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Orion Car Audio 1200D Car Amplifier User Manual

1. 108277 10 08 4 2 Honda 18 amp 20 HP Engine Installation SERVICE MFG PART INDEX NO PART NO NO QTY DESCRIPTION 1 784611 784611 1 HONDA 18HP ENGINE 784629 784629 1 HONDA 20HP ENGINE 2 601002 601002 1 HORIZONTAL MUFFLER FST 3 601003 601003 1 FASTRAK MUFFLER MANIFOLD 4 785378 785378 1 MUFFLER CLAMP 5 785543 N A 2 HONDA 20 MUFFLER GASKET 6 017004 N A 4 LW 312 MED SPRING ZNYC 7 782664 N A 4 NT M8 1 25 HX STAINLESS 8 016253 016253 2 CB 312 18X 750 FUL ZN 9 768523 768523 10 FW 343X 687X 051 080H 10 034272 034272 2 NT 312 18 HX G5 ZNYC 11 787689 787689 1 OIL DRAIN VALVE M14X 12 050161 050161 6 CS 312 18X1 750 HX G5 13 043570 043570 2 CLIP HOSE SINGLE FS 14 785477 N A 1 HONDA 20 AMP RECTIFIER 15 768515 768515 6 FW 281X 625X 051 080H 16 056077 056077 2 CS 250 20X1 000 HX G5 17 601118 601118 2 CN 250 20 X 19 MAX THK 18 712372 712372 1 KEY 1 4 SQ X 0 66 LG 19 799429 799429 1 PULLEY A SEC 4 5 OD 20 784835 784835 1 FASTRAK CLUTCH 21 763417 763417 1 FW 454X1 50X 250 22 785048 785048 1 CS 437 20X3 00 HX G5 Z 23 784918 784918 1 RUBBER BUMPER 24 791251 N A 1 CLUTCH PIGTAIL HARNESS 25 000331 000331 1 SMALL SHORT WIRE TIE 26 070664 070664 4 FW 344X 750X 06 ZNYC 27 058776 058776 6 NT 312 18 HXZY NL 28 600998 600998 1 WIRE HARNESS FASTRAK 29 601063 N A 1 BATTERY CABLE NEGATIVE 30 029876 029876 1 LW 312 INT EXT TOOTH Z 31 601062 N A 1 BATTERY CABLE POSITIVE 32 109340 109340 1
2. Maintenance Viewed from top of unit Engine Oil Fill amp Dipstick Fuel Filter Honda Fuel Filter Kawasaki Fuel Filter Kohler Engine Air Cleaner Engine Oil Drain Plug Battery Fuel Tanks Gauge 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 Gauge Wheel Tires FIG 37 9 18 8 Viewed from top of unit 108277 10 08 WEEKLY MONTHLY ANNUALLY SERVICE AT INTERVALS INDICATED OR 50 OR 100 OR 300 HOURS HOURS HOURS Verify safety start interlock system Prior to each use Visually inspect unit for loose hardware and or damaged parts Prior to each use Visually inspect tires Prior to each use Check oil level engine 1 Prior to each use or every 4 hours Clean air intake screen 4 Prior to each use or every 4 hours Clean foam element 4 Prior to each use or every 4 hours Check fuel level Prior to each use Blades sharpen amp securely fastened Prior to each use Discharge chute securely in place amp in lowe
3. SERVICE MFG PART INDEX NO PART NO NO QTY DESCRIPTION 1 783548 N A 1 BLADE SPINDLE RETAINING 2 783555 N A 2 BEARING BLADE SPINDLE 3 783530 N A 1 SPACER BLADE SPINDLE 4 783514 N A 1 HOUSING BLADE SPINDLE 5 783522 N A 1 SHAFT BLADE SPINDLE NOTES 6 10 108277 10 08 108277 10 08 Chapter 7 Contents Seat Installation 2 Deck Installation na E E a a EEE Deck Belt Routing and Tensioning 7 1 Seat Installation qe x 108277 10 08 7 2 Seat Installation INDEX NO AN Oa BOON ade a aNG on SERVICE MFG PART PART NO 793661 034280 768523 108321 808485 000331 548776 034272 052860 767954 601450 064014 058776 NO QTY DESCRIPTION 793661 1 MICHIGAN STANDARD SEAT 034280 1 CS 312 18X 750 HX G5 768523 9 FW 343 X 687 X 051 080 HD 108321 1 SEAT LATCH 48 54 FST 808485 1 5 16 18 RIVET NUT 000331 2 SMALL SHORT WIRE TIE 107861 1 SEAT PAN 034272 4 NT 312 18 HX G5 ZNYC 052860 2 CS 375 16 X 1 25 HX G5 767954 2 FW 406 X 812 X 060 SAE 601450 2 SEAT SPRING 150 LB IN 064014 2 CS 312 18 X 875 HX G5 058776 2 NT 312 18 HX ZNYC NL NOTES 1 Do not torque Item 7 107861 Seat Pan must pivot 2 Service parts Michigan seat 108277 10 08 793307 793315 797464 797472 797480 793273 SLIDE KIT SWITCH SNAP KIT LH ROUND ARMREST ASSEMBLY RH ROUND ARMREST ASSE
4. 7 5 Chapter 8 Contents Tractor Deals u ad oh a AA AS de EDS ER ita 8 2 54 Deck Decana er ehe 8 4 48 Deck Decals a as ses 8 5 Chapter 9 Contents Assembly Pictures and Aids 9 3 108277 10 08 c 1 Maintenance amp Adjustment Safety Maintenance ara esting vaa aaa ne Gre tanh a ah Adj stMment aces nenn Sa Le c 2 108277 10 08 Chapter 1 General Information This Manual covers Hustler FasTrak models 928267 928275 928291 928502 amp 928520 Frequently Ordered Parts PART NO DESCRIPTION 600979 Pump Drive Belt 791335 Deck Belt 48 789388 Deck Belt 54 785626 Fuel Filter Honda 068478 Fuel Filter Kawasaki amp Kohler 785618 Precleaner Air Filter Honda 785600 Air Filter Element Honda 780155 Precleaner Air Filter Kawasaki 21 Hp 601155 Air Filter Paper Element Kawasaki 21 HP 772111 Precleaner Air Filter Kawasaki 19 HP 772103 Air Filter Element Kawasaki 19 HP 794370 Air Filter Kohler 785634 Engine Oil Filter Honda 772079 Engine Oil Filter Kawasaki 747303 Engine Oil Filter Kohler 600976 Oil Filter ZT 2800 601124 18 50 L F CW Blade 601123 16 50 L F CW Blade Service Literature PART NO DESCRIPTION 601156 FasTrak Owner s Manual 778423 Kawasaki Engine Manual 21 HP 601158 Kawasaki Engine Manual 19 HP 785642 Honda 18 amp 20 HP Engine Manual 794313 Kohler Courage Engine Manual Note When ordering parts you must use the part number as shown fo
5. 3 8 108277 10 08 This page intentionally left blank 108277 10 08 3 9 Steerina and Brake Assembl See Steering Sub Assembly vere re D pm gt NP N ASSEMBLED BRAKE RODS 108277 10 08 Steering and Brake Assembly SERVICE MFG PART INDEX NO PART NO NG QTY DESCRIPTION 1 704163 704163 2 CS 250 20X2 00 HX G5 Z 2 768515 768515 4 FW 281X 625X 051 080H gt 109318 109318 2 PUMP ARM 4 068551 068551 2 NT 250 20 HXZY NL 5 034272 034272 4 NT 312 18 HX G5 ZNYC 6 768523 768523 21 FW 343X 687X 051 080H 7 781922 781922 4 BALL STUD DAMPER FS 8 600221 600221 2 STEERING DAMPER 9 600981 600981 2 PUMP ROD ASSEMBLY 10 023655 023655 6 NT 312 24HXZY NL 11 784439 784439 2 LOCK COLLAR 0 757 ID FS 12 086660 086660 4 NT 375 16 HXZY NL 13 767954 767954 12 FW 406X 812 X 060 SAE 14 005116 005116 2 CS 375 16X1 375 HX G5 15 706168 706168 2 NT 375 16 HX JAM GR5 Z 16 601087 601087 2 PLUNGER SWITCH 17 029876 029876 2 LW 312 INT EXT TOOTH ZN 18 054502 054502 2 NT 375 16 HX GRD 5 ZNY 19 765339 765339 4 IGUS BUSHING 20 107893 107893 1 BRAKE BELL CRANK LS SHOWN 21 107892 107892 1 BRAKE BELL CRANK RS NOT SHOWN 22 600989 600989 2 BRAKE ROD ASSEMBLY 23 080655 080655 2 CS 375 16X1 500 HX G5 24 601131 601131 2 BRAKE ARM RET SPRING 25 005108 00
6. e ad ome ul ENGINE OIL FILTER Ani ENGINE OIL FILTER SO FIG 49 v 9 26 KAWASAKI QU e Sy ENGINE OIL DRAIN VALVE 108277 10 08 TE MorsTicKs SE En EA OL MEE FILLER w y JENGINE OIL e FILTER E Ta A we OIL DRAIN HOSE FIG 50 Attach the oil drain hose furnished with the unit to the oil drain valve when draining the engine oil Oil drain hose must be removed after oil is drained IMPORTANT All oil drips or spills must be cleaned off ofthe exhaust system before operating the machine The oil drain and oil filter are located at the rear of the engine FIG 48 FIG 49 amp FIG 50 Belt replacement FIG 51 and FIG 53 show diagrams and descriptions of the units belt drive systems Inspect these belts frequently for wear and serviceability Replace a belt that shows signs of severe cuts tears sep aration 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 A 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
7. 601681 704643 782995 055749 781831 018846 756270 348458 781229 767962 015495 QTY AN AA R TON ON a a DESCRIPTION STOP HANDLE HEIGHT ADJUSTMENT STOP DECK LIFT INDICATOR E CLIP 1 00 X 625 X 05 FW 812X1 50X 120 ZNYC NT 437 14 HX FLG ZNYC DECK LIFT SPRING CS 437 14 X 1 75 HX G5 CS 437 14 X 1 75 FULTH DECK LIFT CHAIN 3 LINKS CS 312 18 X 1 50 FLTHR DECK LEVELER YOKE CE 750 X 2 25 X 1 75 HEADLESS FW 406 X 812 X 060 SAE STRAIGHT GREASE FITTING NOTES 3 5 on Installati ION ISS Hydro Transm 108277 10 08 3 6 Hydro Transmission Installation ERVICE INDEX NO rs 1 710087 2 038828 3 768523 4 784827 5 028118 6 781872 7 600979 8 025007 9 025296 10 781153 11 107881 12 601084 13 016410 14 767954 15 600987 16 034272 17 036384 18 601020 19 601019 20 601088 21 048553 22 600759 23 055939 24 768515 25 068551 26 601001 27 601018 28 600880 29 000331 1 Torque to 17 ft Ibs 2 Torque to 100 ft Ibs MFG PART NO 710087 038828 768523 784827 028118 781872 600979 025007 025296 781153 107881 601084 016410 767954 600987 034272 036384 601020 601019 601088 048553 600759 055939 768515 068551 601001 601018 600880 000331 QTY p A o D D ND PB D BN NN 3 3 AO a NN 3 NN sa a N DESCRIPTION CS 312 18X2 500 HX G5 CS 312 18X2 250 HX G5 FW 343X 687X 051 080H IDLER PULLEY 4 00 OD FW 62
8. 785808 769166 712257 045898 N A 778365 601094 601096 601089 601098 107902 704932 059832 768515 055947 QTY GO OO ND N 3 ND N 29 AND 3s o DESCRIPTION CHOKE CABLE KAWASAKI ONLY CHOKE CABLE KOHLER amp HONDA ONLY PTO SWITCH KEY SET HOUR METER RED INDICATOR LIGHT KEY SWITCH RELAY THROTTLE CABLE HONDA ONLY THROTTLE CABLE KAWASAKI ONLY THROTTLE CABLE KOHLER ONLY RIVET 188 DIA BLK HD CB 10 24 X 500 ZYNC INSTRUMENT PANEL FW 219 X 500 X 048 ZNYC NT 10 24 HX NL ZN FW 281 X 625 X 051 080 HD CS 250 20 X 500 HX G5 NOTES 1 Part of 600998 600999 601000 601341 or 601342 wire harness 4 13 Fuel System Installation with S N higher than 07102604 108277 10 08 4 14 Fuel System Installation with S N higher than 07102604 SERVICE MFG PART INDEX NO PART NO NO QTY DESCRIPTION 1 779306 779306 2 3 5 FUEL CAP 2 601320 601320 1 RIGHT SIDE FUEL TANK 3 601321 601321 1 LEFT SIDE FUEL TANK 4 000323 000323 6 CLIP 5 712919 712919 8 FW 406 X 1 00 X 12 HRD ZNYC ED 6 055822 055822 8 CS 375 16X 750 HX G5 7 745059 745059 1 3 WAY FUEL VALVE 8 015818 015818 1 FUEL LINE 24 00 LONG 9 015818 015818 1 FUEL LINE 11 00 LONG 10 015818 015818 1 FUEL LINE 36 0 LONG HONDA ONLY 10 015818 015818 1 FUEL LINE 13 0 LONG KAWASAKI 10 015818 015818 1 FUEL LINE 11 0 LONG KOHLER 11 000331 000331 1 WIRE TIE SMALL SHORT 12 034280 034280 2 CS 312 18X 750 H
9. ROD ASSY ANTI SCALP WHEEL ASSY NOTES 2 Service part deck includes decals see 54 Deck Decals on page 8 4 for listing of decals 108277 10 08 6 3 54 Deck Pulley Assembl 54 Deck Assy 108277 10 08 6 4 54 Deck Pulley Assembly ERVICE INDEX NO NO 1 789388 2 025007 3 046821 4 797449 5 784504 6 028118 7 600296 8 797910 9 601434 10 350884 11 781302 12 259812 13 781872 14 782474 15 786889 16 108123 17 108124 18 016972 19 064006 20 768523 21 054502 22 767954 23 005116 24 783506 25 058776 26 601124 27 783738 1 Torque to 118 ft Ibs MFG PART NO 789388 025007 046821 797449 784504 028118 600296 797910 601434 350884 781302 059931 781872 782474 786889 108123 108124 016972 064006 768523 054502 767954 005116 783506 058776 601124 783738 QTY N AA 20002 3a ND OO 9 93 WA W s3 DESCRIPTION B SECTION BELT CS 625 11 X 75 HX G5 FW 656 X 2 00 X 078 ZNYC FW 650X1 00X 180 ZNYC G5 5 00 OD 5 8 IDLER PULLEY FW 625 X 1 00 X 134 ZNYC DECK IDLER SPACER CS 312 18X1 50FLT SH ZY IDLER SLIDE UHMW DECK IDLER IDLER SPRING SPRING CHAIN 13 LINKS CS 625 11X1 25 HX G5Z CW 631 2 250X 187 PNT DECK DRIVE 5 0 PULLEY PULLEY COVER LS PULLEY COVER RH NT 625 11 HX G5 ZNYC CS 312 18X 625 HX G5 FW 343X 687X 051 080H NT 375 16 HX GRD 5 ZNYC FW 406X 812 X 060 SAE CS 375 16X1 375 HX G5 BLADE SPINDLE ASSEMBLY NT 312 1
10. 10 08 4 20 108277 10 08 Chapter 5 Contents Front Wheel Assembly Front Wheel Breakdown Drive Wheel Assembly 5 1 Front Wheel Assembl SERVICE MFG PART INDEX NO PART NO NO QTY DESCRIPTION 1 705954 705954 2 CS 500 13 X 1 25 HX G5 ZNYC 2 344267 344267 2 FW 510 X 2 15 X 187 SPL ZNYC 3 712976 712976 2 FW 531 X 1 375 X 125 ZNYC 4 784223 784223 4 BEARING 5 784603 784603 2 FASTRAK SPACER 6 339689 339689 2 CASTER FORK 7 042630 042630 2 CS 500 13 X 6 50 HX G5 ZNYC 8 767962 767962 4 FW 531 X 1 063 X 090 SAE ZNYC 9 781567 781567 2 NT 500 13 HEX G8 ZNYC NL 10 768044 768044 2 TIRE WHEEL ASSEMBLY 11 X 4 5 RIBBED 11 306969 306969 2 GAGE WHEEL SPACER NOTES 1 Apply grease to zerks see owners manual 2 Torque to 75 ft Ibs 3 Assemble with extended inner race down 5 2 108277 10 08 Front Wheel Breakdown SERVICE MFG PART INDEX NO PART NO NO QTY DESCRIPTION 1 772814 N A 1 3 4 ROLLER BEARING 2 772806 N A 2 BEARING CAP NOTES 1 Inflate to 8 12 psi 108277 10 08 5 3 Drive Wheel Assembly INDEX SERVICE NO PART NO 784264 784272 784280 019521 061077 a A UU N 783134 783142 783159 019521 061077 a A N MFG PART NO 784264 N A N A N A 061077 783134 N A N A N A 061077 1 Inflate tire to 8 12 psi 2 Torque to 65 75 ft lbs QTY B N e Ek ei e DO DESCRIPTION WHEEL TIRE ASSY 18 X 9 50 QTY PER 54
11. 3 4 Hydro Transmission Installation 3 6 Steering Sub Assembly 3 8 Steering and Brake Assembly 3 10 Chapter 4 Contents Honda 18 amp 20 HP Engine Installation 4 2 Kawasaki 19 8 21 HP Engine Installation 4 4 Kohler 19 HP Engine Installation 4 8 Instrument Panel Installation 4 12 Fuel System Installation with S N higher than 07102604 4 14 Fuel System Installation with S N prior to 07102604 4 16 Kawasaki Electrical Schematic 600999 601341 4 18 Kohler Electrical Schematic 601000 601342 4 19 Honda Electrical Schematic 600998 4 20 Chapter 5 Contents Front Wheel Assembly is SERE eden 5 2 Front Wheel Breakdown 5 3 Drive Wheel Assembly 5 4 Chapter 6 Contents 54 Deck Assembly 6 2 54 Deck Pulley Assembly 6 4 48 DECK Assembly ss o ee Mrs mod a Aa 6 6 48 Deck Pulley Assembly 6 8 Blade Spindle Assembly Breakdown 6 10 Chapter 7 Contents Seal Installations Bes rar ER Ka aaa 7 2 Deck Installation er erae heheh oe EE Ee EE GE ESE EE he NGA 7 4 Deck Belt Routing and Tensioning
12. 3 5 781567 2 3 5 2 6 3 6 7 788166 2 3 6 3 6 7 704163 3 11 781708 2 3 6 3 6 7 788968 8 3 704643 3 5 7 4 781831 3 5 789388 1 1 6 5 704932 4 13 781872 3 7 6 5 6 9 791251 4 3 4 5 4 9 705178 3 8 781922 3 11 791335 1 1 6 9 705954 5 2 782474 6 5 6 9 791843 8 3 706168 3 11 782573 8 3 792689 6 9 706531 4 17 782664 4 3 4 5 792762 4 5 4 9 710087 3 7 782995 3 5 792796 4 5 712257 4 13 783134 5 4 793273 7 3 712372 4 3 4 5 4 9 783142 5 4 793307 7 3 712919 4 15 4 17 783159 5 4 793315 7 3 712976 5 2 783506 6 5 6 9 793588 8 3 714618 3 3 783514 6 10 793661 7 3 727016 8 3 783522 6 10 793976 8 5 727172 8 3 8 4 8 5 783530 6 10 794313 1 1 727420 8 4 8 5 783548 6 10 794370 1 1 727438 8 4 8 5 783555 6 10 794503 8 5 727453 8 4 8 5 783738 6 5 6 9 794644 3 3 740696 3 3 784223 5 2 796516 4 9 745059 4 15 4 17 784264 5 4 796524 4 5 747303 1 1 784272 5 4 796623 1 2 756270 3 5 784280 5 4 796631 1 2 763417 4 3 4 5 4 9 784439 3 11 797449 6 5 6 9 765339 3 11 784488 3 5 797464 7 3 767954 2 3 2 4 3 7 3 8 3 11 6 3 784504 6 5 6 9 797472 7 3 6 5 6 7 6 9 7 3 784603 5 2 797480 7 3 i 2 108277 10 08 Part No 797704 797712 797910 799171 108277 10 08 Part Page 4 3 4 5 4 9 2 2 7 3 2 2 1 1 Part No 928275 928291 928502 928520 Page No 108277 10 08
13. 48 Deck Assy 6 8 108277 10 08 48 Deck Pulley Assembly ERVICE INDEX NO rs 1 791335 2 025007 3 046821 4 797449 5 784504 6 028118 7 600296 8 797910 9 601434 10 350884 11 781302 12 259812 13 781872 14 782474 15 792689 16 108148 17 108149 18 016972 19 064006 20 768523 21 054502 22 767954 23 005116 24 783506 25 058776 26 601123 27 783738 1 Torque to 118 ft Ibs MFG PART NO 791335 025007 046821 797449 784504 028118 600296 797910 601434 350884 781302 059931 781872 782474 792689 108148 108149 016972 064006 768523 054502 767954 005116 783506 058776 601123 783738 QTY N 200002 ND OO 9 WA W s3 DESCRIPTION B SECTION BELT CS 625 11 X 75 HX G5 FW 656 X 2 00 X 078 ZNYC FW 650X1 00X 180 ZNYC G5 5 00 OD 5 8 IDLER PULLEY FW 625 X 1 00 X 134 ZNYC DECK IDLER SPACER CS 312 18X1 50FLT SH ZY IDLER SLIDE UHMW DECK IDLER IDLER SPRING SPRING CHAIN 13 LINKS CS 625 11X1 25 HX G5 Z CW 631 2 250X 187 PNT DECK DRIVE 5 0 PULLEY PULLEY COVER LS PULLEY COVER RH NT 625 11 HX G5 ZNYC CS 312 18X 625 HX G5 FW 343X 687X 051 080H NT 375 16 HX GRD 5 ZNYC FW 406X 812 X 060 SAE CS 375 16X1 375 HX G5 BLADE SPINDLE ASSEMBLY NT 312 18 HXZY NL 16 50 L F CW BLADE CS 625 11X3 00 FULL HX NOTES 2 See Deck Belt Routing and Tensioning on page 7 5 for belt tensioning 108277 10 08 6 9 Blade Spindle Assembly Breakdown
14. 768523 029876 024927 768515 044255 601319 771428 030817 601312 792762 055939 038828 780841 601005 601002 016253 785378 034272 796516 036244 784918 799429 712372 784835 791251 763417 785048 000331 108969 109252 601429 024927 104786 MFG PART NO 601067 601342 601000 058776 768523 029876 024927 768515 044255 601319 N A 030817 601312 N A 055939 038828 N A 601005 601002 016253 785378 034272 796516 N A 784918 799429 712372 784835 N A 763417 785048 000331 108969 109252 601429 N A 104786 QTY ha Rs sa ss pars o BR N s3 AA a a dd AK AK 4 2 OO AND 3 N nm A N s3 a a 3s N s DESCRIPTION 19 HP KOHLER COURAGE ENGINE KOHLER WIRE HARNESS KOHLER WIRE HARNESS NT 312 18 HX NL ZNYC FW 343 X 687 X 051 080 HD ZNYC LW 312 INT EXT TOOTH ZNYC NT 250 20 HX GR 5 ZNYC FW 281 X 625 X 051 080 HD ZNYC NT 10 32 HX ZN RED BATTERY CABLE BOOT RED BATTERY CABLE BOOT STARTER SOLENOID 4 RED BATTERY CABLE 9 RED BATTERY CABLE CS 250 20X 750 HX G5 CS 312 18 X 2 25 HX G5 ZNYC EXHAUST GASKET KOHLER EXHAUST MANIFOLD FASTRAK HORIZONTAL MUFFLER CB 312 18 X 750 FUL ZN 1 50 MUFFLER CLAMP NT 312 18 HX G5 ZNYC 3 8 18 OIL DRAIN VALVE CS 375 16X1 000 HX G5 RUBBER BUMPER A SEC 4 5 OD PULLEY 1 4 SQ X 0 66 LG KEY FASTRAK CLUTCH CLUTCH PIGTAIL HARNESS FW 454X1 50X 250 CS 437 20 X 3 00 HX G5 Z WIRE TIE SMALL SHORT MUFFLER HEAT SHIELD HEATSHIELD FST KOH CO
15. EE NE EG ED Se DE 9 32 INTO SON ten AE GED AA PA AA 9 32 Sealadiusimenk isti aro EDE DE DERE EE 9 32 Control lever adjustment 9 32 Steering linkage ss EERS ER are ESE 9 33 Control Lever Neutral Adjustment 9 33 Steering dampener 9 35 Drive straight adjustment EE EER ES EE ee te eed 9 36 Park brake spring adjustment 9 36 Hydraulic pump belt adjustment 9 36 Deck drive belt adjustment 9 37 Engine RPM selling 2 24 22 2224 22262221 aus 9 37 Deck leveling and height adjustment 9 37 9 2 108277 10 08 Assembly Pictures and Aids General Information for all models Instrument panel layout FIG 1 Bf FIG 1 Wire harness routing all models Front of wire harness FIG 2 8 FIG 3 TIE STRAP aw gt der 7 N TO SEAT FROM SAFETY SWITCH CBUSWITCHES FIG 2 FIG 3 9 3 108277 10 08 FasTraks with Honda engines Wire harness battery cable throttle cable and choke cable routing and tie straps FIG 4 amp FIG 5 TIE STRAPS POSITIVE BATTERY A ae NEGATIVE BATTERY CABLE TIE STRAPS NOTE Tie straps on rear seat support tie fuel line from L S fuel tank 9 4 108277 10 08 m connections la 6 FIG FIG 8 and FIG 9 r jou gt HEM 14 7 _ CARBURETORS DRAI
16. OU BR BR ON para o Ek NEER vd on MFG PART NO 714618 768523 348417 601062 601312 601063 024927 029868 055939 771428 740696 601069 794644 000331 o par lt 2 D ON D BN AND N DESCRIPTION CS 312 18 X 4 00 HX G5 FW 343 X 687 X 051 080 HD BATTERY CLAMP STRAP POSITIVE BATTERY CABLE HONDA POSITIVE BATTERY CABLE KAWASAKI amp KOHLER ENGINES NEGATIVE BATTERY CABLE NT 250 20 HX GR 5 ZNYC LW 250 INT EXT TOOTH ZNYC CS 250 20 X 750 HX G5 RED BATTERY CABLE BOOT BATTERY VU1LH 8 CN 312 18 X 200 MAX THK GM 1 50 X 2 12 X 1 75 WIRE TIE SMALL SHORT NOTES 1 When performing service on mower disconnect battery ground cable and do not reconnect to battery until engine is ready to be started See Owners Manual Battery is not installed in export models 3 Used on mowers using Kohler engines with serial numbers prior to 07080126 Also used on mowers using Kawasaki engines with serial numbers prior to 070626321 4 Used on mowers using Kawasaki engines with serial numbers 070626321 and higher 108277 10 08 3 3 Deck Lift Assembl 108277 10 08 Deck Lift Assembly 1 Apply grease to zerks 108277 10 08 INDEX NO NODO dA WIN SRE SEG As N ED 25 SERVICE PART NO 348318 348284 784488 781294 601681 704643 782995 055749 781831 360131 756270 348458 781229 767962 015495 MFG PART NO 348318 348284 784488 781294
17. TRACTOR TIRE 18 X 9 5 WHEEL TIRE VALVE WHEEL NUT QTY PER WHEEL WHEEL TIRE ASSY 18 X 8 50 OTY PER 48 TRACTOR TIRE 18 X 8 50 WHEEL TIRE VALVE WHEEL NUT QTY PER WHEEL NOTES 5 4 108277 10 08 108277 10 08 Chapter 6 Contents 54 Deck Assembly is EER era rue ee 6 2 54 Deck Pulley Assembly 6 4 48 Deck Assembly Sas EER RES ede RR ee entente 6 6 48 Deck Pulley Assembly 6 8 Blade Spindle Assembly Breakdown 6 10 6 1 54 Deck Assembly 6 2 108277 10 08 54 Deck Assembly ERVICE INDEX NO SERVICE 1 548305 2 601117 3 108537 4 034280 5 768523 6 034272 7 767954 8 086660 9 025395 10 108049 11 601069 12 781708 13 767962 14 031997 15 053199 16 781567 17 787994 ED 788166 MFG PART NO 108100 601117 108537 034280 768523 034272 767954 086660 025395 108049 601069 N A N A N A N A 781567 787994 788166 1 Includes items 12 through 15 QTY A_N DA BP POP BA ND ED D Od DM OC AA DESCRIPTION DECK W A 54 FASTRAK DISCHARGE CHUTE ASSY CHUTE MOUNTING PIN CS 312 18X 750 HX G5 FW 343X 687X 051 080H NT 312 18 HX G5 ZNYC FW 406X 812 X 060 SAE NT 375 16 HXZY NL CB 375 16X 1 00 STD CD DISCHARGE CHUTE MOUNTING BRACKET CN 312 18X 200 MAX THK CS 500 13X4 250 HX G5 FW 531X 1 063X 090 SAE ANTI SCALP WHEEL NT 500 13 HX JAM ZNYC NT 500 13 H8ZY NL DECK PIN amp
18. above the engine pulley to allow the belt to be removed from the other pulleys FIG 54 Slide the belt over the transaxle pulleys Slide the belt off of the fixed idler pulley The belt can now be removed from above the engine pulley 0 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 11 Slide the belt over the fixed idler pulley and then over the transaxle pulleys 12 Slide the belt onto the engine pulley 13 Pull the idler pulley over and slide the belt onto it Make certain to keep fingers from getting between the belt and the pulley when the pulley is released and tension is re established 14 Re install the deck drive belt on the electric clutch pulley and make sure it is routed properly on all of the deck pul leys 15 Re tension the deck belt idler per the Deck drive belt adjustment section located elsewhere in this manual 16 Re attach the negative battery cable ON Mower blade maintenance Check the mower blades daily they are the key to power efficiency and well groomed turf Keep them sharp a dull blade will tear rather than cut the grass leaving a brown ragged top on the grass within a few hours A dull blade also requires more power from the engine Replace any blade which is bent cracked or broken 9 29 108277 10 08 gt P WARNING Never attempt to straighten a bent blade by heating or weld a crac
19. fails loss of control will occur especially when operating on a slope A If you lose steering control while operating the machine place the steering control levers in the park brake position immediately Inspect the machine and involve your Hustler dealer to resolve the prob lem before continuing to operate TENSION IDLER SPRING 5 PUMP DRIVE BELT IAS do db GO i FIG 68 Deck drive belt adjustment The spindle belt tension remains constant by means of a tension idler and spring FIG 69 The spring tension should be such that the belt does not slip under normal operating load conditions assuming the belt is not excessively Spring Extension 7 50 Normal spring length 6 0 FIG 69 FIG 70 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 69 Installed spring length should be 7 50 3 orig inally with adjustments of 60 per chain link FIG 69 IMPORTANT Do not over tension the spring to compensate for a badly worn belt or pulley Engine RPM setting The FasTrak 48 54 is designed so that the engine will run at 3450 rpm with transaxle load only At this speed the transaxles are running at their maximum rated speed Deck leveling and height adjustment The mower deck
20. fuel handling precautions Do not smoke while refueling Do not 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 if there is fuel in the tank Use extra caution when handling gasoline and other fuels They are flammable and vapors are explo sive A fire or explosion from gasoline can burn you and others and can damage property Refuel outdoors preferably or in well ventilated areas Never attempt to start engine when there is a strong odor of gasoline fumes present Locate and cor rect 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 as interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge When practical remove 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 con tainer and not a gasoline dispenser nozzle If a gasoline dispenser nozzle must be used keep the noz zle in contact with the rim of the fuel tank or container op
21. hydraulic expansion tank is located in front of the engine and under the operator s platform FIG 40 Check oil level in hydraulic system prior to each use Check more often if system appears to be leaking or otherwise malfunctioning Fluid level should be at the Full Cold line on the expansion tank Use only SAE 20W50 SL service motor oil Change the system oil and filters after the first 75 hours of use or 1 year whichever comes first Thereafter replace filter and oil in each transaxle every 2 years or 200 hours whichever comes first NOTE The filter guard must be removed to access filter Each transaxle s filter is located per FIG 41 A standard oil filter wrench is used to change filter threads are right handed Use a Hustler approved filter element only 9 22 108277 10 08 FILTER GUARD FIG 40 FIG 41 FIG 42 WARNING When washing the mower direct the spray away especially if using a power washer A from the Hydro Gear ZT 2800 transaxle s seals to prevent water intrusion and to ensure component performance WARNING Make sure the transaxles are cool before performing service procedures Fluid changing procedure 1 OOND 12 Park the unit on a level surface Place control levers in the park brake position disengage deck clutch remove igni tion switch key and disconnect negative battery cable Remove the three 1 4 filter guard screws and filter guard Clean any loose debris from arou
22. 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 2 Tilt the seat platform forward Temporarily bypass the seat switch 3 Loosen the rear dampener ball stud nut as shown in FIG 65 The dampener will be adjusted and tightened after neutral is reset 4 Staying clear of the rear drive tires start the engine If the ZT 2800 transaxles 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 control 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 control lever is in the neutral position 9 33 108277 10 08 CONTROL LEVER IN THE NEUTRAL POSITION _ n o NUT CONTROL LEVERS IN PARK BRAKE POSITION u RANSAXLE MS CONTROL ROD FIG 63 5 Shut off the machine Loosen the jam nuts on each end of the transaxle control rod as shown in FIG 62 6 Start the engine Move the control lever to just engage the brake neutral slot and hold it in that position Do not engage the control
23. ramp avoid sudden acceleration 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 9 15 108277 10 08 The following illustrations show the various decals that are located on the machine A brief explanation for those requiring one is shown to help the operator understand the meanings of these decals ADANGER Sir Part Number 727016 AWARNING A Do not remove or modify stabilizer wheels Part Number 771436 Part Number 788968 Part Number 727420 Part Number 727438 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 t
24. the deck belt idler spring FIG 53 Pull the idler to the left of the machine to provide maximum belt clearance 9 28 108277 10 08 6 Remove the existing belt and replace with a new belt 7 Route the new belt per FIG 51 8 Re tension the deck belt idler per the Deck drive belt adjustment section located elsewhere in this manual 9 Re install the deck belt covers 10 Re attach the negative battery cable Transaxle drive belt replacement 1 Park the unit on a flat surface Stop the engine and remove the ignition key Make sure deck clutch switch is in the down OFF position Place control levers in the park brake position Disconnect negative battery cable 2 Place the deck in the lowest position 3 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 out of the anchor bracket slot This will relieve the tension on the deck belt idler spring FIG 53 amp FIG 54 FIG 54 4 Remove the deck drive belt from the electric clutch pulley This belt does not need to be removed from any of the other pulleys 5 Release the tension from the transaxle belt by pulling on the idler pulley extending spring carefully and sliding the belt over it Use caution when releasing the idler pulley as there is still tension on it and it will snap back into posi tion FIG 52 6 Slide the belt off the engine pulley The belt will have to be slid
25. 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 Cor recting 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 person nel Consult your Hustler service center when assistance is needed Seat adjustment The seat can be adjusted forward and rearward by sliding the seat release handle and moving the seat until a com fortable operating position is attained FIG 58 SEAT RELEASE N HANDLE FIG 58 Control lever adjustment The control levers can be adjusted for operator comfort By loosening the cap screws that attaches the upper control lever to the lower lever FIG 59 the upper control lever can be pivoted to fit the operator s personal preference The control levers can also be adjusted up and down Remove the cap screws and slide the upper control lever up or down and align the holes in it with the holes in lower lever Re install the cap screws and tighten The control levers should be adjusted so that they align with each other when in the neutral position FIG 60 UPPER DS CONTRO
26. 0 X 2 15 X 187 SPL 7 781567 781567 2 NT 500 13 H G8 ZNYC NL 8 052860 052860 6 CS 375 16 X 1 25 HX G5 ZNYC 9 767954 767954 6 FW 406 X 812 X 060 SAE ZNYC ED 788166 788166 2 ANTI SCALP WHEEL ASSEMBLY NOTES 1 Includes items 2 through 5 108277 10 08 2 3 Footrest Assembly sd SERVICE PART NO 107839 785485 785493 011320 767954 054502 INDEX NO o OU BOON MFG PART NO 107839 785485 785493 011320 767954 054502 QTY 4 2 2 4 4 4 O N A N DESCRIPTION FLOOR PLATE UPPER STEP TREAD LOWER STEP TREAD CB 375 16 X 750 STD ZNYC FW 406 X 812 X 060 SAE ZNYC NT 375 16 HX GRD 5 ZNYC NOTES 2 4 108277 10 08 108277 10 08 Chapter 3 Contents Battery Installation raus REDE tes ae 3 2 Deck Lift Assembly Sanaa ess AE DEE Ee EDE 3 4 Hydro Transmission Installation 3 6 Steering Sub Assembly 3 8 Steering and Brake Assembly 3 10 3 1 Battery Installation 3 2 108277 10 08 Battery Installation SERVICE PART NO 714618 768523 348417 601062 601312 601063 024927 029868 055939 771428 740696 601069 794644 000331 INDEX NO 0 0 N
27. 16 785147 600941 QTY A A A A A 2 mk mk oa a a a nm nm Ak mk ak mk DESCRIPTION OPERATION RIGHT DECAL STEERING L S DECAL TURF PROD SERIAL NO PLATE FASTRAK DECAL MADE IN U S A DECAL FIRST ZERO TURN DECAL HUSTLER NAME PLATE STEERING R S DECAL ENGINE COMPARTMENT DECAL DECK HEIGHT DECAL INSTRUMENT PANEL DECAL FUEL INDICATOR DECAL TOW VALVE DECAL STABILIZER DECAL PUMP BELT WARNING DECAL BATTERY DECAL SERVICE DECAL PATENT DECAL NOTES 8 3 54 Deck Decals A A SERVICE MFG PART INDEX NO PART NO NO QTY DESCRIPTION 1 799171 799171 1 54 DECK ID DECAL 2 727453 727453 2 BELT amp PULLEY DECAL 3 727438 727438 2 WHIRLING BLADES DECAL 4 727172 727172 1 MADE IN U S A DECAL 5 785055 785055 1 STEP TREAD 3 70 X 9 00 6 781419 781419 1 BELT ROUTING DECAL 7 727420 727420 1 DEFLECTOR SHIELD DECAL NOTES 8 4 108277 10 08 48 Deck Decals SERVICE MFG PART INDEX NO PART NO NO QTY DESCRIPTION 1 793976 793976 1 48 DECK ID DECAL 2 727453 727453 2 BELT amp PULLEY DECAL 3 727438 727438 2 WHIRLING BLADES DECAL 4 727172 727172 1 MADE IN U S A DECAL 5 794503 794503 1 STEP TREAD MINI FST DECAL 6 781419 781419 1 BELT ROUTING DECAL 7 727420 727420 1 DEFLECTOR SHIELD DECAL NOTES 108277 10 08 8 5 8 6 108277 10 08 Chapter 9 Contents Assem
28. 2 3 7 3 4 3 601084 3 7 053199 2 3 6 3 6 7 6 5 6 9 601087 3 11 054502 2 4 3 11 6 5 6 9 5 2 601088 3 7 055749 3 5 7 4 5 2 601089 4 13 055822 4 15 4 17 2 3 5 2 601094 4 13 108277 10 08 i 1 Part Page Part Page No No No No 601095 4 13 767962 2 3 3 5 5 2 6 3 6 7 7 4 784611 4 3 601096 4 13 768044 5 2 784629 4 3 601097 4 13 768515 3 7 3 11 4 3 4 5 4 9 4 13 784710 8 3 601098 4 13 768523 3 3 3 7 3 8 3 11 4 3 4 5 784827 3 7 601099 8 3 4 9 4 15 6 3 6 5 784835 4 3 4 5 4 9 601100 8 3 6 7 6 9 7 3 784918 4 3 4 5 4 9 601117 6 3 6 7 769166 4 13 785048 4 3 4 5 4 9 601118 4 3 4 5 770867 3 8 785055 8 4 601123 1 1 6 9 771428 3 3 4 5 4 9 785121 8 3 601124 1 1 6 5 771436 8 3 785139 8 3 601131 3 11 772079 1 1 1785147 8 3 601155 1 1 772103 1 1 1785154 8 3 601156 1 1 772111 1 1 785220 8 3 601158 1 1 772806 5 3 785378 4 3 4 5 4 9 601206 3 7 772814 5 3 785477 4 3 601207 3 7 776476 4 13 785485 2 4 601221 3 7 778365 4 13 785493 2 4 601312 3 3 4 9 778423 1 1 785543 4 3 601319 4 5 4 9 779306 4 15 4 17 785600 1 1 601320 4 15 780155 1 1 785618 1 1 601321 4 15 780841 4 5 4 9 785626 1 1 601341 4 5 781153 3 7 785634 1 1 601342 4 9 781229 3 5 785642 1 1 601429 4 3 4 5 4 9 781260 3 8 785808 4 13 601434 6 5 6 9 781294 3 5 786889 6 5 601450 7 3 781302 6 5 6 9 787689 4 3 601452 4 5 781419 8 4 8 5 787994 6 3 6 7 601681
29. 277 10 08 Fuel line routing FIG 19 FIG 20 amp FIG 21 Be sure fuel filter does not come in contact with engine FUEL FILTER LEFT Ea LINE TIESTRAP ES FUEL VALVE 4 FUEL LINE a FROM FUEL VALVE LEFT FUEL LINE FUEL VALVE FUEL LINE Er TO PA Sa 38 FUEL LINE f FIG 21 9 8 108277 10 08 FasTraks with Kawasaki engines FOR MOWERS WITH SERIAL NUMBERS PRIOR TO 07102604 Wire harness battery cable and throttle and choke cable routing and tie straps FIG 22 FIG 23 amp FIG 24 FUEL LINE HOKE AND THROTTLE CABLES FIG 22 FIG 23 IE STRAP N FIG 24 NOTE Route fuel line beneath both battery cables Tie straps on rear seat support tie fuel line from L S fuel tank 9 9 108277 10 08 Engine connections for 19 HP FIG 25 amp FIG 26 THROTTLE CABLE FIG 25 Engine connections for 21 HP FIG 27 amp FIG 28 ANT 11 CHOKE CABLE 9 10 FIG 28 108277 10 08 FasTraks with Kohler Engines FOR ENGINES WITH SERIAL NUMBERS PRIOR TO 07102604 FIG 29 FIG 29 FOR ENGINES WITH SERIAL NUMBERS 07102604 AND HIGHER Front of wire harness FIG 30 Route the 4 positive battery cable and the purple and red wires through the cable boot prior to fastening hardware solenoid FIG 31 Mm FIG 30 FIG 31 Route negative battery cable and wireharness from seat and safety switches through hole
30. 3 050161 784918 000331 799429 712372 N A 784835 763417 785048 029876 796524 601341 N A 024927 N A N A 768515 601062 N A 771428 N A 044255 055939 N A 109338 601429 601429 601452 030817 N A 785378 N A N A 108288 034272 016253 601002 601004 601021 043570 792796 109339 N A 104786 108969 QTY 2 Baa D ND Q 3 3 as a a a AK 2 2 AR an LP _ su ph a sss 2 AND ND 3 IA AND AAND 3 3 NN 3 AND A a DESCRIPTION 21HP KAWASAKI ENGINE USED ON 928291 19HP KAWASAKI ENGINE USED ON 928275 NT 312 18 HX ZNYC NL FW 343 X 687 X 051 080 HD CS 312 18 X 1 75 HX G5 RUBBER BUMPER WIRE TIE SMALL SHORT 4 5 OD A SEC PULLEY KEY 1 4 SO X 0 66 LG CLUTCH PIGTAIL HARNESS CLUTCH FW 454 X 1 50 X 250 CS 437 20 X 3 00 HX G5 ZNYC LW 312 INT EXT TOOTH ZNYC OIL DRAIN VALVE M20 X 2 5 FASTRAK KAWASAKI WIRE HARNESS FASTRAK KAWASAKI WIRE HARNESS NT 250 20 HX GR 5 ZNYC CN ZN TIN C7343 1420 CN 250 20 X 19 MAX THICK FW 281 X 625 X 051 080 HD RED BATTERY CABLE 17 RED BATTERY CABLE 9 RED BATTERY CABLE BOOT RED BATTERY CABLE BOOT NT 10 32 HX ZN CS 250 20X 750 HX G5 CS 250 20 X 625 HX G5 HEATSHIELD FST KAW675CC 21HP ONLY UBOLT 250 20X 1 125 DIA 21 HP ONLY UBOLT 250 20X 1 125 DIA 19 HP ONLY UBOLT 250 20 X 1 250 ID 21HP ONLY STARTER SOLENOID MUFFLER GASKET 1 50 MUFFLER CLAMP LW 312 MED SPRING ZNYC NT M8 1 25 HX STAINLESS 21 KAW FASTRAK HEAT SHIELD NT 312 1
31. 5108 2 CS 375 16X3 50 HX G5 Z 26 107894 107894 1 BRAKE SPRING LINK LS SHOWN 27 108430 108430 1 BRAKE SPRING LINK RS NOT SHOWN 28 055939 055939 2 CS 250 20X 750 HX G5 29 016816 016816 2 NT 250 20 HX FL LK ZNY 30 601051 601051 2 OVERTRAVEL SPRING 31 000331 000331 2 WIRE TIE SMALL SHORT 32 036236 036236 1 CS 312 18X1 000 HX G5 33 361295 361295 1 PIVOT TUBE W A PLATED NOTES 1 Supplied with transmissions 2 For mowers with serial numbers prior to 07102604 to replace the dampener mount first remove the original control arms from the transmissions saving the hardware and replace with items 1 2 3 and 4 108277 10 08 3 11 3 12 108277 10 08 108277 10 08 Chapter 4 Contents Honda 18 amp 20 HP Engine Installation 4 2 Kawasaki 19 8 21 HP Engine Installation 4 4 Kohler 19 HP Engine Installation 4 8 Instrument Panel Installation 4 12 Fuel System Installation with S N higher than 07102604 4 14 Fuel System Installation with S N prior to 07102604 4 16 Kawasaki Electrical Schematic 600999 601341 4 18 Kohler Electrical Schematic 601000 601342 4 19 Honda Electrical Schematic 600998 4 20 4 1 on i Installat me Honda 18 amp 20 HP En 5 _ Nu N SZ Y N ES es L IS Pa YEL PART OF ENGINE A RA NA KA is
32. 5X1 00X 134 ZNYC CS 625 11X1 25 HX G5Z PUMP DRIVE BELT CS 625 11X1 750 HX G5 FW 760X 1 625X 08 ZNYC BUSHING PUMP IDLER W A FASTRAK SB 750X 2 000 SH 625 11 CS 375 16X2 00 G5 ZNYC FW 406X 812 X 060 SAE ZT SPACER TUBE NT 312 18 HX G5 ZNYC SPRING 1 4 COIL PL 1 23 LH TRANS ZT2800 20 69 1 RH TRANS ZT2800 20 69 1 TOW LINK ROD 48 54 CP 062DX1 000 LG HML Z OVERFLOW TANK ASSY CS 250 20X 750 HX G5 FW 281X 625X 051 080H NT 250 20 HXZY NL SPRING CLAMP 75 DIA OVERFLOW HOSE 10 LONG HYD FITTING 45 DEG WIRE TIE SMALL SHORT NOTES 3 Service parts available for the transaxles 108277 10 08 601206 601207 601221 ZT2800 FAN 7 ZT2800 PULLEY 4 5 ZT2800 BRAKE ARM 2007 3 7 Steering Sub Assembl CONNECTS TO PARK BRAKE LINKAGE SERVICE MFG PART ITEM NO PART NO NO QTY DESCRIPTION 1 781260 N A 2 STEERING BAR GRIP 2 360487 360487 2 STEERING BAR 3 767954 767954 12 FW 406 X 812 X 060 SAE HD ZN 4 705178 705178 4 CS 375 16X1 750 HX G5 5 086660 086660 6 NT 375 16 HXZY NL 6 107843 107843 1 STEERING ARM W A LH SHOWN 107842 107842 1 STEERING ARM W A RH 7 768523 768523 4 FW 343X 687 X 051 080 HD ZN YL 8 600991 600991 2 SHORT BRAKE LINK ROD 9 023655 023655 2 NT 312 24 HXZY NL 10 107848 107848 1 STEER PIVOT W A LH SHOWN 107847 107847 1 STEER PIVOT W A RH 11 770867 770867 4 IGUS BUSHING 12 705178 705178 2 CS 375 16X1 750 HX G5 NOTES 1 Includes Item 1 781260 Steering Bar Grip
33. 8 HX G5 ZNYC CB 312 18 X 75 FUL ZNYC FASTRAK HORIZONTAL MUFFLER EXHAUST MANIFOLD FASTRAK 21 HP EXHAUST MANIFOLD FASTRAK 19 HP CLIP HOSE SINGLE FS SC M 6 1 0X15 HX FL STP 19 HP ONLY HEATSHIELD FST KAW585CC 19 HP ONLY NT 250 20 HX GR 5 ZNYC OIL DRAIN HOSE NOT SHOWN HEAT SHIELD 4 5 Ph D OOND SERVICE MFG PART INDEX NO PART NO NO QTY DESCRIPTION NOTES Part of Item 16 600999 601341 FasTrak Kawasaki Wire Harness Engine oil capacity See engine manual Engine speed High idle 3450 50 rpm Connected to item 16 600999 601341 FasTrak Kawasaki Wire Harness Torque to 45 48 ft lb Supplied with items 24 and 25 U Bolts Used on mowers with serial numbers prior to 07062321 Used on mowers with serial numbers prior to 07102604 On mowers with serial numbers prior to 07062321 item 24 starter solenoid is located in engine compartment 4 6 108277 10 08 This page intentionally left blank 108277 10 08 4 7 Kohler 19 HP Engine Installation or Y BATTERY BATTERY N CABLE EDREDBLK A o 7 4 8 108277 10 08 Kohler 19 HP Engine Installation INDEX NO 0 NOU BOND ND o A 5 b gt n in E NN 0 0 N OU BU N N o E 22 23 24 25 Ep 2 27 28 29 30 31 32 ED 34 2 Torque to 45 48 ft Ib SERVICE PART NO 601067 601342 601000 058776
34. 8 HXZY NL 18 50 L F CW BLADE CS 625 11X3 00 FULL HX NOTES 2 See Deck Belt Routing and Tensioning on page 7 5 for belt tensioning 108277 10 08 6 5 48 Deck Assembl 108277 10 08 6 6 48 Deck Assembly ERVICE INDEX NO PO E gt 1 548313 2 601117 3 108537 4 034280 5 768523 6 034272 7 025395 8 767954 9 086660 10 108049 11 601069 12 781708 13 767962 14 031997 15 053199 16 781567 17 787994 ED N A MFG PART NO 108125 601117 108537 034280 768523 034272 025395 767954 086660 108049 601069 N A N A N A N A 781567 787994 788166 1 Includes items 12 through 15 QTY A_N DA Ss POP BA ND ND N Od OO DO AA DESCRIPTION DECK W A 48 FASTRAK DISCHARGE CHUTE ASSY CHUTE MOUNTING PIN CS 312 18X 750 HX G5 FW 343X 687X 051 080H NT 312 18 HX G5 ZNYC CB 375 16X 1 00 STD CD FW 406X 812 X 060 SAE NT 375 16 HXZY NL DISCHARGE CHUTE MOUNTING BRACKET CN 312 18X 200 MAX THK CS 500 13X4 250 HX G5 FW 531X 1 063X 090 SAE ANTI SCALP WHEEL NT 500 13 HX JAM ZNYC NT 500 13 H8ZY NL DECK PIN amp ROD ASSY ANTI SCALP WHEEL ASSY NOTES 2 Service part deck includes decals see 48 Deck Decals on page 8 5 for a listing of decals 108277 10 08 6 7 48 Deck Pulley Assembly Le A ann 19 20 i A Se o f a d TT Fes se J pae g e E HE N a o oo E ET fo i Da a
35. 9 360131 3 5 005116 3 11 6 5 6 9 5 4 360487 3 8 008193 7 4 6 5 6 9 361295 3 11 011320 2 4 7 3 548289 2 2 015495 3 5 4 5 548297 2 2 015818 4 15 4 17 1 1 548305 6 3 016253 4 3 4 5 3 7 3 11 548313 6 7 016410 3 7 4 3 548776 7 3 016523 4 9 3 11 1600221 3 11 016816 3 11 8 3 600296 6 5 6 9 016972 6 5 6 9 3 8 3 11 6 3 6 7 600759 3 7 017004 4 3 4 5 4 3 4 5 4 9 600880 3 7 017616 7 4 2 2 600899 8 3 019521 5 4 2 4 600941 8 3 023655 3 8 3 11 2 3 600963 4 17 024927 3 3 4 3 4 5 4 9 3 8 600964 4 17 025007 3 7 6 5 6 9 3 8 600976 1 1 025296 3 7 3 8 1600979 1 1 3 7 025395 6 3 6 7 3 8 600981 3 11 026237 4 13 7 3 1600987 3 7 028118 3 7 6 5 6 9 3 7 600989 3 11 029710 4 10 2 2 600991 3 8 029868 3 3 3 11 1600994 2 2 029876 3 11 4 3 4 5 4 9 3 11 1600998 4 3 030817 4 5 4 9 3 11 600999 4 5 031997 2 3 6 3 6 7 4 13 601000 4 9 034272 3 7 3 11 4 3 4 5 4 9 4 15 6 3 6 7 601001 3 7 6 3 6 7 7 3 6 5 601002 4 3 4 5 4 9 034280 4 15 6 3 6 7 7 3 6 5 601003 4 3 036236 3 11 6 9 601004 4 5 036244 4 9 6 9 601005 4 9 036384 3 7 1 2 601018 3 7 038828 3 7 4 9 1 2 601019 3 7 042630 5 2 4 5 601020 3 7 043570 4 3 4 5 7 3 601021 4 5 044255 4 5 4 9 3 11 601051 3 11 044818 4 5 6 3 6 7 1601062 3 3 4 3 4 5 045898 4 13 4 3 4 5 4 9 601063 3 3 4 3 046821 6 5 6 9 4 9 601067 4 9 047456 4 17 3 11 1601069 3 3 6 3 6 7 048553 3 7 4 5 601081 4 5 050161 4 3 4 5 4 5 1601082 4 5 052860
36. HEATSHIELD FST HON614CC 33 601429 601429 2 UBOLT 250 20X 1 125 DIA ED 024927 N A 4 NT 250 20 HX GR 5 ZNYC 35 108969 108969 1 MUFFLER HEAT SHIELD 104786 104786 1 OIL DRAIN HOSE NOT SHOWN NOTES Part of Item 28 600998 FasTrak wire harness Two wires Connected to Item 28 600998 FasTrak wire harness Torque to 45 48 ft Ib Engine oil capacity See engine manual Engine speed High speed 3450 50 RPM Nuts supplied with item 33 U Bolts AM BRD TE 108277 10 08 4 3 Installation Kawasaki 19 8 21 HP En BATTERY CABLE x Ben POSITIVE PART OF ENGINE NEGATIVE BATTERY me 19 HP EXHAUST amp CLAMP DETAIL 108277 10 08 4 4 Kawasaki 19 amp 21 HP Engine Installation INDEX NO AN Oa BOON 222222 y oar won O Hd 16 17 E gt 7 17 18 19 ED 1 20 7 21 22 De 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 EI 0 41 108277 10 08 SERVICE PART NO 601082 601081 058776 768523 050161 784918 000331 799429 712372 791251 784835 763417 785048 029876 796524 601341 600999 024927 044818 601118 768515 601062 792762 601319 771428 044255 055939 064329 109338 601429 601429 601452 030817 780841 785378 017004 782664 108288 034272 016253 601002 601004 601021 043570 792796 109339 024927 104786 108969 MFG PART NO 601082 601081 058776 76852
37. L al LEVER LOWER CONTRO LEVER FIG 59 FIG 60 9 32 108277 10 08 Steering linkage The neutral adjustment for the control levers in the neutral position is discussed in this section The tractor steering has been factory adjusted to eliminate creeping when the control levers are in the neutral posi tion FIG 61 However should the tractor begin to creep the control lever linkage can be adjusted as follows me FIG 61 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 transaxle control rod FIG 62 Neutral is properly adjusted when the control levers are in the park brake position and the ZT 2800 transaxles 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 FIG 64 WARNING Never work under the machine or attachment unless it is safely supported with jack A stands Make certain machine is secure when it is raised and placed
38. MBLY MOLDED ROUND ARMREST 2 ARMREST STOP ASSEMBLY 7 3 Deck Installation SERVICE INDEX NO a A O N PART NO 055749 017616 767962 704643 008193 MFG PART NO 055749 017616 767962 704643 008193 MOANA QTY DESCRIPTION CS 437 14X1 750 HX G5 CS 500 13X1 750 HX G5 FW 531X 1 063X 090 SAE NT 437 14 HX FLG ZN NT 500 13 HX G5 ZNYC NOTES 7 4 108277 10 08 Deck Belt Routing and Tensioning 8 25 9 25 2 _ am Le gt LE HIN LULU id Tel BO din DI il MEN NOTES 1 Spring length after tensioning new belt Spring length measured from outside of hook to outside of hook Tension spring with deck in leveling position Route belt as shown 108277 10 08 7 5 7 6 108277 10 08 108277 10 08 Tractor Decals Chapter 8 Contents 54 Deck DecalS 4 5 EES EER a ar ne a Ses 48 Deck Decals Hanne 8 1 Tractor Decals 108277 10 08 8 2 Tractor Decals ERVICE INDEX NO EE 1 785121 2 785139 3 N A 4 784710 5 727172 6 782573 7 793588 8 785220 9 788968 10 785154 11 601100 12 791848 13 601099 14 771436 15 600899 16 727016 17 785147 18 600941 108277 10 08 MFG PART NO 785121 785139 083279 784710 727172 782573 793588 785220 788968 785154 601100 791848 601099 771436 600899 7270
39. N NI TUBES TIE STRAP FIG 6 FIG 7 FIG 8 FIG 9 NOTE Route oil sensor wire between oil file tube and engine block Index ter minal on wire in horizontal direction to hold wire off oil filter NOTE Tie carburetor drain tubes and clutch pigtail together to clutch anchor Do not tighten tie strap enough to pinch drain hoses closed 9 5 108277 10 08 FasTraks with Kawasaki engines FOR MOWERS WITH SERIAL NUMBER 07102604 AND HIGHER Front of wire harness FIG 10 Route the 4 positive battery cable and the purple and red wires through the cable boot prior to fastening hardware to solenoid FIG 11 ATE STRAP a SWITCH x SAFE TY SISWITOHE a NEG BATTERY CABLE B Ja FIG 10 FIG 11 Route negative battery cable and wireharness from seat and safety switches through hole in the right side of frame FIG 12 Li EG BATTERY CABLE IREHARNESS FIG 12 9 6 108277 10 08 Wire harness battery cable and throttle and choke cable routing and tie straps FUEL LINE 1 IE STRAP Y GROUND NG IE STRAP WIRE IN FIG 13 amp FIG 14 POSITIVE BATTERY CABLE CABLES NEGATIVE 74 CHOKE AND BATTERY THROTTLE FIG 13 FIG 14 Clutch pigtail to clutch anchor tie strap FIG 15 Safety switches and tie straps FIG 16 IE STRAP FIG 15 FIG 16 Engine connections FIG 17 8 FIG 18 9 7 108
40. Parts Manual HUSTLER Hustler Turf Equipment P O Box 7000 Hesston Kansas 67062 2097 A WARNING A 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 re place immediately Replacements may be ordered per the information found in the Product Information section of the owner s manual t 2 108277 10 08 108277 10 08 108277 10 08 Table of Contents Chapter 1 General Information ss ee ala 1 1 Chapter 2 Contents Rivet Nutlnstallation at a mer re 2 2 Engine Guard and Anti Rollover Wheels 2 3 Footrest Assembly sota SES SEE AG ee are Hee ema wees 2 4 Chapter 3 Contents Battery Instala Ss ue Te tasten 3 2 Deck Lift Assembly Lapponia a ta RMS Re E e
41. URAGE UBOLT 250 20X 1 125 DIA NT 250 20 HX GR 5 ZNYC OIL DRAIN HOSE NOT SHOWN NOTES 1 Part of Item 2 601000 601342 Kohler Wire Harness 3 Torque to 30 35 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 4 Engine oil capacity See engine owner s manual 5 Engine speed High Idle 3450 50 rpm Low idle 1900 100 rpm 108277 10 08 4 9 D Connected to item 2 601000 601342 FasTrak Kohler Wire Harness Bolt and washer supplied with engine For replacement part order 029710 Cap Screw 312 18X 750 HXFLK 8 Used on mowers with serial numbers prior to 07080126 9 On mowers with serial numbers prior to 07062321 item 10 starter solenoid is located in engine compartment 10 For mowers with clip nuts when replacing clip nuts with items 6 and 7 item 12 is required 11 Nuts supplied with U Bolts N 4 10 108277 10 08 This page intentionally left blank 108277 10 08 4 11 Instrument Panel Installation RIGHT FUEL FUSE SIZE AND LOCATION 4 12 108277 10 08 Instrument Panel Installation 108277 10 08 INDEX NO 4 XO N Oa FW N 10 11 12 13 14 15 SERVICE PART NO 601095 601097 776476 785808 769166 712257 045898 026237 778365 601094 601096 601089 601098 107902 704932 059832 768515 055947 MFG PART NO 601095 601097 776476
42. X G5 13 768523 768523 4 FW 343X 687X 051 080H 14 000398 000398 2 CLAMP 15 034272 034272 2 NT 312 18 HX G5 ZNYC NOTES 1 Torque to 20 ft lbs 108277 10 08 4 15 rior to 0710260 Fuel System Installation with S N 108277 10 08 4 16 Fuel System Installation with S N prior to 07102604 SERVICE MFG PART INDEX NO PART NO NO QTY DESCRIPTION 1 779306 779306 2 3 5 FUEL CAP 2 600963 600963 1 RIGHT SIDE FUEL TANK 3 600964 600964 1 LEFT SIDE FUEL TANK 4 000323 000323 6 CLIP 5 712919 712919 8 FW 406 X 1 00 X 12 HRD ZNYC ED 6 055822 055822 8 CS 375 16X 750 HX G5 7 706531 706531 2 GM 1 12X 1 75 X 1 37 X 12 53 7 047456 047456 2 GM 687 X 1 312 X 1 00 X 12 8 745059 745059 1 3 WAY FUEL VALVE Ey 9 015818 015818 1 FUEL LINE 25 3 LONG ED 015818 015818 1 FUEL LINE 8 3 LONG 11 015818 015818 1 FUEL LINE 36 0 LONG HONDA ONLY 11 015818 015818 1 FUEL LINE 13 0 LONG KAWASAKI amp KOHLER 12 000331 000331 3 WIRE TIE SMALL SHORT NOTES 1 Torque to 20 ft lbs 2 See FasTraks with Honda engines on page 9 4 for Honda fuel line routing See FasTraks with Kawasaki engines on page 9 6 for Kawasaki fuel line routing See FasTraks with Kohler Engines on page 9 11 for Kohler fuel line routing 3 Fuel line from left side fuel tank to be routed through grommet and tied to rear seat support with Item 12 4 For mowers with serial numbers prior to 07062321 use th
43. are loose and the deck is sitting tightly on all four blocks FIG 73 FIG 74 amp FIG 75 ae the two nuts on the front of height indicator so that the foot pedal is free FIG 76 Start the leveling process on the left front of the tractor HEIGHT STOP e DJUSTINGI nol STOP Pi 4 lt a te ba Bo BLOCKS FIG 71 FIG 72 Set the amount of threads protruding on the deck lift rod from the lift block at approximately 1 FIG 77 Jam both nuts against the block Push or pull on the deck lift foot pedal until the chain on the left front just becomes tight making sure that the deck stays tight against the 3 block While keeping the chain tight tighten the nuts against the deck lift block on the height indicator rod FIG 76 Go to the right front of the tractor Loosen the 5 16 jam nut on the adjuster lift chain FIG 75 and back the adjuster bolt out to allow the adjuster to move up and down freely Be sure that adjuster is free to move up and down Tighten the adjuster bolt until the chain just becomes tight making sure that the deck stays tight against the 3 block Tighten the adjuster bolt jam nut to prevent the adjuster bolt from moving FIG 75 9 38 108277 10 08 18 DECK LIFT THREADED RODI sat nn ADJUSTERI 19 20 21 22 23 24 25 26 Tighten the hardware holding the chain and adjuster onto the deck lift arm DECK LIFT MET Tm Go to the
44. bly Pictures and Aids 9 3 General Information for all models 9 3 Wire harness routing all models 9 3 FasTraks with Honda engines 9 4 FasTraks with Kawasaki engines 9 6 FasTraks with Kawasaki engines 9 9 FasTraks with Kohler Engines 9 11 Maintenance Adjustment Safety 9 14 Safe Maintenance amp Adjustment Practices 9 14 USING a rampai iess Pied tee Wee ARE RE Fe 9 15 Safety and Instruction Decals 9 15 Maintenance cs ek 9 18 INFOGUCUON A225 ERGER REEDE SEE GEE EE GE hee EDE BEd 9 19 Torque VANESS su Lt aparta EDE DE ER ER Me 9 20 TA EE N MT RE EE eed 9 20 l brication tancia een 9 20 Electrical sysiomti MEE EIE ME TAG een ee 9 20 Access to ZT2800 transaxles 9 22 Hydraulics 9 22 Fluid changing procedure 9 23 F elsystemMas 250 ho ehh dd os ee nu leone Le 9 24 Fuel Shut off Valves 9 25 Endin oil and ilatag ESE a 9 26 Belt replacement as sis asp EE DE da ER 9 27 Deck belt replacement 9 28 108277 10 08 9 1 Transaxle drive belt replacement 9 29 Mower blade maintenance 9 29 Mower blade removal 9 31 AdSense Seale EE
45. chanic The owner should also ensure that the operator mechanic knows that they are responsible for their own safety as well as the safety of other persons within the vicinity Remember the operator mechanic is responsible for accidents or hazards occurring to other people or their property Safe Maintenance amp 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 Place control levers in the park brake position disengage deck clutch remove ignition switch key and disconnect the negative battery cable 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 oper ated in an enclosed area 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 fuel spillage Allow machine to cool before storing Clean flammable material from machine Prevent fires by keeping engine compartment battery hydraulic lines fuel line fuel tank and operator s station clean of accumulated trash grass clipp
46. e Never refuel tractor while engine is running never refuel near an open flame or near devices which can create a spark Refuel outdoors preferably or in well ventilated areas 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 appropri ate 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 per formed by trained personnel only Use a stick or sim
47. e control levers in the park brake position Disconnect negative battery cable Remove the fuel tank from the tractor Dun Re Turn the fuel valve to the closed position middle position FIG 47 Disconnect the tank to fuel valve line from the valve and clamp or cap the end of it 7 Fill fuel tank with proper grade of gasoline and open shut off valve Engine oil and filter Remove the fuel tank s fill cap and pour the fuel out of the fill spout into a clean certified fuel container When fuel tank is drained re attach the fuel tank to the tractor and re route the fuel line to the shut off valve and attach it to the tee Clamp fuel line to shut off valve Check engine oil daily and after every 4 hours of operation Crankcase dipstick and oil filler tube are located as shown in FIG 48 FIG 49 amp FIG 50 Tractor must be setting level when checking oil Refer to engine manual and main tenance 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 fre quently IMPORTANT When removing the oil filter take precautions to minimize oil spillage on the exhaust system HONDA 1 DIPSTICK amp ENGINE OIL FILLER TUBE I DIPSTICK amp DAP ENGINE OIL gt i FILLER TUBE Si BREER B j DRAIN VALVE
48. e following fuel line lengths INDEX NO N PART DESCRIPTION 015818 FUEL LINE 27 3 LONG 10 015818 FUEL LINE 27 3 LONG 5 Used on mowers with serial numbers prior to 07062321 108277 10 08 4 17 Kawasaki Electrical Schematic 600999 601341 x fel N Si o it NO D Hs A amp 7 i ES N e n mn ed ver wg da Ed Oh gt ni 038 y oo o LL u 5 a sls ni o ol 2 x oo ES o al al S pa QIU NYI 81 o 419 91 o A dq 5 oO d AA o D lt SS D if a Sa oo a 4 der y Q QIU NYI 81 oo x o 5 SA E a i A e E E S E see Er gt T E gt D Si D fm 2 pa 2 pm 3 D Mola o x oo Be E i VE ol e gt ala ed S m gt o a NY 81 nr co gt E y b 3 Ph b de lt ei Sy a 2 to 940 9 u r oo 4 18 108277 10 08 Kohler Electrical Schematic 601000 601342 108277 10 08 18 RED BLK ko 3 2 Oi u AN 3G a R S r E an Ba Wid P O
49. e left or right 3 Whichever direction the tractor turns is the slow side Leave the slow side cap screw and jam nut so that they are flush with the frame Holding the cap screw in place lock the jam nut 4 On the fast side through several iterations back out the cap screw gradually until the fast side is slowed to the same speed as the other side and the tractor drives straight After adjustment is finished hold the cap screw still and tighten the jam nut Park brake spring adjustment Occasionally check the park brake spring 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 Position the control lever in the park brake position 3 Measure the park brake spring It should be compressed to 1 7 16 If it is not adjust the nylock nut until the proper spring compression is achieved FIG 67 Mi 1 7 16 a i my SPRING IZ yA sa 4 Repeat for the other side Hydraulic pump belt adiustment The transaxle drive belt tension remains constant by means of a tension idler and spring FIG 68 There is no ten sion adjustment of this belt NOTE 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 9 36 108277 10 08 WARNING If the transaxle belt
50. e machine without a properly functioning seat safety switch Steering dampener The steering dampener FIG 65 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 tractor does not return to neutral from reverse then adjust as follows To set the steering dampeners in the correct operating position follow these steps 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 Place the control lever in the neutral position FIG 61 Loosen the steering dampener s rear ball stud FIG 65 Pull the dampener spring housing to the rear past the point that the internal spring is engaged Release the dampener spring housing and allow the internal spring to bring the housing back to the neutral posi tion Tighten the nut on the steering dampener s rear ball stud To check move the control lever to the reverse position and release The control lever should return to the neutral position If not repeat steps 1 through 6 ah DAN NO 9 35 108277 10 08 DRIVE STRAIGHT ADJUSTMENT po FIG 66 Initially adjust cap screws all the way in so that the steering levers may go fully forward Drive tractor in an open area with both steering handles fully forward The tractor will likely drift slightly to th
51. electrical system is protected by fuses located on the right fuel tank instrument panel FIG 39 The fuses are as follows Function Size Type Main 20 amp blade type Clutch Aux 10 amp blade type Before attempting any failure diagnosis of the electrical system use a test light or voltmeter to check the battery 9 21 108277 10 08 FIG 39 voltage If the battery voltage is satisfactory check the cleanliness and tightness of the terminals and ground connec tions A general understanding of electrical servicing and use of basic test equipment is necessary for troubleshooting and repair Major overhaul or repair of the starting motor or charging system should be performed by trained technicians only Access to ZT2800 transaxles The integrated pump motor units are accessed by lifting the seat platform The seat platform is hinged at the front To raise it remove the lock nut and tilt seat platform up and forward 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 The FasTrak 48 54 is equipped with two Hydro Gear ZT 2800 transaxles FIG 38 IMPORTANT Never use hydraulic or automatic transmission fluid in this system use only motor oil as specified Remember dirt is the primary enemy of any hydraulic system The
52. ening at all times until fueling is complete 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 conditioner opening Keep gas away from eyes and skin The fuel tanks are located in the tractor s fenders FIG 43 Total capacity for the fuel tanks is 10 U S gallons 38 liter FUEL TANK FIG 43 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 con taining methanol or gasohol containing more than 10 ethanol because the fuel system could be damaged Do not mix oil with gasoline 9 24 108277 10 08 Using a fuel stabilizer conditioner in the tractor can provide benefits such as 1 Keeps gasoline fresh during storage of 90 days or less For longer storage drain the fuel tanks 2 Cleans the engine during operation 3 Eliminates gum like varnish buildup in the fuel system IMPORTANT Never use methanol gasoline containing methanol or gasohol containing more than 10 ethanol because the fuel system could be damaged Do not mix oil with gasoline Using a fuel stabi
53. ern as shown FIG 55 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 56 and FIG 57 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 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 PPP 9 31 108277 10 08 Adjustment Introduction Your FasTrak 48 54 was adjusted before it left the factory and was checked during pre delivery setup However after start up and continued use a certain amount of break in wear will cause some adjustments to change Remain alert for unusual noises
54. 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 250 8 2 812 17 375 30 438 48 500 73 562 105 625 145 750 260 875 420 1 00 625 NM SIZE FT LBS NM 11 1 M3 1 1 3 23 M4 2 2 3 40 M5 4 5 6 1 65 M6 LT 10 4 99 M8 18 5 25 143 M10 37 50 200 M12 64 87 350 M14 80 108 5 565 M16 160 215 850 M20 320 435 M24 555 750 NOTE Loctite 592 to be used on all pipe threads Lubricate all grease zerks 1 2 108277 10 08 108277 10 08 Chapter 2 Contents Rivet Nut Installation a an DE DE er EE Ee eee Engine Guard and Anti Rollover Wheels Footrest Assembly se RD ea VERDER EE EE AE ws 2 1 Rivet Nut Installation INDEX NO 4 SERVICE PART NO 548289 548297 N A N A N A MFG PART NO 107819 107890 600994 808493 808485 QTY DESCRIPTION OND a 54 FASTRAK FRAME 48 FASTRAK FRAME 3 8 16 THREAD RIVET NUT 3 8 16 THREAD RIVET NUT 5 16 18 THREAD RIVET NUT NOTES 2 2 108277 10 08 Engine Guard and Anti Rollover Wheels _ Z SERVICE MFG PART INDEX NO PART NO NO QTY DESCRIPTION 1 107840 107840 1 FASTRAK ENGINE GUARD 2 781708 N A 2 CS 500 13 X 4 25 HX G5 ZNYC 3 767962 N A 4 FW 531 X 1 063 X 090 SAE ZNYC 4 031997 N A 2 ANTI SCALP WHEEL 5 053199 N A 2 NT 500 13 HX JAM ZNYC 6 344267 344267 4 FW 51
55. 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 WARNING Shorts caused by battery terminals or metal tools touching metal tractor components can A 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 A 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 Always connect the positive red battery cable before connecting the negative black cable Common circuit failures are usually caused by shorting corroded or dirty terminals loose connections defective wire insulation or broken wires Switches solenoids and ignition components may also fail causing a shorted or open circuit The
56. 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 belt to get it on a pulley as this will cut or damage the fibers of the belt covering Keep oil and grease away from belts and never use belt dressings Any of these will destroy the belt composition in a very short time 9 27 108277 10 08 Viewed from bottom of unit Transaxle belt Engine pulley Transaxle idler pulley Transaxle idler arm Transaxle pulley Electric deck clutch Transaxle idler spring 5 Fixed idler pulley Deck Belt Drive Layout Spindle drive belt Deck blade spindle pulley Spindle belt tension idler Spindle belt tension idler spring 7 5 at operation Deck belt idler pulley Idler arm FIG 51 FIG 52 TENSION IDLER SPRING ANCHOR BRACKET FIG 53 Deck belt replacement 1 Park the unit on a flat surface Stop the engine and remove the ignition key Make sure deck clutch switch is in the down OFF position Place control levers in the park brake position Disconnect negative battery cable 2 Place the deck in the lowest position 3 4 Release the deck belt tension by pulling on the belt tension chain and sliding the chain out of the anchor bracket Remove the deck belt covers slot This will relieve the tension on
57. 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 9 37 108277 10 08 deck The recommended pressures are as follows 10 11 12 13 14 15 16 17 Drive Wheels 8 12 PSI Front Wheels 8 12 PSI WARNING Stop engine Make sure deck clutch switch is in the down OFF position Remove igni tion key Place control levers in the brake position before leaving machine Park the unit on a flat surface Raise deck and place 3 of blocking under all 4 corners of the deck FIG 71 This will set the cutting height at 3 4 NOTE Back of deck will automatically be set 74 higher Set cutting height at 3 14 in the height indicator by placing the height adjusting stop in DR and turning the height stop so that the flat side is against the stop handle Clamp the height adjusting stop against the stop handle This will assure that the height will not move during the setting process Otherwise spring pressure from the deck lift springs will tend to pull the stop away from the handle Loosen all nuts on the deck lift threaded rods and the hardware on the adjuster on the right front until all the deck lift chains
58. he battery Use soda mixed in water to clean corrosion off the terminals Do not remove or modify stabilizer wheels or rear engine guard or injury can result Keep engine and pump compartment s clean especially in exhaust area to prevent fire and provide maximum engine and hydraulic cooling 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 removed or in raised position except when the grass catcher attachment is being used Whirling blades Keep hands and feet away Beware of thrown objects 9 16 108277 10 08 Keep shields or covers in place while machine is in operation Keep hands away from rotating pulleys and belts Part Number 727453 A WARNING If you lose steering control while operating the machine place the steering control levers in 22 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 ee replacement intervals and refer to above paragraph for emergency procedures 9 17 108277 10 08
59. ilar 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 Wearing gloves or wrapping the blade s is advisable when working around or with the blades Do not touch hot parts of machine Keep nuts and bolts tight especially the blade attachment bolts Keep equipment in good 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 Y ES Y o Y Y Y Y Y BS o Y Y Y Y Y ES Y Y Using a ramp Use extreme caution when loading and unloading a unit 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 lt 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
60. in the right side of frame FIG 32 i f pra INEG BATTERY CABLE IREHARNESS 9 11 108277 10 08 Wire harness and battery cable and throttle and choke cable routing and tie straps FIG 33 amp FIG 34 FROM em STRAP BATTERY Pad SS A ER ee r ea 122 TIE STRAP FIG 33 FIG 34 NOTE Tie strap on rear seat support FIG 33 ties fuel line from L S fuel tank similar to Kawasaki engines See Fuel line routing FIG 19 FIG 20 amp FIG 21 on page 9 8 Engine connection FIG 35 THROTTLE CABLE FIG 35 9 12 108277 10 08 Clutch pigtail to clutch anchor tie strap FIG 36 TIE STRAP AN CLUTCH PIGTAIL FIG 36 9 13 108277 10 08 Maintenance amp Adjustment Safety This safety alert symbol is used to call attention to a message intended to provide a reasonable degree of PER SONAL SAFETY for operators and other persons during the normal operation and servicing of this equipment DANGER denotes immediate hazards which WILL result in severe personal injury or death 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 infor mation and NOTE emphasizes general information worthy of special attention All operators should read this manual or be instructed about safe operating and maintenance procedures This i
61. ings and other debris Always clean up spilled fuel and oil 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 y y y y y 9 14 108277 10 08 Y 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 Never leave machine unattended with ignition key in switch especially with children present Be alert and turn the machine off if children enter the area Always wear adequate eye protection when servicing the battery hydraulic system cooling system or when grind ing mower blades and removing accumulated debris Use extra caution when handling gasoline and other fuels They are flammable and vapors are explosiv
62. k 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 person nel Consult your Hustler service center when assistance is needed Torque values Torque values are given below Wheel lug nuts 65 75 FT LBS Blade spindle bolt top 118 FT LBS Blade spindle bolt bottom 118FT LBS Lug nuts only It is recommended that these be checked after the first 2 hours of operation initially every 50 hours and following removal for repair or replacement For all other torques refer to the various tractor parts manuals for standard torque chart See page 21 for ordering information 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 pressure are Drive Wheels 8 12 PSI Front Wheels 8 12 PSI Solid fill tires are not recommended for Hustler turf equipment On any machine with solid filled tires the war ranty claim will be denied WARNING Explosive separation of a tire and rim can cause serious injury or death Do not attempt A 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 defor
63. ked or broken blade as the blade may break and cause serious injury Replace worn or damaged blades WARNING Never work with blades while engine is running or deck clutch switch is engaged on Always place deck clutch switch in the disengaged position place control levers in the park brake position and turn engine off and disconnect negative battery cable Block up mower when you must work under it Wear gloves when handling blades Always check for blade damage if mower strikes rock branch or other foreign object during mowing WARNING Always wear adequate eye protection when grinding mower blades e sharpening pattern Do not sharpen to original pattern below It is easier to get a straight cutting edge following the re sharpening pattern shown above Original edge Warped Blade Replace Cutting plane I Straight Blade Comparison of Warped and Straight Blades FIG 56 9 30 108277 10 08 Cutting edge Twisted Blade an replace Cutting Plane Cutting edge LL traight Blade Edge End view of blades comparing twisted and straightened blades FIG 57 Mower blade removal Use a 15 16 wrench to remove the 5 8 cap screw holding the blade to the spindle shaft from underneath Blade Lock Tool part number 381442 is available from your dealer to prevent the blades from turning while remov ing or and installing the blade bolts Sharpen the blades on a grinder following patt
64. lever far enough to engage the brakes in the brake slot transaxle control rod so you do not get your fingers tools or anything else close to the ZT 2800 transaxle s cooling fans N WARNING This operation is extremely dangerous Pay close attention when adjusting the 7 While holding the control lever position discussed in step 6 carefully adjust the transaxle control rod until the rear wheel starts turning forward Now turn the transaxle 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 transaxle control rod in this position and actuate the parking brake with steering lever The ZT 2800 transaxle should not whine FIG 64 9 34 108277 10 08 8 Hold the transaxle control rod still and turn off the engine JACK STANDS FIG 64 FIG 65 9 Tighten the jam nuts on each end of the transaxle control rod NOTE Do not let transaxle control rod turn while tightening the jam nuts FIG 62 10 Neutral is now set Start the engine and actuate the brakes a few times to confirm that the ZT 2800 transaxle does not whine when the park brake is set 11 Repeat for the other side 12 The steering dampener now needs to be adjusted and tightened FIG 65 13 IMPORTANT Reconnect the seat switch and make sure the seat switch is operating properly Refer to the machine s owner s manual for operation check 1 WARNING Do not operat
65. lizer 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 44 FIG 45 amp FIG 46 is installed in the fuel line between fuel tanks and engine fuel pump on the rear left side of the engine Replace filter annually or after every 100 hours of operation whichever occurs first For fuel filter removal refer to the engine owner s manual EE FIG 46 When replacing the fuel filter check the fuel line hoses for any cracks or leaks Replace as needed Fuel Shut off Valves The fuel shut off valve Hustler p n 745059 is located behind the seat to the right side of the operator FIG 47 Close this valve center position to prevent fuel flow to the engine The valve s two other positions are front and rear 9 25 108277 10 08 To drain a fuel tank use the following method FUEL VALVE RIGHT TANK POSITION FUEL FILTER yy POSITION u FIG 47 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 Plac
66. m a wheel When inflating tires stand to one side and nat 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 gauge 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 The electrical system is a 12 volt negative ground Recommended battery size is a garden tractor BCI group U1R with 225 or better cranking AMP rating A maintenance free battery is recommended Otherwise follow battery manu facturer s maintenance safety storing and charging specifications 9 20 108277 10 08 The battery is located under the seat platform FIG 38 FIG 38 WARNING Battery posts terminals and related accessories contain lead and lead compounds A chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling WARNING Avoid skin and clothing contact with battery acid Always wear eye protection when A 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
67. nd the filter FIG 42 Place an oil drain pan beneath the oil filter and remove the oil filter from the transaxle By removing the filter this also drains the system oil After the oil has been drained wipe the filter base surface off and apply a film of new oil to the gasket of the new replacement filter Install the new filter by hand turn 3 4 to one full turn after the filter gasket contacts the filter base surface Re install the filter guard with three 1 4 screws Torque the screws to 65 in Ibs each Repeat steps 2 6 for the opposite side transaxle Drain oil filters of all free flowing oil prior to disposal Place used oil in appropriate containers Remove the top port plug from the left side and right side transaxles prior to filling with oil This will allow the transaxles to vent during oil fill Remove the cap from the transaxle s expansion tank 11 Fill oil reservoir with 20W 50 motor oil until oil just appears at the bottom of each transaxle s top port approxi mately 2 qts per transaxle 4 qts total Install the top port plug into each transaxle as the oil level reaches this port nstall and torque the top port plugs to 180 in lbs 9 23 108277 10 08 13 Continue to fill the transaxles through the expansion tank until the Full Cold line is reached on the expansion tank 14 Re install the expansion tank cap by hand Be careful not to overtighten Fuel system A DANGER Observe usual
68. r 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 neces sary 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 108277 10 08 1 1 Options Available From Your Dealer PART NO 108197 797704 797712 108223 796623 796631 DESCRIPTION 54 FasTrak Mulch Kit 18 50 MUL F CW Blade 18 50 GAT F CW Blade 48 FasTrak Mulch Kit 16 50 MUL F CW Blade 16 50 GAT F CW Blade Hardware Description Codes amp Abbreviations The following codes are used throughout this parts manual Refer to this list when ordering parts ABBREVIATION Standard Torques DESCRIPTION ABBREVIATION Carriage Bolt MB Clevis Pin MS Cotter Pin NT Clip Nut SC Cap Screw SH Cup Washer SB Fender Washer SS Flat Washer OD Hex Head ID Lock Washer DESCRIPTION Machine Bushing Machine Screw Nut Self Tapping Cap Screw Socket Head Shoulder Bolt Set Screw Outside Diameter Inside Diameter The following chart lists the standard torque values for the threaded
69. right rear of the tractor Make sure that there is still slack in the chain If not loosen the two nuts on the block holding the threaded rod until there is slack in the deck lift chain FIG 75 Tighten the appropriate nut until the chain just becomes tight making sure that the deck stays tight against the 3 block Tighten the other nut on the opposite side of the block and jam them tightly together against the block Go to the left rear of the tractor Make sure that there is still slack in the chain If not loosen the two nuts on the block holding the threaded rod until there is slack in the deck lift chain FIG 73 Tighten the appropriate nut until the chain just becomes tight Tighten the other nut on the opposite side of the block and jam them tightly together against the block 9 39 108277 10 08 27 Compress the deck lift assist springs so that there is 72 of space between the front nut on the spring and the rear nut on the deck lift block FIG 77 Typical both sides 28 When completed all chains will be tight and deck cutting height will be set to the deck height indicator 9 40 108277 10 08 Numerical Index Part Page Part Page Part Page No No No No Index Part Numbers 3 3 3 7 3 11 4 5 4 9 348284 3 5 000323 4 15 4 17 4 13 348318 3 5 000331 3 3 3 7 3 11 4 3 4 5 4 9 4 3 3948417 3 3 4 15 4 17 7 3 4 3 4 5 4 9 6 5 6 9 7 3 348458 3 5 000398 4 15 4 13 350884 6 5 6 9 005108 3 11 6 5 6
70. s the owner s responsibility Improper use or maintenance by the operator mechanic or owner can result in injury To reduce the poten tial 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 located in front of and to the right of the seat are designed to give the operator mechanic 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 operator mechanic reads and understands this manual and all decals before operating this machine It is also the owner s responsibility to make certain that the operator mechanic is a qualified and physically able individual properly trained in the operation of this equipment Local regula tions may restrict the age of the operator me
71. s ES el sat DE j 5 4 m ru a 3 d SER 038 7 o o me pra amp 2 AE mm T nh Ga u Sie ala 2 ein co o rl kas LE se SE Ja lt Ad ro QIU NYI 81 o 119 91 o o S amp 2 35 o z o a YT CORI ao IE bai 2 gt En o o Be Ly oO Z o a ce O3H NYL 81 so u Lee Le LS Sal p gt De a E 5 5 ie id 3 4 2 LU 5 Si a 3 co IE el o ela 2 S TE oo o a NWI 81 as ERI IE Es 5 4 19 Honda Electrical Schematic 600998 Wig 1 re u LHA NTO FI u 931311934 3 14138 TI Ng 817 aay SI io ES 3 QIY NYI 81 TE 5 NYO gl 82 NYA 8 te AR 5 980 8 a H917 3N19N3 a HOLIMS LY3S o a GIY NVI 81 d 940 8 HOLIMS TYHLNIN HOLIMS TYHLNIN 3 A E gt o 138 NY1 81 a NW 8h Fl we o gt gt 1134 LUWLS NG CV E WE 81 22 me 81 el we 91 oz 10 8 7 443114 2 pa TINA pa Ba 118 91 NG lt GY Fl 1418 0384 pl 108277
72. st position Prior to each use Check hydraulic oil level Daily Clean engine and transaxle compartment Daily Change transaxle oil and filter 7 Every 200 hours or 2 years Grease deck height pivots X no Grease gauge wheel bearings X Change engine oil and filter 1 3 T X TT Clean cylinder and head fins a X Check battery connections X Check tire pressure with a gauge X Check hydraulic oil level X Clean engine exterior a X Clean amp re gap spark plugs a X Check pump and deck belt tension and condition 5 X Check fuel and hydraulic lines 6 X Check fuel valve and grommet 6 X Tighten lug nuts on wheels 2 X o Change fuel filter KI Replace spark plugs X NOTES 1 Initial oil change is after 5 hours of operation Thereafter change oil after every 40 hours operation 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 rec ommendations 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 if worn or cracking is noticed Other wise replace every 200 hours or 2 years whichever comes first 6 Check fuel line hoses fuel valve and grommets for any cracks or leaks 7 Initial system oil and filter change m
73. ust be after the first 75 hours of use or 1 year whichever comes first Thereaf ter replace filter and oil in each transaxle every 2 years or 200 hours whichever comes first REFERENCES a Refer to Engine Owner s Manual NOTE After completing maintenance cycle 300 hours repeat cycle Introduction Regular maintenance is the best prevention for costly downtime or expensive premature repair The following 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 9 19 108277 10 08 wear or damage A good time to detect potential problems is while performing scheduled maintenance service Cor recting 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 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 dec

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