Hustler-turf 108277 User Manual

•••••••Hustler Turf Equipment•••••P.O. Box 7000•••Hesston, Kansas•67062-2097 Parts Manual

2-2 108277 10/08Rivet Nut InstallationNOTES:INDEX NO.SERVICE PART NO.MFG. PART NO.QTY. DESCRIPTION1 548289 107819 1 54" FASTRAK FRAME548297 10789

9-30 108277 10/08WARNING: Never attempt to straighten a bent blade by heating, or weld a cracked or broken bladeas the blade may break and cause serio

9-31 108277 10/08Mower blade removalUse a 15/16" wrench to remove the 5/8" cap screw holding the blade to the spindle shaft from underneath.

9-32 108277 10/08AdjustmentIntroductionYour FasTrak 48/54 was adjusted before it left the factory and was checked during pre delivery setup. However,

9-33 108277 10/08Steering linkageThe neutral adjustment for the control levers in the neutral position is discussed in this section.The tractor steeri

9-34 108277 10/085. Shut off the machine. Loosen the jam nuts on each end of the transaxle control rod as shown in FIG. 62.6. Start the engine. Move t

9-35 108277 10/088. Hold the transaxle control rod still and turn off the engine.9. Tighten the jam nuts on each end of the transaxle control rod. NOT

9-36 108277 10/08DRIVE STRAIGHT ADJUSTMENT:1. Initially adjust cap screws all the way in so that the steering levers may go fully forward.2. Drive tr

9-37 108277 10/08WARNING: If the transaxle belt fails, loss of control will occur especially when operating on a slope.If you lose steering control wh

9-38 108277 10/08deck. The recommended pressures are as follows:WARNING: Stop engine. Make sure deck clutch switch is in the down (OFF) position. Remo

9-39 108277 10/0818. Tighten the hardware holding the chain and adjuster onto the deck lift arm.19. Go to the right rear of the tractor.20. Make sure

108277 10/08 2-3Engine Guard and Anti Rollover WheelsNOTES:1. Includes items 2 through 5.INDEX NO.SERVICE PART NO.MFG. PART NO.QTY. DESCRIPTION1 10784

9-40 108277 10/0827. Compress the deck lift assist springs so that there is ½” of space between the front nut on the spring and the rear nut on the de

108277 10/08 i-1Numerical IndexPart PageNo. No.Part PageNo. No.Part PageNo. No.IndexPart Numbers000323 4-15, 4-17000331 3-3, 3-7, 3-11, 4-3, 4-5, 4-

Part PageNo. No.Part PageNo. No.Part PageNo. No.i-2 108277 10/08601095 4-13601096 4-13601097 4-13601098 4-13601099 8-3601100 8-3601117 6-3, 6-760111

108277 10/08 i-3Part PageNo. No.Part PageNo. No.Part PageNo. No.797704 1-2797712 1-2797910 6-5, 6-9799171 8-4799429 4-3, 4-5, 4-9808485 2-2, 7-38084

Part PageNo. No.Part PageNo. No.Part PageNo. No.i-4 108277 10/08

2-4 108277 10/08Footrest AssemblyNOTES:INDEX NO.SERVICE PART NO.MFG. PART NO.QTY. DESCRIPTION1 107839 107839 1 FLOOR PLATE2 785485 785485 2 UPPER STEP

108277 10/08 3-1Chapter 3 ContentsBattery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Deck Lift Asse

3-2 108277 10/08Battery Installation12345667777810911111213

108277 10/08 3-3Battery InstallationNOTES:1. When performing service on mower, disconnect battery ground cable and do not reconnect to battery until e

3-4 108277 10/08Deck Lift Assembly12344444555556666666778889101010101112131415151515

108277 10/08 3-5Deck Lift AssemblyNOTES:1. Apply grease to zerks.INDEX NO.SERVICE PART NO.MFG. PART NO.QTY. DESCRIPTION1 348318 348318 1 STOP HANDLE2

3-6 108277 10/08Hydro Transmission Installation119131813234567841791011109121413143316152021252824222423262826262727292

108277 10/08 3-7Hydro Transmission InstallationNOTES:1. Torque to 17 ft-lbs.2. Torque to 100 ft-lbs3. Service parts available for the transaxles:IN

t-2 108277 10/08 IMPORTANT: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section

3-8 108277 10/08Steering Sub-AssemblyNOTES:1. Includes Item 1 (781260 Steering Bar Grip).ITEM NO.SERVICE PART NO.MFG. PART NO.QTY. DESCRIPTION1 78126

108277 10/08 3-9This page intentionally left blank.

3-10 108277 10/08Steering and Brake Assembly13222413106211925231075810676539116141516TRACTOR FRAME336322854292630HYDRO TRANSAXLE19203118133122ASSEMBLE

108277 10/08 3-11Steering and Brake AssemblyNOTES:1. Supplied with transmissions.2. For mowers with serial numbers prior to 07102604, to replace the

3-12 108277 10/08

108277 10/08 4-1Chapter 4 ContentsHonda 18 & 20 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . . 4-2Kawasaki 19 & 21 HP E

4-2 108277 10/08Honda 18 & 20 HP Engine Installation111}536789102927PART OFENGINEYEL1261217141516912182019212223242591229BLK1RED/BLK1PURBRN1GRA/PU

108277 10/08 4-3Honda 18 & 20 HP Engine InstallationNOTES:1. Part of Item 28 (600998 FasTrak wire harness).2. Two wires.3. Connected to Item 28

4-4 108277 10/08Kawasaki 19 & 21 HP Engine Installation1134315445514YEL11PUR1BLKNEGATIVEBATTERYCABLEPOSITIVEBATTERYCABLE1RED1RED/BLK17182021182226

108277 10/08 4-5Kawasaki 19 & 21 HP Engine InstallationINDEX NO.SERVICE PART NO.MFG. PART NO.QTY. DESCRIPTION1 601082 601082 1 21HP KAWASAKI ENGIN

108277 10/08 t-3

4-6 108277 10/08NOTES:1. Part of Item 16 (600999/601341 FasTrak Kawasaki Wire Harness).2. Engine oil capacity:See engine manual.3. Engine speed; Hi

108277 10/08 4-7This page intentionally left blank.

4-8 108277 10/08Kohler 19 HP Engine Installation12345NEGATIVEBATTERYCABLEBLK17778POSITIVEBATTERYCABLERED1101211RED/BLK1BLK14131415}1716184192021222324

108277 10/08 4-9Kohler 19 HP Engine InstallationNOTES:1. Part of Item 2 ( 601000/601342 Kohler Wire Harness).2. Torque to 45-48 ft-lb3. Torque to 3

4-10 108277 10/086. Connected to item 2 (601000/601342 FasTrak Kohler Wire Harness).7. Bolt and washer supplied with engine. For replacement part, o

108277 10/08 4-11This page intentionally left blank.

4-12 108277 10/08Instrument Panel Installation2113567181210913114141515FUSE SIZEAND LOCATION10a 20a11RIGHT FUELTANK64

108277 10/08 4-13Instrument Panel InstallationNOTES:1. Part of 600998, 600999, 601000, 601341 or 601342 wire harness.INDEX NO.SERVICE PART NO.MFG. PAR

4-14 108277 10/08Fuel System Installation (with S/N higher than 07102604)112344556671277891041111131213131314141515

108277 10/08 4-15Fuel System Installation (with S/N higher than 07102604)NOTES:1. Torque to 20 ft-lbs.INDEX NO.SERVICE PART NO.MFG. PART NO.QTY. DESC

t-4 108277 10/08

4-16 108277 10/08Fuel System Installation (with S/N prior to 07102604)112344556677889101141112

108277 10/08 4-17Fuel System Installation (with S/N prior to 07102604)NOTES:1. Torque to 20 ft-lbs.2. See “FasTraks with Honda engines” on page 9-4

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

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

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

108277 10/08 5-1Chapter 5 ContentsFront Wheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2Front Wheel Breakdown

5-2 108277 10/08Front Wheel AssemblyNOTES:1. Apply grease to zerks, see owners manual.2. Torque to 75 ft.-lbs.3. Assemble with extended inner race

108277 10/08 5-3Front Wheel BreakdownNOTES:1. Inflate to 8-12 psi.INDEX NO.SERVICE PART NO.MFG. PART NO.QTY. DESCRIPTION1 772814 N/A 1 3/4" ROLL

5-4 108277 10/08Drive Wheel AssemblyNOTES:1. Inflate tire to 8-12 psi.2. Torque to 65-75 ft-lbs.INDEX NO.SERVICE PART NO.MFG. PART NO.QTY. DESCRIPTI

108277 10/08 6-1Chapter 6 Contents54" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-254" Deck

108277 10/08 c-1Table of ContentsChapter 1General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Chapter 2 Co

6-2 108277 10/0854" Deck Assembly291481061265744115555171712121213131314141315151616161515111711651413

108277 10/08 6-354" Deck AssemblyNOTES:1. Includes items 12 through 15.2. Service part deck includes decals (see “54" Deck Decals” on page

6-4 108277 10/0854" Deck Pulley Assembly212357101413151681112174451920202019201919212220222324261413252754" Deck Assy11181446339185

108277 10/08 6-554" Deck Pulley AssemblyNOTES:1. Torque to 118 ft.-lbs.2. See “Deck Belt Routing and Tensioning” on page 7-5 for belt tensionin

6-6 108277 10/0848" Deck Assembly2471491061253844115555171712121213131314141315151616161515111761415

108277 10/08 6-748" Deck AssemblyNOTES:1. Includes items 12 through 15.2. Service part deck includes decals (see “48" Deck Decals” on page

6-8 108277 10/0848" Deck Pulley Assembly21235101413151681112171818345192020201920191921222025222324261413142748" Deck Assy11467439145

108277 10/08 6-948" Deck Pulley AssemblyNOTES:1. Torque to 118 ft.-lbs.2. See “Deck Belt Routing and Tensioning” on page 7-5 for belt tensionin

6-10 108277 10/08Blade Spindle Assembly BreakdownNOTES:INDEX NO.SERVICE PART NO.MFG. PART NO.QTY. DESCRIPTION1 783548 N/A 1 BLADE SPINDLE RETAINING2 7

108277 10/08 7-1Chapter 7 ContentsSeat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2Deck Installa

c-2 108277 10/08Maintenance & Adjustment Safety . . . . . . . . . . . . . . . . . . . . . . . . . 9-14Maintenance. . . . . . . . . . . . . . . .

7-2 108277 10/08Seat Installation1167839101131246235313

108277 10/08 7-3Seat InstallationNOTES:1. Do not torque, Item 7 (107861 Seat Pan) must pivot.2. Service parts, (Michigan seat):INDEX NO.SERVICE PART

7-4 108277 10/08Deck InstallationNOTES:INDEX NO.SERVICE PART NO.MFG. PART NO.QTY. DESCRIPTION1 055749 055749 4 CS .437-14X1.750 HX G52 017616 017616 2

108277 10/08 7-5Deck Belt Routing and TensioningNOTES:1. Spring length after tensioning new belt. Spring length measured from outside of hook to outs

7-6 108277 10/08

108277 10/08 8-1Chapter 8 ContentsTractor Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-254" Deck

8-2 108277 10/08Tractor Decals161574213891011121314171856

108277 10/08 8-3Tractor DecalsNOTES:INDEX NO.SERVICE PART NO.MFG. PART NO.QTY. DESCRIPTION1 785121 785121 1 OPERATION RIGHT DECAL2 785139 785139 1 STE

8-4 108277 10/0854" Deck DecalsNOTES:INDEX NO.SERVICE PART NO.MFG. PART NO.QTY. DESCRIPTION1 799171 799171 1 54" DECK ID DECAL2 727453 72745

108277 10/08 8-548" Deck DecalsNOTES:INDEX NO.SERVICE PART NO.MFG. PART NO.QTY. DESCRIPTION1 793976 793976 1 48" DECK ID DECAL2 727453 72745

108277 10/08 1-1Chapter 1General InformationThis Manual covers Hustler FasTrak models 928267, 928275, 928291, 928502, & 928520 .Frequently Ordered

8-6 108277 10/08

108277 10/08 9-1Chapter 9 ContentsAssembly Pictures and Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3General Information for

9-2 108277 10/08Transaxle drive belt replacement . . . . . . . . . . . . . . . . . . . . . 9-29Mower blade maintenance . . . . . . . . . . . . . . . .

9-3 108277 10/08Assembly Pictures and AidsGeneral Information for all modelsInstrument panel layout (FIG. 1).Wire harness routing (all models).Front o

9-4 108277 10/08FasTraks with Honda enginesWire harness, battery cable, throttle cable, and choke cable routing and tie straps (FIG. 4 & FIG. 5).N

9-5 108277 10/08Engine connections )FIG. 6, FIG. 7, FIG. 8, and FIG. 9).NOTE: Route oil sensor wire between oil file tube and engine block. Index ter-

9-6 108277 10/08FasTraks with Kawasaki enginesFOR MOWERS WITH SERIAL NUMBER 07102604 AND HIGHER.Front of wire harness (FIG. 10). Route the 4" pos

9-7 108277 10/08Wire harness, battery cable, and throttle and choke cable, routing and tie straps (FIG. 13 & FIG. 14) .Clutch pigtail to clutch an

9-8 108277 10/08Fuel line routing (FIG. 19, FIG. 20 & FIG. 21).Be sure fuel filter does not come in contact with engine.FIG. 19 FIG. 20FIG. 21LEFT

9-9 108277 10/08FasTraks with Kawasaki enginesFOR MOWERS WITH SERIAL NUMBERS PRIOR TO 07102604:Wire harness, battery cable, and throttle and choke cab

1-2 108277 10/08Options Available From Your DealerHardware Description Codes & AbbreviationsThe following codes are used throughout this parts man

9-10 108277 10/08Engine connections for 19 HP (FIG. 25 & FIG. 26).Engine connections for 21 HP (FIG. 27 & FIG. 28).FIG. 25 FIG. 26FIG. 27 FIG.

9-11 108277 10/08FasTraks with Kohler EnginesFOR ENGINES WITH SERIAL NUMBERS PRIOR TO 07102604 (FIG. 29):FOR ENGINES WITH SERIAL NUMBERS 07102604 AND

9-12 108277 10/08Wire harness and battery cable, and throttle and choke cable, routing and tie straps (FIG. 33, & FIG. 34) .NOTE: Tie strap on re

9-13 108277 10/08Clutch pigtail to clutch anchor tie strap (FIG. 36).FIG. 36TIESTRAPCLUTCHPIGTAIL

9-14 108277 10/08Maintenance & Adjustment SafetyThis safety alert symbol is used to call attention to a message intended to provide a reasonable d

9-15 108277 10/08?Except when changing or checking belt, always keep belt covers on mower for safety as well as cleanliness.?Stop the engine before re

9-16 108277 10/08The following illustrations show the various decals that are located on the machine. A brief explanation, for those requiring one, is

9-17 108277 10/08Keep shields or covers in place while machine is in operation.Keep hands away from rotating pulleys and belts.If you lose steering co

9-18 108277 10/08MaintenanceFIG. 3713Viewed from top of unit121414132c3b8151111101066577162a2b94Viewed from top of unit1 Engine Oil Fill & Dipstic

9-19 108277 10/08NOTES:1. Initial oil change is after 5 hours of operation. Thereafter, change oil after every 40 hours operation. Change more often u

108277 10/08 2-1Chapter 2 ContentsRivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Engine Guard and

9-20 108277 10/08wear or damage. A good time to detect potential problems is while performing scheduled maintenance service. Cor-recting the problem a

9-21 108277 10/08The battery is located under the seat platform. FIG. 38WARNING: Battery posts, terminals, and related accessories contain lead and l

9-22 108277 10/08voltage. If the battery voltage is satisfactory, check the cleanliness and tightness of the terminals and ground connec-tions. A gene

9-23 108277 10/08WARNING: When washing the mower, direct the spray away (especially if using a power washer)from the Hydro-Gear ZT 2800 transaxle’s s

9-24 108277 10/0813.Continue to fill the transaxles through the expansion tank until the “Full Cold” line is reached on the expansion tank.14.Re-insta

9-25 108277 10/08Using a fuel stabilizer/conditioner in the tractor can provide benefits such as:1. Keeps gasoline fresh during storage of 90 days or

9-26 108277 10/08To drain a fuel tank use the following method:1. Park the unit on a flat surface. Stop the engine and remove the ignition key. Make s

9-27 108277 10/08Attach the oil drain hose, furnished with the unit, to the oil drain valve when draining the engine oil. Oil drain hose must be remov

9-28 108277 10/08Deck belt replacement1. Park the unit on a flat surface. Stop the engine and remove the ignition key. Make sure deck clutch switch is

9-29 108277 10/086. Remove the existing belt and replace with a new belt.7. Route the new belt per FIG. 51.8. Re-tension the deck belt idler per the D