED/BLK 108277 10/08 POSITIVE BATTERY CABLE...
  • Page 33 Kohler 19 HP Engine Installation SERVICE INDEX NO. PART NO. 601067 601342 601000 058776 768523 029876 024927 768515 044255 601319 771428 030817 601312 792762 055939 038828 780841 601005 601002 016253 785378 034272 796516 036244 784918 799429 712372 784835 791251 763417 785048 000331 108969...
  • Page 34 6. Connected to item 2 (601000/601342 FasTrak Kohler Wire Harness). 7. Bolt and washer supplied with engine. For replacement part, order 029710 (Cap Screw .312-18X .750 HXFLK). 8. Used on mowers with serial numbers prior to 07080126. 9. On mowers with serial numbers prior to 07062321, item 10 (starter solenoid) is located in engine compartment.
  • Page 35 This page intentionally left blank. 108277 10/08 4-11...

  • Page 36: Instrument Panel Installation

    Instrument Panel Installation RIGHT FUEL TANK FUSE SIZE AND LOCATION 4-12 108277 10/08...
  • Page 37 Instrument Panel Installation SERVICE INDEX NO. PART NO. 601095 601097 776476 785808 769166 712257 045898 026237 778365 601094 601096 601089 601098 107902 704932 059832 768515 055947 1. Part of 600998, 600999, 601000, 601341 or 601342 wire harness. 108277 10/08 MFG. PART QTY.

  • Page 38: Fuel System Installation (With S/N Higher Than 07102604)

    Fuel System Installation (with S/N higher than 07102604) 4-14 108277 10/08...
  • Page 39 Fuel System Installation (with S/N higher than 07102604) SERVICE INDEX NO. PART NO. 779306 601320 601321 000323 712919 055822 745059 015818 015818 015818 015818 015818 000331 034280 768523 000398 034272 1. Torque to 20 ft-lbs. 108277 10/08 MFG. PART QTY. 779306 3.5"...

  • Page 40: Fuel System Installation (With S/N Prior To 07102604)

    Fuel System Installation (with S/N prior to 07102604) 4-16 108277 10/08...
  • Page 41 Fuel System Installation (with S/N prior to 07102604) SERVICE INDEX NO. PART NO. 779306 600963 600964 000323 712919 055822 706531 047456 745059 015818 015818 015818 015818 000331 1. Torque to 20 ft-lbs. 2. See “FasTraks with Honda engines” on page 9-4 for Honda fuel line routing.

  • Page 42: Kawasaki Electrical Schematic (600999/601341)

    Kawasaki Electrical Schematic (600999/601341) 4-18 108277 10/08...

  • Page 43: Kohler Electrical Schematic (601000/601342)

    Kohler Electrical Schematic (601000/601342) 108277 10/08 4-19...

  • Page 44: Honda Electrical Schematic (600998)

    Honda Electrical Schematic (600998) 4-20 108277 10/08...

  • Page 45: Chapter 5 Contents

    Chapter 5 Contents Front Wheel Assembly........5-2 Front Wheel Breakdown .

  • Page 46: Front Wheel Assembly

    Front Wheel Assembly SERVICE INDEX NO. PART NO. 705954 344267 712976 784223 784603 339689 042630 767962 781567 768044 306969 1. Apply grease to zerks, see owners manual. 2. Torque to 75 ft.-lbs. 3. Assemble with extended inner race down. MFG. PART QTY.

  • Page 47: Front Wheel Breakdown

    Front Wheel Breakdown SERVICE INDEX NO. PART NO. 772814 772806 1. Inflate to 8-12 psi. 108277 10/08 768044 MFG. PART QTY. 3/4" ROLLER BEARING BEARING CAP NOTES: DESCRIPTION...

  • Page 48: Drive Wheel Assembly

    Drive Wheel Assembly INDEX SERVICE MFG. PART PART NO. 784264 784264 784272 784280 019521 061077 061077 783134 783134 783142 783159 019521 061077 061077 1. Inflate tire to 8-12 psi. 2. Torque to 65-75 ft-lbs. QTY. WHEEL/TIRE ASSY 18 X 9.50 (QTY PER 54" TRACTOR) TIRE 18 X 9.5 WHEEL TIRE VALVE...

  • Page 49: Chapter 6 Contents

    Chapter 6 Contents 54" Deck Assembly ........6-2 54"...

  • Page 50: 54" Deck Assembly

    54" Deck Assembly 108277 10/08...
  • Page 51 54" Deck Assembly SERVICE INDEX NO. PART NO. 548305 601117 108537 034280 768523 034272 767954 086660 025395 108049 601069 781708 767962 031997 053199 781567 787994 788166 1. Includes items 12 through 15. 2. Service part deck includes decals (see “54" Deck Decals” on page 8-4 for listing of decals).

  • Page 52: 54" Deck Pulley Assembly

    54" Deck Pulley Assembly 54" Deck Assy 108277 10/08...
  • Page 53 54" Deck Pulley Assembly SERVICE INDEX NO. PART NO. 789388 025007 046821 797449 784504 028118 600296 797910 601434 350884 781302 259812 781872 782474 786889 108123 108124 016972 064006 768523 054502 767954 005116 783506 058776 601124 783738 1. Torque to 118 ft.-lbs. 2.

  • Page 54: 48" Deck Assembly

    48" Deck Assembly 108277 10/08...
  • Page 55 48" Deck Assembly SERVICE INDEX NO. PART NO. 548313 601117 108537 034280 768523 034272 025395 767954 086660 108049 601069 781708 767962 031997 053199 781567 787994 1. Includes items 12 through 15. 2. Service part deck includes decals (see “48" Deck Decals” on page 8-5 for a listing of decals).

  • Page 56: 48" Deck Pulley Assembly

    48" Deck Pulley Assembly 48" Deck Assy 108277 10/08...
  • Page 57 48" Deck Pulley Assembly SERVICE INDEX NO. PART NO. 791335 025007 046821 797449 784504 028118 600296 797910 601434 350884 781302 259812 781872 782474 792689 108148 108149 016972 064006 768523 054502 767954 005116 783506 058776 601123 783738 1. Torque to 118 ft.-lbs. 2.

  • Page 58: Blade Spindle Assembly Breakdown

    Blade Spindle Assembly Breakdown SERVICE INDEX NO. PART NO. 783548 783555 783530 783514 783522 MFG. PART QTY. BLADE SPINDLE RETAINING BEARING, BLADE SPINDLE SPACER, BLADE SPINDLE HOUSING, BLADE SPINDLE SHAFT, BLADE SPINDLE NOTES: 6-10 DESCRIPTION 108277 10/08...

  • Page 59: Chapter 7 Contents

    Chapter 7 Contents Seat Installation ......... 7-2 Deck Installation .

  • Page 60: Seat Installation

    Seat Installation 108277 10/08...
  • Page 61 Seat Installation SERVICE INDEX NO. PART NO. 793661 034280 768523 108321 808485 000331 548776 034272 052860 767954 601450 064014 058776 1. Do not torque, Item 7 (107861 Seat Pan) must pivot. 2. Service parts, (Michigan seat): 793307 793315 797464 797472 797480 793273 108277 10/08...

  • Page 62: Deck Installation

    Deck Installation SERVICE INDEX NO. PART NO. 055749 017616 767962 704643 008193 MFG. PART QTY. 055749 CS .437-14X1.750 HX G5 017616 CS .500-13X1.750 HX G5 767962 FW .531X 1.063X.090 SAE 704643 NT .437-14 HX FLG ZN 008193 NT .500-13 HX G5 ZNYC NOTES: DESCRIPTION 108277 10/08...

  • Page 63: Deck Belt Routing And Tensioning

    Deck Belt Routing and Tensioning 1. Spring length after tensioning new belt. Spring length measured from outside of hook to outside of hook. Tension spring with deck in leveling position. 2. Route belt as shown. 108277 10/08 NOTES:...
  • Page 64 108277 10/08...

  • Page 65: Chapter 8 Contents

    Chapter 8 Contents Tractor Decals ......... . 8-2 54"...

  • Page 66: Tractor Decals

    Tractor Decals 108277 10/08...
  • Page 67 Tractor Decals SERVICE INDEX NO. PART NO. 785121 785139 784710 727172 782573 793588 785220 788968 785154 601100 791848 601099 771436 600899 727016 785147 600941 108277 10/08 MFG. PART QTY. 785121 OPERATION RIGHT DECAL 785139 STEERING L.S. DECAL 083279 TURF PROD SERIAL NO PLATE 784710 FASTRAK DECAL 727172...

  • Page 68: 54" Deck Decals

    54" Deck Decals SERVICE INDEX NO. PART NO. 799171 727453 727438 727172 785055 781419 727420 MFG. PART QTY. 799171 54" DECK ID DECAL 727453 BELT & PULLEY DECAL 727438 WHIRLING BLADES DECAL 727172 'MADE IN U.S.A.' DECAL 785055 STEP TREAD 3.70 X 9.00 781419 BELT ROUTING DECAL 727420...

  • Page 69: 48" Deck Decals

    48" Deck Decals SERVICE INDEX NO. PART NO. 793976 727453 727438 727172 794503 781419 727420 108277 10/08 MFG. PART QTY. 793976 48" DECK ID DECAL 727453 BELT & PULLEY DECAL 727438 WHIRLING BLADES DECAL 727172 'MADE IN U.S.A.' DECAL 794503 STEP TREAD MINI FST DECAL 781419 BELT ROUTING DECAL...
  • Page 70 108277 10/08...

  • Page 71: Chapter 9 Contents

    Assembly Pictures and Aids ....... 9-3 General Information for all models ..... 9-3 Wire harness routing (all models).
  • Page 72 Transaxle drive belt replacement ..... 9-29 Mower blade maintenance ......9-29 Mower blade removal .

  • Page 73: Assembly Pictures And Aids

    Assembly Pictures and Aids General Information for all models Instrument panel layout (FIG. 1). Wire harness routing (all models). Front of wire harness (FIG. 2 & FIG. 3). TIE STRAP TO SEAT SWITCH FIG. 2 PTO CLUTCH SWITCH FIG. 1 FROM SAFETY SWITCHES TIE STRAP...

  • Page 74: Fastraks With Honda Engines

    FasTraks with Honda engines Wire harness, battery cable, throttle cable, and choke cable routing and tie straps (FIG. 4 & FIG. 5). TIE STRAPS SEAT SWITCH WIRE FUEL LINE OIL SENSOR WIRE NOTE: Tie straps on rear seat support tie fuel line from L.S. fuel tank. TIE STRAP CHOKE &...
  • Page 75 Engine connections )FIG. 6, FIG. 7, FIG. 8, and FIG. 9). SENSOR WIRE FUEL LINE FIG. 6 SENSOR WIRE FILL TUBE FUEL LINE FIG. 8 NOTE: Route oil sensor wire between oil file tube and engine block. Index ter- minal on wire in horizontal direction to hold wire off oil filter. NOTE: Tie carburetor drain tubes and clutch pigtail together to clutch anchor.

  • Page 76: Fastraks With Kawasaki Engines

    FasTraks with Kawasaki engines FOR MOWERS WITH SERIAL NUMBER 07102604 AND HIGHER. Front of wire harness (FIG. 10). Route the 4" positive battery cable and the purple and red wires through the cable boot prior to fastening hardware to solenoid (FIG. 11). TIE STRAP TIE STRAP FROM...
  • Page 77 Wire harness, battery cable, and throttle and choke cable, routing and tie straps (FIG. 13 & FIG. 14) . FUEL LINE GROUND WIRE NEGATIVE BATTERY CABLE FIG. 13 Clutch pigtail to clutch anchor tie strap (FIG. 15). Safety switches and tie straps (FIG. 16) STRAP FIG.
  • Page 78 Fuel line routing (FIG. 19, FIG. 20 & FIG. 21). Be sure fuel filter does not come in contact with engine. LEFT FUEL LINE FIG. 19 LEFT FUEL LINE FUEL VALVE FUEL LINE TO FILTER FUEL FILTER TIESTRAP FUEL LINE FROM FUEL VALVE FIG.

  • Page 79: Fastraks With Kawasaki Engines

    FasTraks with Kawasaki engines FOR MOWERS WITH SERIAL NUMBERS PRIOR TO 07102604: Wire harness, battery cable, and throttle and choke cable, routing and tie straps (FIG. 22, FIG. 23, & FIG. 24) . FUEL LINE TIE STRAP GROUND WIRE CHOKE AND THROTTLE CABLES FIG.
  • Page 80 Engine connections for 19 HP (FIG. 25 & FIG. 26). CHOKE CABLE FIG. 25 Engine connections for 21 HP (FIG. 27 & FIG. 28). THROTTLE CABLE FIG. 27 THROTTLE CABLE STRAP CHOKE CABLE 9-10 SENSOR WIRE FIG. 26 SENSOR WIRE FIG.

  • Page 81: Fastraks With Kohler Engines

    FasTraks with Kohler Engines FOR ENGINES WITH SERIAL NUMBERS PRIOR TO 07102604 (FIG. 29): FOR ENGINES WITH SERIAL NUMBERS 07102604 AND HIGHER: Front of wire harness (FIG. 30). Route the 4" positive battery cable and the purple and red wires through the cable boot prior to fastening hardware to solenoid (FIG.
  • Page 82 Wire harness and battery cable, and throttle and choke cable, routing and tie straps (FIG. 33, & FIG. 34) . FROM BATTERY STRAP FIG. 33 NOTE: Tie strap on rear seat support (FIG. 33) ties fuel line from L.S. fuel tank similar to Kawasaki engines.
  • Page 83 Clutch pigtail to clutch anchor tie strap (FIG. 36). STRAP CLUTCH PIGTAIL FIG. 36 9-13 108277 10/08...

  • Page 84: Maintenance & Adjustment Safety

    Maintenance & Adjustment Safety This safety alert symbol is used to call attention to a message intended to provide a reasonable degree of PER- SONAL 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.

  • Page 85: Using A Ramp

    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.
  • Page 86 The following illustrations show the various decals that are located on the machine. A brief explanation, for those requiring one, 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.
  • Page 87 Keep shields or covers in place while machine is in operation. Keep hands away from rotating pulleys and belts. Part Number 727453 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.

  • Page 88: Maintenance

    Maintenance Locator Chart Maintenance 2a. Fuel Filter (Honda) 2b. Fuel Filter (Kawasaki) 2c. Fuel Filter (Kohler) 3. Engine Air Cleaner 4. Engine Oil Drain Plug 5. Battery 6. Fuel Tanks 7. Gauge Wheel Bearing Zerks (2) 8. Engine Oil Filter 9.

  • Page 89: Introduction

    SERVICE AT INTERVALS INDICATED Verify safety start interlock system Visually 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 &...

  • Page 90: Torque Values

    It is important for level mowing that the tires have the same amount of air pressure. The recommended pressure are: Solid fill tires are not recommended for Hustler turf equipment. On any machine, with solid filled tires, the war- ranty claim will be denied.
  • Page 91 The battery is located under the seat platform. FIG. 38 WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. WARNING: Avoid skin and clothing contact with battery acid. Always wear eye protection when checking the battery, acid can cause serious injury to skin and eyes.

  • Page 92: Access To Zt2800 Transaxles

    voltage. If the battery voltage is satisfactory, check the cleanliness and tightness of the terminals and ground connec- tions. A general understanding of electrical servicing and use of basic test equipment is necessary for troubleshooting and repair. Major overhaul or repair of the starting motor or charging system should be performed by trained technicians only. Access to ZT2800 transaxles The integrated pump/motor units are accessed by lifting the seat platform.

  • Page 93: Fluid Changing Procedure

    FIG. 40 WARNING: When washing the mower, direct the spray away (especially if using a power washer) from the Hydro-Gear ZT 2800 transaxle’s seals to prevent water intrusion and to ensure component performance. WARNING: Make sure the transaxles are cool before performing service procedures. Fluid changing procedure 1.

  • Page 94: Fuel System

    13. Continue to fill the transaxles through the expansion tank until the “Full Cold” line is reached on the expansion tank. 14. Re-install the expansion tank cap by hand. Be careful not to overtighten. Fuel system DANGER: Observe usual fuel handling precautions: Do not smoke while refueling.

  • Page 95: Fuel Shut-Off Valves

    Using a fuel stabilizer/conditioner in the tractor can provide benefits such as: 1. Keeps gasoline fresh during storage of 90 days or less. For longer storage, drain the fuel tanks. 2. Cleans the engine during operation. 3. Eliminates gum-like varnish buildup in the fuel system. IMPORTANT: Never use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged.

  • Page 96: Engine Oil And Filter

    To drain a fuel tank use the following method: 1. Park the unit on a flat surface. Stop the engine and remove the ignition key. Make sure deck clutch switch is in the down (OFF) position Place control levers in the park brake position. Disconnect negative battery cable. 2.

  • Page 97: Belt Replacement

    Attach the oil drain hose, furnished with the unit, to the oil drain valve when draining the engine oil. Oil drain hose must be removed after oil is drained. IMPORTANT: All oil drips or spills must be cleaned off of the exhaust system before operating the machine.

  • Page 98: Deck Belt Replacement

    2. Deck blade spindle pulley 3. Spindle belt tension idler 4. Spindle belt tension idler 5. Deck belt idler pulley 6. Idler arm FIG. 51 ANCHOR BRACKET Deck belt replacement 1. Park the unit on a flat surface. Stop the engine and remove the ignition key. Make sure deck clutch switch is in the down (OFF) position Place control levers in the park brake position.

  • Page 99: Transaxle Drive Belt Replacement

    6. Remove the existing belt and replace with a new belt. 7. Route the new belt per FIG. 51. 8. Re-tension the deck belt idler per the Deck drive belt adjustment section located elsewhere in this manual. 9. Re-install the deck belt covers. 10.
  • Page 100 WARNING: Never attempt to straighten a bent blade by heating, or weld a cracked or broken blade as the blade may break and cause serious injury. Replace worn or damaged blades. WARNING: Never work with blades while engine is running or deck clutch switch is engaged (on). Always place deck clutch switch in the disengaged position, place control levers in the park brake position and turn engine off and disconnect negative battery cable.

  • Page 101: Mower Blade Removal

    Mower blade removal Use a 15/16" wrench to remove the 5/8" cap screw holding the blade to the spindle shaft from underneath. Blade Lock Tool, part number 381442, is available from your dealer to prevent the blades from turning while remov- ing or and installing the blade bolts.

  • Page 102: Adjustment

    Introduction Your FasTrak 48/54 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.

  • Page 103: Steering Linkage

    Steering linkage The neutral adjustment for the control levers in the neutral position is discussed in this section. The tractor steering has been factory adjusted to eliminate creeping when the control levers are in the neutral posi- tion (FIG. 61). However, should the tractor begin to creep, the control lever linkage can be adjusted as follows: CONTROL LEVER IN THE NEUTRAL POSITION CONTROL LEVER NEUTRAL ADJUSTMENT...
  • Page 104 CONTROL LEVER IN THE NEUTRAL POSITION JAM NUT FIG. 62 5. Shut off the machine. Loosen the jam nuts on each end of the transaxle control rod as shown in FIG. 62. 6. Start the engine. Move the control lever to just engage the brake (neutral) slot and hold it in that position (Do not engage the control lever far enough to engage the brakes in the brake slot).

  • Page 105: Steering Dampener

    8. Hold the transaxle control rod still and turn off the engine. ENGINE GUARD JACK STANDS FIG. 64 9. Tighten the jam nuts on each end of the transaxle control rod. NOTE tightening the jam nuts (FIG. 62). 10. Neutral is now set. Start the engine and actuate the brakes a few times to confirm that the ZT 2800 transaxle does not whine when the park brake is set.

  • Page 106: Drive Straight Adjustment

    DRIVE STRAIGHT ADJUSTMENT: 1. Initially adjust cap screws all the way in so that the steering levers may go fully forward. 2. Drive tractor in an open area with both steering handles fully forward. The tractor will likely drift slightly to the left or right. 3.

  • Page 107: Deck Drive Belt Adjustment

    WARNING: If the transaxle belt fails, loss of control will occur especially when operating on a slope. If you lose steering control while operating the machine, place the steering control levers in the park brake position immediately. Inspect the machine and involve your Hustler dealer to resolve the prob- lem before continuing to operate.
  • Page 108 deck. The recommended pressures are as follows: Drive Wheels Front Wheels WARNING: Stop engine. Make sure deck clutch switch is in the down (OFF) position. Remove igni- tion key. Place control levers in the brake position before leaving machine. 2. Park the unit on a flat surface. 3.
  • Page 109 18. Tighten the hardware holding the chain and adjuster onto the deck lift arm. DECK LIFT THREADED ROD CHAINS FIG. 73 5/16" BOLT JAM NUT ADJUSTER HARDWARE FIG. 75 Lift Block 19. Go to the right rear of the tractor. 20.
  • Page 110 27. Compress the deck lift assist springs so that there is ½” of space between the front nut on the spring and the rear nut on the deck lift block (FIG. 77). Typical both sides. 28. When completed, all chains will be tight, and deck cutting height will be set to the deck height indicator.

  • Page 111: Index

    Numerical Index Part Page Index Part Numbers 000323 4-15 4-17 000331 3-3 3-11 4-15 4-17 000398 4-15 005108 3-11 005116 3-11 008193 011320 015495 015818 4-15 4-17 016253 016410 016523 016816 3-11 016972 017004 017616 019521 023655 3-11 024927 025007 025296 025395 026237...
  • Page 112 Part Page 601095 4-13 601096 4-13 601097 4-13 601098 4-13 601099 601100 601117 601118 601123 601124 601131 3-11 601155 601156 601158 601206 601207 601221 601312 601319 601320 4-15 601321 4-15 601341 601342 601429 601434 601450 601452 601681 704163 3-11 704643 704932 4-13 705178...
  • Page 113 Part Page 797704 797712 797910 799171 108277 10/08 Part Page 799429 808485 808493 928267 Part Page 928275 928291 928502 928520...
  • Page 114 Part Page Part Page Part Page 108277 10/08...

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