Hustler Turf Fastrak 36 And 42 Decks Users Manual

!! Hustler-25 Hustler Turf Lawn Mower Manuals - Lawn Mower Manuals – The Best Lawn Mower Manuals Collection

to the manual 028a5c1a-1af3-4197-b33d-f43723840e9d

: Hustler-Turf Hustler-Turf-Fastrak-36-And-42-Decks--Users-Manual-565994 hustler-turf-fastrak-36-and-42-decks--users-manual-565994 hustler-turf pdf

Open the PDF directly: View PDF .
Page Count: 98

Download
Open PDF In Browser	View PDF

Hustler FasTrak
36" & 42" Decks
Parts Manual

•••••••
Hustler Turf Equipment

•••••
P.O. Box 7000

•••
Hesston, Kansas

•
67062-2097

WARNING:
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects or other reproductive harm.

IMPORTANT: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code
Section 4442 to use or operate this engine on any forest-covered, brush-covered, or grass-covered unimproved land. Other
states or federal areas may have similar laws.
This spark ignition system complies with Canadian ICES-002.

The Engine Owner’s Manual provides information regarding the U.S. Environmental Protection Agency (EPA) and the
California Emission Control Regulation of emission systems, maintenance and warranty.
Keep Engine Owner’s Manual with your unit. Should the Engine Owner’s Manual become damaged or illegible, replace immediately. Replacements may be ordered per the information found in the Product Information section of the
owner’s manual.

cl-2

333559 9/08

333559 9/08

cl-3

cl-4

333559 9/08

Table of Contents
Chapter 1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Chapter 2
Tractor Frame Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Engine Guard and Anti-rollover Bracket Assemblies . . . . . . . . . . . 2-3
Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Chapter 3
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2
3-3
3-4
3-6
3-8

Chapter 4
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) . . . . .

4-2
4-6
4-10
4-12
4-14
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" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deck Pulley Assembly 36" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deck Assembly 42" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deck Pulley Assembly 42" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blade Spindle Assembly Breakdown . . . . . . . . . . . . . . . . . . . . . . .

6-2
6-4
6-8
6-10
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 . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
333559 09/08

c-1

9-2
9-7
9-20
i-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.
793836
793828
793893
068478
785626
794370
787226
747303
787234
793794
793802

DESCRIPTION
Pump Drive Belt
Deck Belt 36"
Deck Belt 42"
Fuel Filter Kohler
Fuel Filter Honda
Air Filter, Kohler
Air Filter, Honda
Engine Oil Filter, Kohler
Engine Oil Filter, Honda
20.50" 42D X 0.631 CW Blade
13.75" 42D X 0.631 CW Blade

Service Literature
PART NO.
601156
794313
787242

DESCRIPTION
Owners Manual
Kohler Engine Manual
Honda 16 HP Engine Manual

Options
PART NO.
793331
338442

DESCRIPTION
Armrest Kit
Mulch Kit, 36/42"

Note: When ordering parts, you must use the part number as shown for each part, not the index number. Always give
the model and serial number to your parts and service representative.
Note: Items sold in bulk such as seals and hoses are sold by the foot.

Using this manual
Illustrations used were current at the time of printing, but subsequent production changes may cause your machine to
vary slightly in detail. Excel Industries, Inc. reserves the right to redesign and change the machine as deemed necessary, without notification. If a change has been made to your machine which is not reflected in this parts manual, see
your Hustler dealer for current information and parts.

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
CB
CE
CP
CS
CW
FDRW
FW
HX
LW
MB
MS
NT
SC
SH
SB
SS
OD
ID

DESCRIPTION
Carriage Bolt
Clevis Pin
Cotter Pin
Cap Screw
Cup Washer
Fender Washer
Flat Washer
Hex Head
Lock Washer
Machine Bushing
Machine Screw
Nut
Self Tapping Cap Screw
Socket Head
Shoulder Bolt
Set Screw
Outside Diameter
Inside Diameter

Standard Torques
The following chart lists the standard torque values for the threaded fasteners found in this manual. Torque all cap
screws, nuts and set screws to these values unless a different torque is shown in the Notes section next to the fastener

SIZE

FT-LBS

NM

SIZE

FT-LBS

NM

.250
.312
.375
.438
.500
.562
.625
.750
.875
1.00

8.2
17
30
48
73
105
145
260
420
625

11.1
23
40
65
99
143
200
350
565
850

M3
M4
M5
M6
M8
M10
M12
M16
M20
M24

1
2.2
4.5
7.7
18.5
37
64
160
320
555

1.3
3
6.1
10.4
25
50
87
215
435
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
2

1

3

INDEX
NO.
1

SERVICE
PART NO.

MFG. PART
NO.

QTY.

DESCRIPTION

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

NOTES:

2-2

333559 09/08

Engine Guard and Anti-rollover Bracket Assemblies
1

3

4
2

3

3

8

5
6
9
7

1

INDEX
NO.

SERVICE
PART NO.

MFG. PART
NO.

QTY.

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

10

788166

788166

2

ANTI SCALP WHEEL ASSEMBLY

NOTES:

1. Includes items 6 through 9.

333559 09/08

DESCRIPTION

2-3

Footrest Assembly
3

1
4

2

1
6
7

6

5
7

INDEX
NO.

SERVICE
PART NO.

MFG. PART
NO.

QTY.

DESCRIPTION

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

7

054502

054502

4

NT .375-16 HX GRD 5 ZNYC

ZNYC

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
2

1

3
4

5

6
2

3
7

8

4
4

PART OF WIRE
HARNESS (BLK)

2

9

INDEX
NO.

SERVICE
PART NO.

MFG. PART
NO.

QTY.

1

314989

314989

1

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)

DESCRIPTION
BATTERY CLAMP STRAP

8

786640

786640

1

NEGATIVE BATTERY CABLE

9

793489

793489

1

BATTERY CLAMP ROD

NOTES:

3-2

333559 09/08

Deck Lift Assembly
1
2
3

5
6
7
8
9

4
9

10

8

11 1
9
1

7

11

12

7
8

13
14

9

9

7

5
16

17

7

INDEX
NO.

SERVICE
PART NO.

MFG. PART
NO.

QTY.

1

348318

348318

1

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
E CLIP 1.00 X.625X .050

DESCRIPTION
STOP HANDLE

9

781294

781294

5

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

NOTES:

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

333559 09/08

16

3-3

15

Hydro Transmission Installation S/N Prior To 07091558
1

12
1

2

3

5

4

10

6

8

9

7

12

12
21

4
12
1

13 1

2
13
11

14
15

19
20

16
18

17

3-4

333559 09/08

Hydro Transmission Installation S/N Prior To 07091558

3

INDEX
NO.

SERVICE
PART NO.

MFG. PART
NO.

QTY.

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

DESCRIPTION

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

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

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

333559 09/08

PART NUMBER
SERIAL NUMBER
06081543

DESCRIPTION

DESCRIPTION

792013

AXLE NUT

788877

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

3-5

AXLE NUT

Hydro Transmission Installation S/N Higher Than 07091558
1

11
1

3
2
4
5

9
8
6

11
7
20
8

11

21

4
1

11
12

19

3-6

1

2
10

18

12

14

13
16

15
17

333559 09/08

Hydro Transmission Installation S/N Higher Than 07091558
INDEX
NO.

SERVICE
PART NO.

MFG. PART
NO.

QTY.

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

DESCRIPTION

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

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

NOTES:

1. Torque to 17 ft.-lbs.
2. Hydro transmission service parts:
PART NUMBER
PRIOR TO
SERIAL NUMBER
06081543

333559 09/08

PART NUMBER
SERIAL NUMBER
06081543

DESCRIPTION

DESCRIPTION

792013

AXLE NUT

788877

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

3-7

AXLE NUT

Steering and Brake Assembly
1

2
4
5
6

3

9

8

7

8
11 20

4
19
10

12

10
4

14 13

5

21
22

15

23
8
11 13 11
8
17

16

13
8
18 2

11

7
23

8

9

13
41
24

26

35

35

28

27

28

21
8

8

11

39
36 37
38

See Note 4

20

25

27

27
40

33

28
29

30
3

3-8

8

31 32 11

333559 09/08

Steering and Brake Assembly
INDEX
NO.

4

MFG. PART
NO.

QTY.

DESCRIPTION

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

5

3
3
3
3
3
3
3

SERVICE
PART 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

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

1

2

FROM
RECTIFIER
3

1 RED/BLK 37

4
6

POSITIVE
BATTERY
CABLE

23

5

2

1

YEL

PART OF
ENGINE
TO ENGINE
(4 WIRES)
8
9

11

13

12

7

14

8
10

15

16

17
18
19

20

21
PART OF
ENGINE

24

22 4
28
26

4

2

35

36

34

27

25

33
32

31
30
29

4-2

333559 09/08

Honda 16 HP Engine Installation

333559 09/08

INDEX
NO.

SERVICE
PART NO.

MFG.
PART NO.

QTY.

1

785394

785394

1

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

10

787267

N/A

1

HONDA 16 AMP RECTIFIER

11

794644

794644

1

GM 1.50 X 2.12 X 1.75 X .12

DESCRIPTION
HONDA 16HP ENGINE (USED ON 927368 &
927376)

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)

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

1

35

TO STARTER
SOLENOID
FROM NEGATIVE
BATTERY TEMINAL

1

5
1

3
1

1

4

2

8
9
RED 2
PUR

6

TO BATTERY

7

11
RED/BLK

7

16
17 5

10

2

15
17

14

6

5

18

7

19

6
20

7
12

21

13
22

23
24

25

31

32 28

8

30

33

33
34

29
27
4-6

26
333559 09/08

Kohler 15 & 17 HP Engine Installation
INDEX
NO.

SERVICE
PART NO.

MFG.
PART NO.

QTY.

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

DESCRIPTION

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

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

7 35

793117

793117

1

KOHLER WIRE HARNESS

601127

601127

1

KOHLER WIRE HARNESS

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
1
2

4
9
5
12
6
1

12
1

7

3
4

6

7

1

11

4
5

4
10
4

8

8

4-10

333559 09/08

Fuel System Installation
INDEX
NO.

SERVICE
PART NO.

MFG.
PART NO.

QTY.

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)

5

015818

015818

1

FUEL LINE, 12.00" LONG
(KOHLER)

6

015818

015818

1

FUEL LINE, 14.00" LONG
(KOHLER)

11

015818

015818

1

FUEL LINE, 8.5" LONG

12

781880

781880

2

BUMPER, .500X 1.00X .312 X.188

DESCRIPTION

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
1

2

3
4
5

6

8

7
9
1

10
5

1

7

1

8
11

12
13

13
12

10a

20a
FUSE SIZE
AND LOCATION

4-12

333559 09/08

Instrument Panel Installation
INDEX
NO.

SERVICE
PART NO.

MFG.
PART NO.

QTY.

1

786657

786657

1

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

2

DESCRIPTION
CHOKE CABLE (KOHLER)

9

321059

321059

1

INSTRUMENT PANEL

10

026237

N/A

2

RELAY

11

793810

793810

1

THROTTLE CABLE (HONDA)

778365

778365

1

THROTTLE CABLE (KOHLER)

12

055947

055947

3

CS .250-20X .500 HX G5 ZNYC

13

768515

768515

3

FW .281 X .625 X .051/.080 HD ZNYC

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
2

1

3
3

1

4
3

5
2

9

3

4

6

8

2

8
4

3

5

7

3

4

6
10

8
9

1

2

10

11

INDEX
NO.

SERVICE
PART NO.

MFG. PART
NO.

QTY.

1

705954

705954

2

DESCRIPTION
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

10

306969

306969

2

GAGE WHEEL SPACER

11

768044

768044

2

TIRE/WHL 11X4-5 RIBBED

NOTES:

1. Apply grease to zerks, see owners manual.
2. Torque to 75 ft.-lbs.
3. Assemble with extended inner race down.

5-2

333559

Front Wheel Breakdown -768044

2

768044

1

2

INDEX
NO.

SERVICE
PART NO.

MFG.
PART NO.

QTY

1

772814

N/A

1

3/4" ROLLER BEARING

2

772806

N/A

2

BEARING CAP

NOTES:

1. Inflate tire to 8-12 psi.

333559 08/08

5-3

DESCRIPTION

Drive Wheel Assembly

1

6

4

2
3
2

INDEX
NO.

3

5

SERVICE
PART NO.

MFG.
PART 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

QTY

DESCRIPTION

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)

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"

1

4
5
6
2

8

7

2

9
10

3

8
9
12

10

13
11
9
13

12

9

12

14
15

16
17

18

6-2

17

19

333559 09/08

Deck Assembly 36"

1

INDEX
NO.

SERVICE
PART NO.

MFG. 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

QTY.

DESCRIPTION

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

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

788166

788166

1

ANTI SCALP WHEEL ASSY

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"

1

2
3
4
5

10
8
9
6
7
2
3

11

12

13

1

14

4

16

1

13
14
15

17
5

18

17
18

19

19
20
20
22
18

20

22

23

18
21

23

24
25
14
14
1

13

6-4

333559 09/08

Deck Pulley Assembly 36"

3
3
3
3
3

INDEX
NO.

SERVICE
PART NO.

MFG. 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

QTY.

DESCRIPTION

9

364315

059931

1

SPRING CHAIN

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

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

2
3
28

4

29
5
11

30
9
32
31
12

15

13

6-6

333559 09/08

This page intentionally left blank.

333559 08/08

6-7

Deck Assembly 42"

1
4
5
2

6

2

7
8
9
3

10

8
9

12

10
11

13

12

9

13

12

9
15
14

16
17

18
17
19

6-8

333559 09/08

Deck Assembly 42"

1

INDEX
NO.

SERVICE
PART NO.

MFG. 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

QTY.

DESCRIPTION

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

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

788166

788166

1

ANTI SCALP WHEEL ASSY

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"

1

2
3
4
5

6

7
10
9
8
4
11

3
2

5

1

13
14

12

15
16

19

17

18
19
18

19

21

20
17
22
14
1

23

24

6-10

333559 09/08

Deck Pulley Assembly 42"
INDEX
NO.

SERVICE
PART NO.

MFG. PART
NO.

1

793893

793893

1

A-SECTION BELT (FASTRAK 42")

2

025007

025007

2

CS .625-11 X 1.75 HX G5 ZNYC

3

046821

046821

2

FW .656 X 2.00 X .078 ZNYC

4

797449

797449

2

FW .650 X 1.00 X .180 ZNYC G5

5

784504

784504

2

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

6

784199

784199

6

CS .312-18 X 1.25 FLT SH ZY

QTY.

DESCRIPTION

7

601434

601434

2

UHMW IDLER SLIDE

8

321877

321877

1

DECK IDLER

9

259812

059931

1

SPRING CHAIN

10

781302

781302

1

IDLER SPRING
RIGHT PULLEY COVER

11

321398

321398

1

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

31

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

2
3
4

27

5

28

11

29
9
31
30
15

12

3

6-12

333559 09/08

This page intentionally left blank.

333559 08/08

6-13

Blade Spindle Assembly Breakdown
1

2

3

4

2

5

c
INDEX
NO.

SERVICE
PART NO.

MFG. PART
NO.

QTY.

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

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

5

5

2
3

4
4

5
4
1

2

INDEX
NO.

SERVICE
PART NO.

MFG. PART
NO.

QTY.

1

781567

781567

2

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

DESCRIPTION
NT .500-13 HX GR 8 ZY NL

NOTES:

7-2

333559

Belt Routing and Tensioning

NOTES:

1. Spring length after tensioning belt–measured from outside of hook to outside
of hook.
2. Route belt as shown.

333559 08/08

7-3

Seat Installation

1
2
3
4
5

2

3

7

6

1

8

9

INDEX
NO.

SERVICE
PART NO.

MFG. 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

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

3
5

4

6

2
1

13
7
8
9

16

14

10

11

15

12

17

8-2

333559

Tractor Decals
INDEX
NO.

SERVICE
PART NO.

MFG. 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

10

793703

793703

1

INSTRUMENT PANEL DECAL

QTY.

DESCRIPTION

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

NOTES:

333559 08/08

8-3

42" Deck Decals

2
1
3

5

4

6

x
INDEX
NO.

SERVICE
PART NO.

MFG. PART
NO.

QTY.

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

DESCRIPTION

NOTES:

8-4

333559

36" Deck Decals

1

2

3

4
5

6

x
INDEX
NO.

SERVICE
PART NO.

MFG. PART
NO.

QTY.

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

NOTES:

333559 08/08

DESCRIPTION

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. To reduce the potential for injury,
comply with these safety instructions and always pay attention to the safety alert symbol, which means DANGER or
WARNING - “personal safety instructions.” Failure to comply with the instructions may result in personal injury or death.
Incorrect usage of this machine may result in severe injury. Personnel operating and maintaining it should be trained in
the proper use and should read the manuals completely and thoroughly before attempting to set-up, operate, adjust, or
service this machine.

The Quick Reference Decals 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 other persons within the vicinity. 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 adjustments or repairs to the tractor drive system, mower deck or any attachment while
the tractor engine is running or deck clutch is engaged. Repairs or maintenance requiring engine power should
be performed by trained personnel only.
Never work under the machine or attachment unless it is safely supported with jack stands. Make certain machine
is secure when it is raised and placed on the jack stands. The jack stands should not allow the machine to move
when the engine is running and the drive wheels are rotating. Use only certified jack stands. Use only
appropriate jack stands, with a minimum weight rating of 2000 pounds to block the unit up. Use in pairs only.
Follow the instructions supplied with the vehicle stands.
Before working on or under the deck, make certain engine cannot be accidentally started. Shut engine off and
remove ignition switch key for maximum safety. Repairs or maintenance requiring engine power should be
performed by trained personnel only.
Use a stick or similar instrument to clean under the mower making sure that no part of the body, especially arms
and hands are under mower.
Exercise caution when working under the deck as the mower blades are extremely sharp. 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
Specific safety warning decals are located on the equipment near the immediate areas of potential hazards. These
decals should not be removed or obliterated. Replace them if they become non-readable.
The following illustrations show the various safety decals that are located on the machine. A brief explanation is shown to help the operator understand the meanings of these decals.
Read Owner’s Manual and Quick Reference Decal before attempting to operate this machine.

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

Part Number
727016

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.

Part Number
793547

If you loose steering control while operating the machine, place the
steering control levers in the park brake position immediately. Inspect the machine and involve
your Hustler dealer to resolve the problem before continuing to operate.
If pump belt fails, steering control will be lost. Refer to owner’s manual for inspection and
replacement intervals and refer to above paragraph for emergency procedures.

Part Number
600899

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

Do not refuel while in enclosed trailer or other enclosed areas.
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.
Part Number
793570

333559 09/08

9-5

Whirling blades! Keep hands and feet away. Beware of thrown objects. 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. Beware of thrown object.

Part Number
794297

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

Part Number
727453

9-6

333559 09/08

Maintenance
MAINTENANCE LOCATOR
CHART
6
3a

5

11

10

7

9

3b
15
16

4
8
1
2
11

7

10

6

9

1.
2.
3a.
3b.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

12

14

Engine Oil Fill & Dipstick (Honda & Kohler)
Fuel Filter
Engine Air Cleaner (Honda)
Engine Air Cleaner (Kohler)
Engine Oil Drain Plug)
Battery
Fuel Tanks
Wheel Bearing Zerks (2)
Engine Oil Filter
Deck Lift Pivot Zerks (4)
Park Brake Switch (2)
Drive Tire
Deck Belt
Pump Belt
Blades
Engine Air Intake Screen
Front Tires

Viewed from top of unit

13

FIG. 1
333559 09/08

9-7

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 & 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 ANNUALLY OF
HOURS
100 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
Prior to each use
Prior to each use
X
X
X
X
X
X
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

NOTES:
1. Initial oil change is after 5 hours of operation. Thereafter, change oil after ever 40 hours. 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 replace of worn 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 fol9-8

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:

Wheel (lug) nuts
Blade spindle top bolt
Blade spindle bottom bolt

Ft.-lbs.
65-75
118
118

Nm
88.14-101.7
160
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
8-12
8-12

Drive Tires
Front Wheels

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

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

Lubrication
1. Grease the front wheel bearings per the Maintenance Schedule. Use SAE multi-purpose grease.
2. Grease the four deck lift pivots, located to the side of the operator’s footrest per the Maintenance
Schedule. Use SAE multi-purpose grease.

Electrical system
333559 09/08

9-9

The electrical system is a 12 volt, negative ground. Recommended battery size is a garden tractor BCI
group UIR with 225 or better cranking AMP rating. A maintenance-free battery is recommended. Otherwise, follow battery manufacturer’s maintenance, safety, storing, and charging specification.
The Battery is located under the seat platform (FIG. 2).
WARNING: Battery post, 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: 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 battery acid. Always wear eye protection when
checking the battery, acid can cause serious injury to skin and eyes. If contact occurs, flush area
with clean water and call physician immediately. Acid will also damage clothing. Do not drink the
battery electrolyte. Do not allow open flame near the battery when charging. Hydrogen gas forms
inside the battery. This gas is both toxic and flammable and may cause an explosion if exposed to
flame. Always remove the negative ground first and replace it last. Do not overfill battery.
Electrolyte may overflow and damage paint, wiring or structure. When cleaning the battery, use
soap and water. be careful not to get soap and water into the battery. Clean the battery terminals
with a solution of four parts water and one part baking soda when they become corroded.

BATTERY

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
Clutch/Aux

20 amp, blade type
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 tightness of the terminals and
ground connections. A general understanding of electrical servicing and use of basic test equipment is necessary for troubleshooting and repair.

FUSES

FIG. 3
Major overhaul or repair of the starting motor or charging system should be performed by trained technicians only.

Access to integrated pump/motor units
The integrated pump/motor units are accessed by lifting the seat platform. The seat platform is hinged at
the front. 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).
LOCK NUT
FLAT WASHER

FIG. 4
If the seat is equipped with the optional arm rest kit, make certain to place the control arms in the park
brake position and pivot the arm rests upward before placing the seat platform in the full forward position to
prevent damage to the arm rests.

Hydraulic system

333559 09/08

9-11

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 20W50 engine oil. If they ever become low on
oil, fill to the level shown in FIG. 6.

FIG. 6

Fuel system
DANGER: Observe usual fuel handling precautions:
Do not smoke while refueling. Extinguish all cigarettes, cigars, pipes and other sources of ignition.
Do not remove fuel cap or fill tank with engine running or while engine is hot. Clean up any gasoline
spills.
Allow engine to cool before storing machine inside a building.
Keep fuel away from open flame or spark and store machine away from open flame or spark 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 swallowed. Long-term exposure to vapors can cause
serious injury and illness. Avoid prolonged breathing of vapors. Keep face away from nozzle and
gas tank or 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 tractor’s fenders (FIG. 7). Total capacity for the fuel tanks is 6 U. S. gallons
(22.71 L.).
FUEL TANK

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. Keeps gasoline fresh during storage of 90 days or less. For longer storage, drain the fuel tanks
2. Cleans the engine during operation.
3. Eliminates gum-like varnish buildup in the fuel system.
IMPORTANT: Do not use fuel additives containing methanol or ethanol.
Add the correct amount of gas stabilizer/conditioner to the gas. Follow the gas stabilizer/conditioner manufacturer’s directions for best results.
The fuel filter (FIG. 8, & FIG. 9) is installed in the fuel line between fuel tanks and engine fuel pump. Replace
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

INLET HOSE

INLET HOSE

FUEL FILTER
FUEL FILTER
FIG. 8 HONDA

FIG. 9 KOHLER
FUEL SHUT-OFF
VALVE

LEFT FUEL
TANK POSITION
RIGHT 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
is IN THE DOWN (OFF) POSITION. Place control levers in the park position. Disconnect negative battery
cable.
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
drain the remaining fuel from the hose.
4. Remove the fuel tank from the tractor. Remove the fuel cap, tip the tank and drain the fuel into an approved
fuel container.
5. When fuel tank is drained, re-attach the fuel tank to the tractor andre-connect the fuel line to the fuel tank
fitting. Make certain hose clamp is properly installed.
6. Fill fuel tank with proper grade of gasoline and open shut-off valve.

Engine oil and filter
9-14

333559 09/08

Check engine oil daily and after every 4 hours of operation. Crankcase dipstick and oil filler tube ar located
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.
DIPSTICK & ENGINE
OIL FILLER TUBE

ENGINE OIL
FILTER
ENGINE OIL
DRAIN PLUG

DIPSTICK &
ENGINE OIL
FILLER TUBE
ENGINE OIL
FILTER

FIG. 11 HONDA

FIG. 12 KOHLER

ENGINE OIL
DRAIN PLUG

FIG. 13 KOHLER

333559 09/08

9-15

Engine mounting bolts
If the original engine mounting bolts are ever removed from the tractor, do not reuse. The original bolts are
self-tapping and if they are 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 checking and cracking, or burns caused by slipping. Slight raveling of belt covering
does not indicate failure, trim ravelling with a sharp knife.
WARNING: If the pump belt fails, loss of control will occur especially when operating on a slope.
If you lose steering control while operating the machine, place the steering control levers
in the park brake position immediately. Inspect the machine and involve your Hustler
dealer to resolve the problem before continuing to operate.

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

Deck belt replacement
DECK BELT DRIVE LAYOUT
1. SPINDLE DRIVE BELT

2

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

4
2

6
3

5

1

FIG. 14
1. Park the unit on a flat surface. Stop the engine and remove the ignition key. Make sure deck clutch switch
is in the down (OFF) position. Place control levers in the park brake position. Disconnect negative
battery cable.
2. Place the deck in the lowest position.
3. Remove the deck belt covers.
4. Release the deck belt tension by pulling on the belt tension chain and sliding the chain out of the anchor
9-16

333559 09/08

5.
6.
7.
8.
9.
10.

bracket slot. This will relieve the tension on the deck belt idler spring (FIG. 14.
Pull the idler to the left of the machine to provide maximum belt clearance.
Remove the existing belt and replace with a new belt.
Route the new belt per FIG. 14.
Re-tension the deck belt idler per the Deck drive belt adjustment section located elsewhere in the manual.
Re-install the deck belt covers.
Re-attach the negative 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

5

5

1

7

3

8

2 6

4
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 removed from any
of the other pulleys.
7. Release the tension from the integrated pump/motor belt by pulling on the belt tension chain and sliding
the chain out of the anchor bracket slot. (FIG. 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 integrated pump/motor pulleys and fans.
10. The belt can now be removed from above the engine pulley.
11. Install new belt by sliding it up and over the engine pulley. Make certain it is not in the pulley groove at this
time but is above the pulley.
12. Slide the belt over the integrated pump/motor pulleys.

333559 09/08

9-17

13. Slide the belt onto the engine pulley.
14. Slide the belt onto the engine pulley.
SPRING
ENGINE
PULLEY

ANCHOR
BRACKET
SLOT

DECK IDLER
PULLEY

CHAIN

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 properly 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-attach the negative 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 stripped, worn or undercut threads. Torque bolts on spindles to 118
foot-pounds (160.01Nm) when reinstalling blades.
IMPORTANT: The blade sail (curved part) must be pointing upward toward the inside of the deck to
ensure proper cutting.
WARNING: When mounting blades, rotate them after installation to ensure blade tips do not
touch each other or sides of the mower.

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

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

9-18

333559 09/08

Warped Blade (Replace)
Cutting
plane

Straight Blade (Replace)

Comparison of Warped and Straight Blades
Re sharpening
pattern

FIG. 19

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

Cutting edge

Cutting Plane

Twisted Blade Edge
(replace)
Cutting edge

Straight Blade Edge
End view of blades, comparing
twisted and straightened blades

Original edge

FIG. 20
FIG. 18

333559 09/08

9-19

Adjustments
Introduction
Your FasTrak 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 adjustment using the following method:
1. Shut engine off, place control levers in the park brake position, disengage deck clutch,
remove ignition switch key and disconnect negative battery cable before doing any
adjustments.
2. Raise and block the tractor up so the drive wheels are off of the floor.
WARNING: Never work under the machine or attachment unless it is safely supported with jack
stands. Make certain machine is secure when it is raised and placed on the jack stands. The jack
stands should not allow the machine to move when the engine is running and the drive wheels are
rotating. Use only certified jack stands. Use only appropriate jack stands, with a minimum
weight rating 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 accordingly. When
adjusting the nuts, the spacing between the inside of the nuts 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 adjustments are made and the proper clearance is restored, actuate and release
the brakes with the steering lever several times.Check to make sure the brake arm on
the EZT is engaging and fully disengaging the teeth of the brake gear.
9. Repeat this process for the opposite side if required.
10. Assemble the rear tires and re-torque the lug nuts to 65-75 ft.-lbs.(88.14-101.7 NM)
11. Raise the rear of the tractor and remove the jack stands. Lower the tractor.

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

9-20

333559 09/08

.06"-.125"
GAP

BRAKE
GEAR

7/8"

LOCK
NUT

BRAKE
GEAR

BRAKE
LEVER ARM

BRAKE
LEVER ARM
FIG. 21

FIG. 22

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

Control lever neutral adjustment
Before considering any adjustment, check the tire air pressure. Unequal tire pressure will cause the tractor
to drift to one side. Refer to tire pressure information in the Maintenance section of this manual.
NOTE:
Proper park brake adjustment must be completed before the control
lever neutral adjustment can be done.
Fine adjustment to the unit’s steering is made with the adjustable pump linkage rods(FIG. 24).
Neutral is properly adjusted when the control levers are in the park brake position and the EZT transmissions do not “whine” .
If this occurs, the control linkage may be adjusted as follows:
1. Raise and block the tractor frame keeping the rear drive tires free and clear of any
obstructions so they are free to rotate. The engine will be running and tires rotating
during this operation.
WARNING: Never work under the machine or attachment unless it is safely supported with jack
stands. Make certain machine is secure when it is raised and placed on the jack stands. The jack
stands should not allow the machine to move when the engine is running and the drive wheels are
rotating. Use only certified jack stands. Use only appropriate jack stands, with a minimum
weight rating of2000 pounds to block the unit up. Use in pairs only. Follow the instructions

333559 09/08

9-21

FRONT DAMPER
BALL STUD

JAM
NUT

PUMP ROD
ADJUSTER ASSEMBLY
JAM
NUT
FIG. 24
supplied with the vehicle stands.

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 off 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).
WARNING: This operation is extremely dangerous. Pay close attention when adjusting
the pump control rod so you do not get your fingers, tools, or anything else close to the EZT pump
cooling fans.
7. While holding the steering lever position discussed in step 6,carefully adjust the pump
control rod until the rear wheel starts turning forward. Now turn the pump control rod in
the opposite direction until the moment when the wheel just stops turning forward.
Turn the control rod another 1/2 turn in this direction.Hold the pump rod in this position
and actuate the parking brake with steering lever. The EZT should not whine.
8. Hold the pump control rod still and turn off the engine.
9. Tighten the jam nuts on each end of the pump control rod.
NOTE:
Do not let pump control rod turn while tightening the jam nuts.
10. Neutral is now set. Start the engine and actuate the brakes a few times to confirm that
the EZT does not whine when the park brake is set.
11. Repeat for the other side.
12. The steering dampener now needs to be adjusted and tightened.
13. Reconnect the seat switch and make sure the seat switch is operating properly per the
following procedure:
A. The operator must be on the seat when testing the seat switch.
B. Set both control levers in the park brake position.
C. Start the engine and allow it to warm up to operating temperature.
D. With the deck clutch switch down and the control levers in the park brake position, slowly raise off
of the seat. The engine should continue to run.
E. With the deck clutch switch up and/or the control levers in the neutral position, slowly raise off of
the seat. The engine should stop.
F. If the engine fails to stop when the deck clutch switch is up or one or both of the control levers are
not in the park brake position and the operator is off the seat, check the function of the seat switch.
If the seat switch is not operating properly (is not opening or closing) and if the cause can not be
9-22

333559 09/08

determined, replace the seat switch. If the problem can not be located, contact your Hustler
Dealer.
WARNING: The safety interlock system should always function per steps 4 and 5. If it does not
function properly, it should be corrected immediately. Do not operate machine without properly
functioning seat safety switch.

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

Steering dampener adjustment
The steering dampener is spring loaded to return the control levers to the neutral position from the reverse
position. This gives the operator a sense of neutral during operation.If the steering control lever does not
return to neutral from reverse then adjust as follows:
To set the steering dampeners in the correct operating position follow these steps:
1. Shut engine off, place control levers in the park brake position, disengage deck clutch,
remove ignition switch key and disconnect negative battery cable before doing any
adjustments.
2. If you have not already done so, loosen the front ball stud that is attached to the
forward dampener socket, FIG. 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 brake and pull the steering lever to the reverse position and allow
the dampener to return the lever to the neutral position. If the steering lever does not
return to the neutral position (centered with the brake slot), then either you have not
adjusted the dampener correctly, or it is damaged and needs to be replaced.
5. Repeat for the opposite side.

Hydraulic pump belt adjustment
The pump drive belt tension remains constant by means of a tension idler and spring (FIG. 25). There is no
tension adjustment of this belt.

TENSION
IDLER

SPRING
PUMP
DRIVE
BELT

FIG. 25
NOTE:
Inspect the belt every 100 hours and replace as needed.Replace the
belt every 200 hours or every two (2) years whichever comes first.
WARNING: If the pump belt fails, loss of control will occur especially when operating on a slope.
If you lose steering 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.

333559 09/08

9-23

Deck drive belt adjustment
The spindle belt tension remains constant by means of a tension idler and spring (FIG. 26). The spring tenTENSION
IDLER
SPRING

ANCHOR
BRACKET

CHAIN

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).

7.50”

1.50”

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:

Drive Tires
Front Wheels

PSI
8-12
8-12

9-24

333559 09/08

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

2. Park the unit on a flat surface.
3. Raise deck and place 3" tall spacer blocks under the edge of the deck - two in front on
each side and two in back on each side. (FIG. 28). Remove the height adjusting stop

SPACER BLOCKS

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)
HEIGHT
STOP
HANDLE

HEIGHT ADJUSTING
STOP

FIG. 29
4. Loosen the two nuts that hold the deck adjusting bar in position. (FIG. 30)
ADJUSTING BAR

NUTS
FIG. 30

333559 09/08

9-25

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

NUTS

FIG. 31
6. Loosen the left rear deck leveling bracket by loosening the flange nuts. (FIG. 32)
5/16" BOLT

JAM NUT
FLANGE NUTS

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)
11. Tighten the rear nut against the block attached to the deck lifting pedal 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
No.

Page
No.

Part
No.

Page
No.

Part
No.

Page
No.

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

2-4
3-9, 6-5
8-3
3-9, 6-3, 6-9, 7-4
3-9
4-3
5-2
3-2
3-9
3-9
2-2
6-3
2-3, 4-3, 4-7
2-4
2-2
2-4
7-4
2-3
6-11
4-13
6-5, 6-11
6-5, 6-11
6-3, 6-9
3-5, 3-7
3-9
6-3, 6-9
4-3, 4-7
6-5
6-3, 6-9
3-3
3-5, 3-7
3-5, 3-7
1-1
5-2
2-3, 5-2
3-3
3-3
3-3
3-9
3-9
6-3, 6-9
3-3
3-9
3-5, 3-7, 6-5
4-3
2-2
2-2
6-9
6-3
3-9
8-3
8-3

601156
601434
704478
704643
704932
705178
705954
706531
710087
712257
712372
712919
712927
712976
714998
718288
727016
727172
739144
740696
745059
747303
756270
763417
767954

1-1
6-5
4-7
3-3, 7-2
4-13
3-9
5-2
4-3, 4-7
3-5, 3-7
4-13
4-3, 4-7
3-7
4-3, 6-5, 6-11
5-2
4-13
3-5, 3-9
8-3
8-4, 8-5
4-3, 4-7
3-2
4-11
1-1
3-3
4-7
2-4, 3-9, 4-3, 4-7,
4-11, 6-3, 6-5, 6-9,
6-11, 7-4
2-3, 3-3, 5-2, 6-3,
6-9, 7-2
5-2
3-9
4-3, 4-7, 4-13
3-5, 3-7, 3-9, 4-3,
4-7, 6-3, 6-5, 6-9,
6-11, 7-4
3-2, 4-7
8-3
5-3
5-3
4-13
4-13
4-11
3-5, 3-7
3-9
3-3
3-9
3-3
6-5, 6-11
2-3, 3-9, 5-2, 6-3,
6-9, 7-2
2-3, 6-3, 6-9
3-3

Index
Part Numbers
000323
000331
005116
005231
011320
015495
015818
016253
017004
017129
017616
019521
024927
025007
025296
026237
028118
029868
029876
030817
031997
034272
034280
036244
036384
042630
043570
044255
045898
046821
048553
050161
052860
053199
054502
055749
055822
055939
055947
056077
058776
059832
059931
060731
061077
061101
064006
068478
068551

4-11
4-11
6-5, 6-11
4-3
2-4
3-3
4-11
4-3, 4-7
4-7
6-5, 6-11
7-2
5-4
3-2, 3-9, 4-3,
3-5, 3-7, 6-5,
3-3, 3-5, 3-7
4-13
3-5, 3-7
3-2
3-9, 4-3
4-7
2-3, 6-3, 6-9
3-3, 3-5, 3-7,
4-3, 4-7, 6-3,
6-3, 6-9, 7-4
4-7, 6-3, 6-9,
3-5, 3-7
5-2
4-3
4-7
4-13
6-5, 6-11
3-9
4-3
4-3, 4-7, 7-4
2-3, 6-3, 6-9
2-4, 6-3, 6-5,
6-11
3-3, 7-2
4-11
3-2
4-13
4-3, 4-7
6-5, 6-11
4-13
6-5
3-9
5-4
3-5, 3-7
6-5, 6-11
1-1
3-9

FADFST3642 9/08

4-7
6-11

3-9,
6-9
7-4

6-9,

i-1

767962
768044
768259
768515
768523

771428
771436
772806
772814
776476
778365
779306
781153
781211
781229
781260
781294
781302
781567
781708
781831

Part
No.

Page
No.

Part
No.

Page
No.

Part
No.

Page
No.

781872
781880
781922
782474
782573
782664
782995
783134
783142
783159
783506
783514
783522
783530
783548
783555
783696
784223
784264
784272
784280
784504
784603
784710
784827
784918
785030
785048
785063
785139
785147
785220
785295
785394
785485
785543
785808
785832
786632
786640
786657
787069
787226
787234
787242
787267
788166
788232
788877

6-5, 6-11
4-11, 6-3, 6-9
3-9
6-5, 6-11
8-3
4-3
3-3
5-4
5-4
5-4
6-5, 6-11
6-14
6-14
6-14
6-14
6-14
3-9
5-2
5-4
5-4
5-4
6-5, 6-11
5-2
8-3
3-5, 3-7
4-3, 4-7
4-13
4-3, 4-7
3-2
8-3
8-3
8-3
4-11
4-3
2-4
4-3
4-13
6-5, 6-11
3-2
3-2
4-13
6-5, 6-11
1-1
1-1
1-1
4-3
2-3, 6-3, 6-9
3-5, 3-7
3-5, 3-7

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

8-3
4-3, 4-7
4-3
3-5, 3-7
3-5, 3-7
4-7
4-7
4-3, 4-7
3-5, 3-7
3-5, 3-7
3-5, 3-7
4-7
4-7
4-11
4-11
4-11
3-9
4-3
4-7
4-3, 4-7
4-7
4-3
4-7
4-3
3-9
3-9
7-4
1-1
5-4
3-2
3-3
8-5
8-4
8-3
8-3
8-4, 8-5
8-3
3-9
3-9
7-4
8-4, 8-5
8-3
4-3, 4-7
6-5, 6-11
6-5
1-1, 6-5, 6-11
1-1, 6-5
4-13
1-1, 6-5

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

1-1, 3-5, 3-7
2-4
7-4
2-2
4-7
1-1, 6-11
4-11
4-3
4-3, 4-7
8-4, 8-5
8-3
1-1
1-1
3-9
3-5
8-4, 8-5
8-3
3-5
4-3, 4-7
3-9
3-5, 3-7
3-5, 3-7
3-5, 3-7
3-5, 3-7
3-5, 3-7
3-5, 3-7
3-5, 3-7
3-5, 3-7
3-5, 3-7
3-9
3-9
4-7
3-9
3-9
6-5, 6-11
7-4
3-9
3-9
3-9
3-5, 3-7
3-5, 3-7
4-11
6-3, 6-9
2-2, 2-3
1-1
1-1
1-1
1-1

i-2

FADFST3642 9/08



---

Source Exif Data:

File Type                       : PDF
File Type Extension             : pdf
MIME Type                       : application/pdf
PDF Version                     : 1.6
Linearized                      : Yes
Page Mode                       : UseOutlines
XMP Toolkit                     : 3.1.1-111
Creator Tool                    : FrameMaker 8.0
Modify Date                     : 2008:10:01 15:04:46-05:00
Create Date                     : 2008:09:10 07:16:57Z
Metadata Date                   : 2008:10:01 15:04:46-05:00
Format                          : application/pdf
Title                           : untitled
Producer                        : Acrobat Distiller 8.1.0 (Windows)
Document ID                     : uuid:330ed0cc-d7a2-48be-9c55-9bd2d8ed7ab0
Instance ID                     : uuid:4d68772d-8ff4-11dd-a8f6-0017f20bffe4
Page Count                      : 98
Creator                         : FrameMaker 8.0

EXIF Metadata provided by EXIF.tools