hustler 54 manual
TRANSCRIPT
Parts Manual
Hustler Turf Equipment
P.O. Box 7000
Hesston, Kansas
67062-2097
WARNING:The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
IMPORTANT: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate this engine on any forest-covered, brush-covered, or grass-covered unimproved land. Other states or federal areas may have similar laws.This spark ignition system complies with Canadian ICES-002.
The Engine Owners 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 Owners Manual with your unit. Should the Engine Owners Manual become damaged or illegible, replace immediately. Replacements may be ordered per the information found in the Product Information section of the owners manual.
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Table of ContentsChapter 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Section 2 Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Guard and Anti Rollover Wheels. . . . . . . . . . . . . . . . . . . . . Engine Guard and Anti Rollover WheelsCE . . . . . . . . . . . . . . . . . Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3 Battery Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydro Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering and Brake Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 4 Honda 18 & 20 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . Kawasaki 19 & 21 HP Engine Installation . . . . . . . . . . . . . . . . . . . . Instrument Panel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Panel Installation CE. . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kawasaki Electrical Schematic (601341) . . . . . . . . . . . . . . . . . . . . Kohler Electrical Schematic (601342) . . . . . . . . . . . . . . . . . . . . . . . Honda Electrical Schematic (600998). . . . . . . . . . . . . . . . . . . . . . . Section 5 Front Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Front Wheel Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Drive Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Section 6 54" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54" Deck Pulley AssemblyUS Version . . . . . . . . . . . . . . . . . . . . 54" Deck Pulley AssemblyCE Version . . . . . . . . . . . . . . . . . . . . 48" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48" Deck Pulley AssemblyUS Version . . . . . . . . . . . . . . . . . . . . 48" Deck Pulley AssemblyCE Version . . . . . . . . . . . . . . . . . . . . Section 7 Seat Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Deck Belt Routing and Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Section 8 Tractor DecalsUS Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tractor DecalsCE Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54" Deck DecalsUS Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54" Deck DecalsCE Version . . . . . . . . . . . . . . . . . . . . . . . . . . . .108277 05/10 c-1
2-2 2-3 2-4 2-5 3-2 3-4 3-6 3-8 3-10 4-2 4-6 4-10 4-12 4-14 4-16 4-17 4-18
6-2 6-4 6-6 6-8 6-10 6-12
8-2 8-4 8-6 8-7
48" Deck DecalsUS Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 48" Deck DecalsCE Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Section 9 Assembly Pictures and Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedures and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 9-13 9-23 i-1
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Section 1 General InformationThis Manual covers Hustler FasTrak models 928267, 928275, 928291, 928502, & 928520 .
Frequently Ordered PartsPART NO. 600979 791335 789388 785626 068478 785618 785600 780155 601155 772111 772103 794370 785634 772079 747303 600976 601124 601123 DESCRIPTION Pump Drive Belt Deck Belt 48" Deck Belt 54" Fuel Filter Honda Fuel Filter Kawasaki & Kohler Precleaner Air Filter Honda Air Filter Element Honda Precleaner Air Filter Kawasaki 21 Hp Air Filter Paper Element Kawasaki 21 HP Precleaner Air Filter Kawasaki 19 HP Air Filter Element Kawasaki 19 HP Air Filter Kohler Engine Oil Filter Honda Engine Oil Filter Kawasaki Engine Oil Filter Kohler Oil Filter ZT 2800 18.50"-L-F-CW Blade 16.50"-L-F-CW Blade
Service LiteraturePART NO. 601156 778423 601158 785642 794313 DESCRIPTION FasTrak Owners Manual Kawasaki Engine Manual 21 HP Kawasaki Engine Manual 19 HP Honda 18 & 20 HP Engine Manual Kohler Courage Engine Manual
Note: When ordering parts, you must use the part number as shown for each part, not the index number. Always give the model and serial number to your parts and service representative. Note: Items sold in bulk such as seals and hoses are sold by the foot.
Using this manualIllustrations used were current at the time of printing, but subsequent production changes may cause your machine to vary slightly in detail. Excel Industries, Inc. reserves the right to redesign and change the machine as deemed necessary, without notification. If a change has been made to your machine which is not reflected in this parts manual, see your Hustler dealer for current information and parts.
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Options Available From Your DealerPART 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 & AbbreviationsThe following codes are used throughout this parts manual. Refer to this list when ordering parts.
ABBREVIATION CB CE CP CN CS CW FDRW FW HX LW
DESCRIPTION Carriage Bolt Clevis Pin Cotter Pin Clip Nut Cap Screw Cup Washer Fender Washer Flat Washer Hex Head Lock Washer
ABBREVIATION MB MS NT SC SH SB SS OD ID
DESCRIPTION Machine Bushing Machine Screw Nut Self Tapping Cap Screw Socket Head Shoulder Bolt Set Screw Outside Diameter Inside Diameter
Standard TorquesThe following chart lists the standard torque values for the threaded fasteners found in this manual. Torque all cap screws, nuts and set screws to these values unless a different torque is shown in the Notes section next to the fastener.
SIZE .250 .312 .375 .438 .500 .562 .625 .750 .875 1.00
FT-LBS 8.2 17 30 48 73 105 145 260 420 625
NM 11.1 23 40 65 99 143 200 350 565 850
SIZE M3 M4 M5 M6 M8 M10 M12 M14 M16 M20 M24 NOTE:
FT-LBS 1 2.2 4.5 7.7 18.5 37 64 80 160 320 555
NM 1.3 3 6.1 10.4 25 50 87 108.5 215 435 750
Loctite 592 to be used on all pipe threads. Lubricate all grease zerks.
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Section 2Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Engine Guard and Anti Rollover Wheels . . . . . . . . . . . . . . . . . . . . . . 2-3 Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
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Rivet Nut Installation2
3
1 3
3 4
INDEX NO. 1 2 3 4
SERVICE PART NO. 548289 548297 N/A N/A N/A
MFG. PART NO. 107819 107890 600994 808493 808485
QTY. 1 1 2 8 1
DESCRIPTION 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:
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Engine Guard and Anti Rollover Wheels
1
7
4
6
5
6
3 9 2 8
INDEX NO. 1 2 3 4 5 6 7 8 9
SERVICE PART NO. 107840 781708 767962 031997 053199 344267 781567 052860 767954 788166
MFG. PART NO. 107840 N/A N/A N/A N/A 344267 781567 052860 767954 788166
QTY. 1 2 4 2 2 4 2 6 6 2
DESCRIPTION FASTRAK ENGINE GUARD CS .500-13 X 4.25 HX G5 ZNYC FW .531 X 1.063 X .090 SAE ZNYC ANTI-SCALP WHEEL NT .500-13 HX JAM ZNYC FW .510 X 2.15 X .187 SPL NT .500-13 H G8 ZNYC NL CS .375-16 X 1.25 HX G5 ZNYC FW .406 X .812 X .060 SAE ZNYC ANTI SCALP WHEEL ASSEMBLY
1
NOTES:
1. Includes items 2 through 5.
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Footrest Assembly3
2
4
1 4
5 6
5
5 6
INDEX NO. 1 2 3 4 5 6
SERVICE PART NO. 107839 785485 785493 011320 767954 054502
MFG. PART NO. 107839 785485 785493 011320 767954 054502
QTY. 1 2 2 4 4 4 FLOOR PLATE
DESCRIPTION
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:
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Section 3Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Hydro Transmission Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Steering Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Steering and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
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Battery Installation
1
2 3 7 8 7 9 10 7 6 13 5 12 7 6
4
11
11
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Battery InstallationINDEX NO. 1 2 3 SERVICE PART NO. 714618 768523 348417 601062 601312 601063 024927 029868 055939 771428 740696 601069 794644 000331 MFG. PART NO. 714618 768523 348417 601062 601312 601063 024927 029868 055939 771428 740696 601069 794644 000331 QTY. 2 2 1 1 1 1 2 4 2 1 1 2 2 1 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 & 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
3 4
4 4 5 6 7 8 9
2
1
10 11 12 13
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. 2. 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.
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Deck Lift Assembly1
2
3
4 6 5 7 4 5 6 11 12 5 4 15 4 6 8 7 10 9 10 15 5 5 6 14 13 6 10 4 8 10 15 6 15 8 6
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Deck Lift AssemblyINDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 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 601681 704643 782995 055749 781831 018846 756270 348458 781229 767962 015495 QTY. 1 1 1 7 6 8 2 3 1 4 1 1 1 2 4 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 DESCRIPTION
1
15
NOTES:
1. Apply grease to zerks.
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Hydro Transmission Installation1 2 3 3
4 5 7 8 4 18 17 9 10 11 10 9 14 3 25 22 24 14 16 1 24 23 26 13 3 19 15 12 2 6
13 29
28 27 26 28 27 26 20 21
3-6
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Hydro Transmission InstallationINDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 SERVICE 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 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. 4 4 16 2 1 1 1 1 2 2 1 1 2 2 1 8 1 1 1 2 2 1 2 4 2 4 2 2 2 DESCRIPTION CS .312-18X2.500 HX G5 CS .312-18X2.250 HX G5 FW .343X.687X.051/.080H IDLER PULLEY 4.00"OD FW .625X1.00X.134 ZNYC CS .625-11X1.25 HX G5 Z 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:
1. Torque to 17 ft-lbs. 2. Torque to 100 ft-lbs 3. Service parts available for the transaxles:601206 601207 601221 600976 ZT2800 FAN, 7" ZT2800 PULLEY, 4.5" ZT2800 BRAKE ARM - 2007 OIL FILTER
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Steering Sub-Assembly1
2
3 4 3
5 3 8 6 7 73
3
CONNECTS TO PARK BRAKE LINKAGE
9 11 3 3
5 11 10
12
ITEM NO. 1
SERVICE PART NO. 781260 360487 767954 705178 086660 107843 107842 768523 600991 023655 107848 107847 770867 705178
MFG. PART NO. N/A 360487 767954 705178 086660 107843 107842 768523 600991 023655 107848 107847 770867 705178
QTY. 2 2 12 4 6 1 1 4 2 2 1 1 4 2
DESCRIPTION STEERING BAR GRIP STEERING BAR FW .406 X .812 X .060 SAE HD ZN CS .375-16X1.750 HX G5 NT .375-16 HXZY NL STEERING ARM W/A LH (SHOWN) STEERING ARM W/A RH FW .343X .687 X .051/.080 HD ZN/YL SHORT BRAKE LINK ROD NT .312-24 HXZY NL STEER PIVOT W/A LH (SHOWN) STEER PIVOT W/A RH IGUS BUSHING CS .375-16X1.750 HX G5
1
2 3 4 5 6 7 8 9 10 11 12
NOTES:
1. Includes Item 1 (781260 Steering Bar Grip).
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Steering and Brake AssemblySee Steering Sub-Assembly on page 3-8.8 13 12 6 9 6 11 25 18 20 13 23 22 121
1 2 7 6 7 6 2 4 4 3 101
6 5
3
6 10 6 14 15 20 21 17 16 22 5
ASSEMBLED BRAKE RODS
13
23
25 BELL CRANK DETAIL 18 19 10 6
TRACTOR FRAME
13
24 32 6 33 31 31 13 25
13 20 21 22 19 13 23
5
28
HYDRO TRANSAXLE
4
30 29 26 27
BRAKE ARM
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Steering and Brake AssemblyINDEX NO. 1 2 SERVICE PART NO. 704163 768515 109318 068551 034272 768523 781922 600221 600981 023655 784439 086660 767954 005116 706168 601087 029876 054502 765339 107893 107892 600989 080655 601131 005108 107894 108430 055939 016816 601051 000331 036236 361295 MFG. PART NO. 704163 768515 109318 068551 034272 768523 781922 600221 600981 023655 784439 086660 767954 005116 706168 601087 029876 054502 765339 107893 107892 600989 080655 601131 005108 107894 108430 055939 016816 601051 000331 036236 361295 QTY. 2 4 2 2 4 21 4 2 2 6 2 4 12 2 2 2 2 2 4 1 1 2 2 2 2 1 1 2 2 2 2 1 1 DESCRIPTION CS .250-20X2.00 HX G5 Z FW .281X.625X.051/.080H PUMP ARM NT .250-20 HXZY NL NT .312-18 HX G5 ZNYC FW .343X.687X.051/.080H BALL STUD DAMPER (FS) STEERING DAMPER PUMP ROD ASSEMBLY NT .312-24 HX ZY NL LOCK COLLAR 0.757 ID(FS) NT .375-16 HXZY NL FW .406X .812 X.060 SAE CS .375-16X1.375 HX G5 NT .375-16 HX JAM GR5 Z PLUNGER SWITCH LW .312 INT-EXT TOOTH ZN NT .375-16 HX GRD 5 ZNY IGUS BUSHING BRAKE BELL CRANK LS (SHOWN) BRAKE BELL CRANK RS (NOT SHOWN) BRAKE ROD ASSEMBLY CS .375-16X1.500 HX G5 BRAKE ARM RET. SPRING CS .375-16X3.50 HX G5 Z BRAKE SPRING LINK LS (SHOWN) BRAKE SPRING LINK RS (NOT SHOWN) CS .250-2 0X .750 HX G5 NT .250-20 HX FL LK ZNY OVERTRAVEL SPRING WIRE TIE, SMALL/SHORT CS .312-18X1.000 HX G5 PIVOT TUBE W/A PLATED
2
3 4 5 6 7
3
8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
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 transmissionssaving the hardware, and replace with items 1,2 3 and 4. 3. Serviceable parts for Item 8 (Steering Damper) include: 601425 (Connector Body) and 601426 (Cap Lock).
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3-12
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Section 4Honda 18 & 20 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . . 4-2 Kawasaki 19 & 21 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . 4-6 Kohler 19 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Instrument Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Fuel System Installation (with S/N higher than 07102604) . . . . . . . 4-16 Fuel System Installation (with S/N prior to 07102604). . . . . . . . . . . 4-18 Kawasaki Electrical Schematic (600999/601341) . . . . . . . . . . . . . . 4-20 Kohler Electrical Schematic (601000/601342). . . . . . . . . . . . . . . . . 4-21 Honda Electrical Schematic (600998) . . . . . . . . . . . . . . . . . . . . . . . 4-22
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Honda 18 & 20 HP Engine Installation1 12 11 YEL 1 8 9 34 15 3 33 7 27 9 9 35 27 10 9 271
13
PART OF ENGINE
32 5 6
}
4 12 2 26 12 26 13 26 27
TAN/RED 1 28 BRN 1 9 30 GRA/PUR 2 29 PUR 1 31 PART OF ENGINE1
9
1
BLK
RED/BLK
14 17
9 12 18 15 16 19 9 12 25 20 21 234
24
3
22
4-2
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Honda 18 & 20 HP Engine InstallationINDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 SERVICE PART NO. N/A N/A 601002 601003 785378 785543 017004 782664 016253 768523 034272 787689 050161 043570 785477 768515 056077 601118 712372 799429 784835 763417 785048 784918 791251 000331 070664 058776 600998 601063 029876 601062 109340 601429 024927 108969 104786 MFG. PART NO. 784611 784629 601002 601003 785378 N/A N/A N/A 016253 768523 034272 787689 050161 043570 N/A 768515 056077 601118 712372 799429 784835 763417 785048 784918 N/A 000331 070664 058776 600998 N/A 029876 N/A 109340 601429 N/A 108969 104786 QTY. 1 1 1 1 1 2 4 4 2 10 2 1 6 2 1 6 2 2 1 1 1 1 1 1 1 1 4 6 1 1 1 1 1 2 4 1 1 DESCRIPTION HONDA 18HP ENGINE HONDA 20HP ENGINE HORIZONTAL MUFFLER FST FASTRAK MUFFLER MANIFOLD MUFFLER CLAMP HONDA (20) MUFFLER GASKET LW .312 MED SPRING ZNYC NT M8-1.25 HX STAINLESS CB .312-18X .750 FUL ZN FW .343X.687X.051/.080H NT .312-18 HX G5 ZNYC OIL DRAIN VALVE M14X CS .312-18X1.750 HX G5 CLIP HOSE SINGLE(FS) HONDA 20 AMP RECTIFIER FW .281X.625X.051/.080H CS .250-20X1.000 HX G5 CN .250-20 X .19 MAX THK KEY 1/4 SQ X 0.66 LG PULLEY A SEC 4.5 OD FASTRAK CLUTCH FW .454X1.50X.250 CS .437-20X3.00 HX G5 Z RUBBER BUMPER CLUTCH PIGTAIL HARNESS SMALL/SHORT WIRE TIE FW .344X .750X.06 ZNYC NT .312-18 HXZY NL WIRE HARNESS FASTRAK BATTERY CABLE NEGATIVE LW .312 INT-EXT TOOTH Z BATTERY CABLE POSITIVE HEATSHIELD, FST HON614CC UBOLT .250-20X 1.125 DIA NT .250-20 HX GR.5 ZNYC MUFFLER HEAT SHIELD OIL DRAIN HOSE (NOT SHOWN)
7
NOTES:
1. Part of Item 28 (600998 FasTrak wire harness). 2. Two wires. 3. Connected to Item 28 (600998 FasTrak wire harness). 4. Torque bolt to 45-48 ft-lbs. Replace (do not reuse) capscrew if removed or loosened. Use only hand tools to install this fastener. 5. Engine oil capacity: See engine manual.108277 05/10 4-3
6. Engine speed; High speed - 3450 50 RPM . 7. Nuts supplied with item 33 (U-Bolts).
4-4
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Kawasaki 19 & 21 HP Engine Installation1 3 4 37 15 12 PART OF ENGINE YEL 1{
3 4 64 10
TAN/RED 1 BRN 16 18 17 19 18 20 PUR 1 18 20 RED 1 POSITIVE 21 BATTERY CABLE
5 9
7 8 11 125
1 BLK 14
NEGATIVE BATTERY CABLE
13
1 RED/BLK
22 40
26 18 BLK 1
27 18 35 23 24 25 31 29 17 18
}30
28 5
4
2 40 18 40 39 38 32 4 34 33 4-6 4 36 24 37 19 HP EXHAUST & CLAMP DETAIL 108277 05/10 27 29 30
41
Kawasaki 19 & 21 HP Engine InstallationINDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 SERVICE PART NO. N/A N/A 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 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 601452 030817 780841 785378 017004 782664 108288 034272 016253 601002 601004 601021 043570 792796 109339 024927 104786 41 108969 MFG. PART NO. 601082 601081 058776 768523 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. 1 1 4 11 4 1 1 1 1 1 1 1 1 1 1 1 1 5 2 2 11 1 1 2 1 1 2 2 1 1 2 1 1 2 1 4 4 1 2 2 1 1 1 1 1 1 4 1 1 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 SQ 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 .312-18 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
7 8 7
16 17 17 17 18 19
7 7
19 20 20 21 22
8
22 23 24
6
40
108277 05/10
4-7
NOTES:
1. Part of Item 16 (600999/601341 FasTrak Kawasaki Wire Harness). 2. Engine oil capacity:See engine manual. 3. Engine speed; High idle3450 50 rpm. 4. Connected to item 16 (600999/601341 FasTrak Kawasaki Wire Harness). 5. Torque bolt to 45-48 ft-lbs. Replace (do not reuse) capscrew if removed or loosened. Use only hand tools to install this fastener. 6. Supplied with items 24 and 25 (U-Bolts). 7. Used on mowers with serial numbers prior to 07062321. 8. Used on mowers with serial numbers prior to 07102604. 9. On mowers with serial numbers prior to 07062321, item 24 (starter solenoid) is located in engine compartment.
4-8
108277 05/10
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108277 05/10
4-9
Kohler 19 HP Engine Installation1
3 7 14 33 16 17 4 31 15 32 7 33 5 NEGATIVE BATTERY CABLE 18 71 RED 1 BLK
7
2 6
}
7 POSITIVE BATTERY CABLE 9 10
}30
11 8
1 RED/BLK
7 121 BLK
4 19
20 4 13
7
610
21 3 23 296
22
24 25 27 282
26
4-10
108277 05/10
Kohler 19 HP Engine InstallationINDEX NO. 1 2 SERVICE PART NO. N/A 601342 601000 058776 768523 029876 024927 768515 044255 601319 771428 030817 601312 792762 055939 038828 780841 601005 601002 016253 785378 034272 796516 036244 784918 799429 712372 784835 791251 763417 785048 000331 108969 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. 1 1 1 1 4 1 4 10 1 2 1 1 1 1 2 1 1 1 1 2 1 2 1 3 1 1 1 1 1 1 1 1 1 1 2 4 1 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 COURAGE UBOLT .250-20X 1.125 DIA NT .250-20 HX GR.5 ZNYC OIL DRAIN HOSE (NOT SHOWN)
8
2 3 4 5 6 7 8 9
8
9 10 11
8
11 12 13 14 15 16 17 18 19 20
3
21 22 23 24 25
6
26 27 28 29 30 31 32
11 3334
NOTES:
1. Part of Item 2 (601000/601342 Kohler Wire Harness). 2. Torque bolt to 45-48 ft-lbs. Replace (do not reuse) capscrew if removed or loosened. Use only hand tools to install this fastener. 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.108277 05/10 4-11
4. Engine oil capacity: See engine owners manual. 5. Engine speed; High Idle345050 rpm, Low idle1900100 rpm. 6. Connected to item 2 (601000/601342 FasTrak Kohler Wire Harness). 7. Bolt and washer supplied with engine. For replacement part, order 029710 (Cap Screw .312-18X .750 HXFLK). 8. Used on mowers with serial numbers prior to 07080126. 9. On mowers with serial numbers prior to 07062321, item 10 (starter solenoid) is located in engine compartment. 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.
4-12
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108277 05/10
4-13
Instrument Panel Installation1 2 3 4 6 101
7
5 11
6 1 12 8 13
1
9
15 14
RIGHT FUEL TANK
14 15
10a
20a
FUSE SIZE AND LOCATION 4-14 108277 05/10
Instrument Panel InstallationINDEX NO. 1 2 3 4 5 6 7 8 SERVICE PART NO. 601095 601097 776476 785808 769166 712257 045898 026237 778365 601094 601096 9 10 11 12 13 14 15 601089 601098 107902 704932 059832 768515 055947 MFG. PART NO. 601095 601097 776476 785808 769166 712257 045898 N/A 778365 601094 601096 601089 601098 107902 704932 059832 768515 055947 QTY. 1 1 1 1 1 1 1 2 1 1 1 2 2 1 2 2 3 3 DESCRIPTION CHOKE CABLE (KAWASAKI ONLY) CHOKE CABLE (KOHLER & 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.
108277 05/10
4-15
Fuel System Installation (with S/N higher than 07102604)1 2
1
3
9 7 4 8 5 7 12 13
12 11 41
13
6
14 5 7 14 4 13 15 61
13 15
10
4-16
108277 05/10
Fuel System Installation (with S/N higher than 07102604)INDEX NO. 1 2 3 4 5 SERVICE PART NO. 779306 601320 601321 000323 712919 055822 745059 015818 015818 015818 015818 015818 000331 034280 768523 000398 034272 MFG. PART NO. 779306 601320 601321 000323 712919 055822 745059 015818 015818 015818 015818 015818 000331 034280 768523 000398 034272 QTY. 2 1 1 6 8 8 1 1 1 1 1 1 1 2 4 2 2 3.5" FUEL CAP RIGHT SIDE FUEL TANK LEFT SIDE FUEL TANK CLIP FW .406 X 1.00 X .12 HRD ZNYC CS .375-16X .750 HX G5 3-WAY FUEL VALVE FUEL LINE (24.00" LONG) FUEL LINE 11.00" LONG) FUEL LINE (36.0" LONG) (HONDA ONLY) FUEL LINE (13.0" LONG) (KAWASAKI) FUEL LINE (11.0" LONG) (KOHLER) WIRE TIE SMALL/SHORT CS .312-18X .750 HX G5 FW .343X.687X.051/.080H CLAMP NT .312-18 HX G5 ZNYC DESCRIPTION
1
6 7 8 9 10 10 10 11 12 13 14 15
NOTES:
1. Torque to 20 ft-lbs.
108277 05/10
4-17
Fuel System Installation (with S/N prior to 07102604)1 2 1 3
10 4 8 7 5 9 7
4
1
6
12
5 8 61
4
11
4-18
108277 05/10
Fuel System Installation (with S/N prior to 07102604)INDEX NO. 1 2 3 4 5 SERVICE PART NO. 779306 600963 600964 000323 712919 055822 706531 047456 745059 015818 015818 015818 015818 000331 MFG. PART NO. 779306 600963 600964 000323 712919 055822 706531 047456 745059 015818 015818 015818 015818 000331 QTY. 2 1 1 6 8 8 2 2 1 1 1 1 1 3 3.5" FUEL CAP RIGHT SIDE FUEL TANK LEFT SIDE FUEL TANK CLIP FW .406 X 1.00 X .12 HRD ZNYC CS .375-16X .750 HX G5 GM 1.12 X 1.75 X 1.37 X .12 GM .687 X 1.312 X 1.00 X .12 3-WAY FUEL VALVE FUEL LINE (25.3" LONG) FUEL LINE 8.3" LONG) FUEL LINE (36.0" LONG) (HONDA ONLY) FUEL LINE (13.0" LONG) (KAWASAKI & KOHLER) WIRE TIE SMALL/SHORT DESCRIPTION
1 5 4 4
6 7 7 8 9 10 11 11 12
NOTES:
1. Torque to 20 ft-lbs. 2. See FasTraks with Honda engines on page 9-3 for Honda fuel line routing. See FasTraks with Kawasaki engines on page 9-5 for Kawasaki fuel line routing. See FasTraks with Kohler Engines on page 9-10 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 the following fuel line lengths:INDEX NO. 9 10 SERVICE PART NO. 015818 015818 DESCRIPTION FUEL LINE (27.3" LONG) FUEL LINE (27.3" LONG)
5. Used on mowers with serial numbers prior to 07062321.
108277 05/10
4-19
Kawasaki Electrical Schematic (600999/601341)
4-20
108277 05/10
Kohler Electrical Schematic (601000/601342)
108277 05/10
4-21
Honda Electrical Schematic (600998)
4-22
108277 05/10
Section 5Front Wheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Front Wheel Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Drive Wheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
108277 05/10
5-1
Front Wheel Assembly1 33
2
4 1 5 2 3 6 8 5 8 9 112
7
3
4
4
3
4
3
6 8 8 7
1
10
11
INDEX NO. 1 2 3 4 5 6 7 8 9 10 11
SERVICE PART NO. 705954 344267 712976 784223 784603 339689 042630 767962 781567 768044 306969
MFG. PART NO. 705954 344267 712976 784223 784603 339689 042630 767962 781567 768044 306969
QTY. 2 2 2 4 2 2 2 4 2 2 2
DESCRIPTION CS .500-13 X 1.25 HX G5 ZNYC FW .510 X 2.15 X .187 SPL ZNYC FW .531 X 1.375 X .125 ZNYC BEARING FASTRAK SPACER CASTER FORK CS .500-13 X 6.50 HX G5 ZNYC FW .531 X 1.063 X .090 SAE ZNYC NT .500-13 HEX G8 ZNYC NL TIRE/WHEEL ASSEMBLY 11 X 4-5 RIBBED GAGE WHEEL SPACER
NOTES:
1. Apply grease to zerks, see owners manual. 2. Torque to 75 ft.-lbs. 3. Assemble with extended inner race down.5-2 108277 05/10
Front Wheel Breakdown768044 2
1
2
INDEX NO. 1 2
SERVICE PART NO. 772814 772806
MFG. PART NO. N/A N/A
QTY. 1 2
DESCRIPTION 3/4" ROLLER BEARING BEARING CAP
NOTES:
1. Inflate to 8-12 psi.
108277 05/10
5-3
Drive Wheel Assembly
1
3
2
5
2
1
4
INDEX NO. 1 2 3 4 5 1 2 3 4 5
SERVICE PART NO. 784264 784272 784280 019521 061077 783134 783142 783159 019521 061077
MFG. PART NO. 784264 N/A N/A N/A 061077 783134 N/A N/A N/A 061077
QTY. 2 1 1 1 4 2 1 1 1 4
DESCRIPTION WHEEL/TIRE ASSY 18 X 9.50 (QTY PER 54" TRACTOR) TIRE 18 X 9.5 WHEEL TIRE VALVE WHEEL NUT (QTY PER WHEEL) WHEEL/TIRE ASSY 18 X 8.50 (QTY PER 48" TRACTOR) TIRE 18 X 8.50 WHEEL TIRE VALVE WHEEL NUT (QTY PER WHEEL)
NOTES:
1. Inflate tire to 8-12 psi. 2. Torque to 65-75 ft-lbs.
5-4
108277 05/10
Section 654" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 54" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 54" Deck Pulley Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 48" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 48" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 48" Deck Pulley Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Blade Spindle Assembly Breakdown . . . . . . . . . . . . . . . . . . . . . . . . 6-14
108277 05/10
6-1
54" Deck Assembly
3
2 18 5 7 16 3 5 6 10 9 8 8 12 11 8 17 19 4
13
1
10 8 12 9
14 13 15
14 14 10 13 13
6-2
108277 05/10
54" Deck AssemblyITEM NO. SERVICE PART NO. 548305 601806 601824 601843 086660 112448 767954 768523 034280 787994 034272 601069 788166 781567 025395 781708 767962 031997 053199 MFG. PART NO. 108100 601806 601824 601843 086660 112448 767954 768523 034280 787994 034272 601069 788166 781567 025395 N/A N/A N/A N/A QTY 1 1 1 1 3 1 2 4 2 2 2 4 4 4 2 4 8 4 4 DESCRIPTION DECK W/A 54" FASTRAK DISCHARGE CHUTE TORSION SPRING CHUTE PIN NT .375-16 HXZY NL CHUTE BRACKET FW .406 X .812 .060 SAE HD ZN FW .343X.687X.051/.080H CS .312-18X .750 HX G5 DECK PIN & ROD ASSY NT .312-18 HX G5 ZNYC CN .312-18X.200 MAX THK ANTI SCALP WHEEL ASSY NT .50-13 HX LK NY CB .375-16 X 1.00 STD CD CS .500-13 X 4.25 HX G5 ZN FW .531 X 1.063 X .090 SAE HD ZN ANTI-SCALP WHEEL NT .500-13 HX JAM ZN
2
1 2 3 4 5 6 7 8 9 10 11 12
1 1314 15 16 17 18 19
NOTES:
1. Includes items 16 through 19. 2. Service part deck includes decals (see 54" Deck Decals on page 8-4 for listing of decals). 3. For mowers with serial numbers high than 09120000.
108277 05/10
6-3
54" Deck Assembly
2
2 8 6 5 10 3 5 17 11 4 12 13 15 14 13 12 9 14 16 15 16 15 17 15 13 12 14 14 13 16 5 1 11 17 5 4 5 6 11 6 5 7
12
6-4
108277 05/10
54" Deck AssemblyINDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 SERVICE PART NO. 548305 601117 108537 034280 768523 034272 767954 086660 025395 108049 601069 781708 767962 031997 053199 781567 787994 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 QTY. 1 1 1 3 6 3 2 2 2 1 4 4 8 4 4 4 2 4 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 & ROD ASSY ANTI-SCALP WHEEL ASSY
1
NOTES:
1. Includes items 12 through 15. 2. For mowers with serial numbers prior to 09120000. 3. Service part deck includes decals (see 54" Deck Decals on page 8-4 for listing of decals).
108277 05/10
6-5
54" Deck Pulley Assembly
1
2 3 4 5 62
8
12
11
10
7 9 18 18 3 4 13 1 14 5 19 20 5 21 22 15 16
17
3 4
19
20
19 20 54" Deck Assy
20 25 19 24 22 14 27 14 13 1 6-6 23
20
26
108277 05/10
54" Deck Pulley AssemblyINDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 SERVICE PART NO. 789388 025007 046821 797449 784504 028118 600296 797910 601434 350884 781302 259812 781872 782474 786889 108123 108124 016972 064006 768523 054502 767954 005116 783506 058776 601124 783738 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. 1 1 3 3 3 1 1 6 2 1 1 1 6 8 3 1 1 2 4 10 12 24 12 3 6 3 2 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 18.50"-L-F-CW BLADE CS .625-11X3.00 FULL HX DESCRIPTION
NOTES:
1. Torque to 118 ft.-lbs. 2. See Deck Belt Routing and Tensioning on page 7-5 for belt tensioning.
108277 05/10
6-7
48" Deck Assembly2
3
18
5 7
16 4 17 19
3 5 9 8 10 12 8 11 8 1 13 10
6
8 9
12 14 13 15
14 14 10 13
13
6-8
108277 05/10
48" Deck AssemblyITEM NO. SERVICE PART NO. 548313 601806 601824 601843 086660 112448 767954 768523 034280 787994 034272 601069 788166 781567 025395 781708 767962 031997 053199 MFG. PART NO. 108125 601806 601824 601843 086660 112448 767954 768523 034280 787994 034272 601069 788166 781567 025395 N/A N/A N/A N/A QTY 1 1 1 1 3 1 2 4 2 2 2 4 4 4 2 4 8 4 4 DESCRIPTION DECK W/A 48" FASTRAK DISCHARGE CHUTE TORSION SPRING CHUTE PIN NT .375-16 HXZY NL CHUTE BRACKET FW .406 X .812 .060 SAE HD ZN FW .343X.687X.051/.080H CS .312-18X .750 HX G5 DECK PIN & ROD ASSY NT .312-18 HX G5 ZNYC CN .312-18X.200 MAX THK ANTI SCALP WHEEL ASSY NT .50-13 HX LK NY CB .375-16 X 1.00 STD CD CS .500-13 X 4.25 HX G5 ZN FW .531 X 1.063 X .090 SAE HD ZN ANTI-SCALP WHEEL NT .500-13 HX JAM ZN
2
1 2 3 4 5 6 7 8 9 10 11 12
1
13 14 15 16 17 18 19
NOTES:
1. Includes items 16 through 19. 2. Service part deck includes decals (see 48" Deck Decals on page 8-5 for a listing of decals). 3. For mowers with serial numbers high than 09120000.
108277 05/10
6-9
48" Deck Assembly
2
2 9 6 5 8 10
3 5 4 17 4 5 12 13 15 14 11 13 12 14 7 15 16 16 15 13 16 1 17 5 11 5 6 5
4
17
15 13
14 12 14 12
6-10
108277 05/10
48" Deck AssemblyINDEX NO. SERVICE PART NO. 548313 601117 108537 034280 768523 034272 025395 767954 086660 108049 601069 781708 767962 031997 053199 781567 787994 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 QTY. 1 1 1 3 6 3 2 2 2 1 4 4 8 4 4 4 2 4 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 & ROD ASSY ANTI-SCALP WHEEL ASSY
3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
1
NOTES:
1. Includes items 12 through 15. 2. For mowers with serial numbers prior to 09120000. 3. Service part deck includes decals (see 48" Deck Decals on page 8-5 for a listing of decals).
108277 05/10
6-11
48" Deck Pulley Assembly
1 2 3 4 52
12
6 11 10 7 8
9 18 17 3 4 5 14 19 20 5 19 20 21 22 19 20 48" Deck Assy 15 16 18 3 4 13 1
19 20 14 25 14 27
20
24 22 23 26
14 13 1 6-12
108277 05/10
48" Deck Pulley AssemblyINDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 SERVICE PART NO. 791335 025007 046821 797449 784504 028118 600296 797910 601434 350884 781302 259812 781872 782474 792689 108148 108149 016972 064006 768523 054502 767954 005116 783506 058776 601123 783738 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. 1 1 3 3 3 1 1 6 2 1 1 1 6 8 3 1 1 2 4 10 12 24 12 3 6 3 2 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 DESCRIPTION
NOTES:
1. Torque to 118 ft.-lbs. 2. See Deck Belt Routing and Tensioning on page 7-5 for belt tensioning.
108277 05/10
6-13
Blade Spindle Assembly Breakdown1
2
3
4
2
5
INDEX NO. 1 2 3 4 5
SERVICE PART NO. 783548 783555 783530 783514 783522
MFG. PART NO. N/A N/A N/A N/A N/A
QTY. 1 2 1 1 1
DESCRIPTION BLADE SPINDLE RETAINING BEARING, BLADE SPINDLE SPACER, BLADE SPINDLE HOUSING, BLADE SPINDLE SHAFT, BLADE SPINDLE
NOTES:
6-14
108277 05/10
Section 7Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Deck Belt Routing and Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
108277 05/10
7-1
Seat Installation1
2
3
4
5 6 7
3 13 3 6 11 9 10 8
3
12
1
7-2
108277 05/10
Seat InstallationINDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 SERVICE PART NO. 793661 034280 768523 108321 808485 000331 548776 034272 052860 767954 601450 064014 058776 MFG. PART NO. 793661 034280 768523 108321 808485 000331 107861 034272 052860 767954 601450 064014 058776 QTY. 1 1 9 1 1 2 1 4 2 2 2 2 2 DESCRIPTION MICHIGAN STANDARD SEAT CS .312-18X .750 HX G5 FW .343 X .687 X .051/.080 HD SEAT LATCH, 48/54 FST 5/16-18 RIVET NUT SMALL/SHORT WIRE TIE SEAT PAN NT .312-18 HX G5 ZNYC CS .375-16 X 1.25 HX G5 FW .406 X .812 X .060 SAE SEAT SPRING 150 LB/IN CS .312-18 X .875 HX G5 NT .312-18 HX ZNYC NL
NOTES:
1. Do not torque, Item 7 (107861 Seat Pan) must pivot. 2. Service parts, (Michigan seat):793307 793315 797464 797472 797480 793273 SLIDE KIT SWITCH-SNAP KIT LH ROUND ARMREST ASSEMBLY RH ROUND ARMREST ASSEMBLY MOLDED ROUND ARMREST (2) ARMREST STOP ASSEMBLY
108277 05/10
7-3
Deck Installation
3
1
2
4
5
3
4
INDEX NO. 1 2 3 4 5
SERVICE PART NO. 055749 017616 767962 704643 008193
MFG. PART NO. 055749 017616 767962 704643 008193
QTY. 4 2 4 8 2
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 05/10
Deck Belt Routing and Tensioning
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. 2. Route belt as shown.
108277 05/10
7-5
7-6
108277 05/10
Section 8Tractor Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 54" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 48" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
108277 05/10
8-1
Tractor Decals
4 5
6 3
2
8 7
10 16 1 15 11 18 17 12
13
9 14
8-2
108277 05/10
Tractor DecalsINDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 SERVICE PART NO. 785121 785139 N/A 784710 727172 782573 793588 785220 788968 785154 601100 791848 601099 771436 600899 727016 785147 600941 MFG. PART NO. 785121 785139 083279 784710 727172 782573 793588 785220 788968 785154 601100 791848 601099 771436 600899 727016 785147 600941 QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 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:
108277 05/10
8-3
54" Deck Decals6
3
7
5 4
3
2
1
2
INDEX NO. 1 2 3 4 5 6 7
SERVICE PART NO. 799171 727453 727438 727172 785055 781419 727420
MFG. PART NO. 799171 727453 727438 727172 785055 781419 727420
QTY. 1 2 2 1 1 1 1
DESCRIPTION 54" DECK ID DECAL BELT & PULLEY DECAL WHIRLING BLADES DECAL 'MADE IN U.S.A.' DECAL STEP TREAD 3.70 X 9.00 BELT ROUTING DECAL DEFLECTOR SHIELD DECAL
NOTES:
8-4
108277 05/10
48" Deck Decals6
3
7
5 4 3
2 2 1
INDEX NO. 1 2 3 4 5 6 7
SERVICE PART NO. 793976 727453 727438 727172 794503 781419 727420
MFG. PART NO. 793976 727453 727438 727172 794503 781419 727420
QTY. 1 2 2 1 1 1 1
DESCRIPTION 48" DECK ID DECAL BELT & PULLEY DECAL WHIRLING BLADES DECAL 'MADE IN U.S.A.' DECAL STEP TREAD MINI FST DECAL BELT ROUTING DECAL DEFLECTOR SHIELD DECAL
NOTES:
108277 05/10
8-5
8-6
108277 05/10
.
Section 9Assembly Pictures and Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 General Information for all models . . . . . . . . . . . . . . . . . . . . . 9-2 Deck spindle torque procedure: . . . . . . . . . . . . . . . . . . . . . . . 9-2 Wire harness routing (all models). . . . . . . . . . . . . . . . . . . . . . 9-3 FasTraks with Honda engines . . . . . . . . . . . . . . . . . . . . . . . . 9-4 FasTraks with Kawasaki engines . . . . . . . . . . . . . . . . . . . . . 9-6 FasTraks with Kohler Engines . . . . . . . . . . . . . . . . . . . . . . . 9-9 Packing and crating (all models). . . . . . . . . . . . . . . . . . . . . . 9-11 Procedures and Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12 Deck leveling procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12 Park Brake and Steering Control Adjustment . . . . . . . . . . . 9-15 Parking Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 9-18 Engine adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18 Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
108277 05/10
9-1
Assembly Pictures and AidsGeneral Information for all modelsInstrument panel layout (FIG. 1).
PTO CLUTCH SWITCH FIG. 1
Wire harness routing (all models).Front of wire harness (FIG. 2 & FIG. 3). TIE STRAP TIE STRAP
TO SEAT SWITCH FIG. 2
FROM SAFETY SWITCHES FIG. 3
9-2
108277 05/10
FasTraks with Honda enginesWire harness, battery cable, throttle cable, and choke cable routing and tie straps (FIG. 4 & FIG. 5). TIE STRAPS TIE STRAP
SEAT SWITCH WIRE CHOKE & THROTTLE CABLES SAFETY SWITCH WIRES FIG. 4 FUEL LINE POSITIVE BATTERY CABLE
OIL SENSOR WIRE
NEGATIVE BATTERY CABLE
TIE STRAPS FIG. 5 Tie straps on rear seat support tie fuel line from L.S. fuel tank.
NOTE:
108277 05/10
9-3
Engine connections )FIG. 6, FIG. 7, FIG. 8, and FIG. 9). OIL SENSOR WIRE CARBURETOR DRAIN TUBES
TIE STRAP FUEL LINE FIG. 6
TIE STRAP
CLUTCH ANCHOR
FIG. 7
CHOKE CABLE OIL SENSOR WIRE
OIL FILL TUBE
FUEL LINE THROTTLE CABLE FIG. 8 NOTE: NOTE: FIG. 9
Route oil sensor wire between oil file tube and engine block. Index terminal on wire in horizontal direction to hold wire off oil filter. Tie carburetor drain tubes and clutch pigtail together to clutch anchor. Do not tighten tie strap enough to pinch drain hoses closed.
9-4
108277 05/10
FasTraks with Kawasaki enginesFOR MOWERS WITH SERIAL NUMBER 07102604 AND HIGHER. Front of wire harness (FIG. 10). Route the 4" positive battery cable and the purple and red wires through the cable boot prior to fastening hardware to solenoid (FIG. 11). TIE STRAP POS. BAT. CABLE
TIE STRAP
TO SEAT SWITCH FROM SAFETY SWITCHES NEG. BATTERY CABLE BOOT PUR/RED WIRES
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). RIGHT SIDE
NEG. BATTERY CABLE FIG. 12
WIREHARNESS
108277 05/10
9-5
Wire harness, battery cable, and throttle and choke cable, routing and tie straps (FIG. 13 & FIG. 14) . FUEL LINE TIE STRAP GROUND WIRE
TIE STRAP
POSITIVE BATTERY CABLE FUEL LINE CLUTCH WIRE
NEGATIVE BATTERY CABLE
CHOKE AND THROTTLE CABLES
CLUTCH PIGTAIL FIG. 13 Clutch pigtail to clutch anchor tie strap (FIG. 15). Safety switches and tie straps (FIG. 16) FIG. 14
TIE STRAP
CLUTCH PIGTAIL
TIE STRAP
SAFETY SWITCH FIG. 15 Engine connections (FIG. 17 & FIG. 18). OIL FILL TUBE OIL SENSOR WIRE CHOKE CABLE FIG. 16
CHOKE CABLE
THROTTLE CABLE TIE STRAPS FIG. 17 Fuel line routing (FIG. 19, FIG. 20 & FIG. 21). 9-6 FIG. 18
THROTTLE CABLE
108277 05/10
Be sure fuel filter does not come in contact with engine.
FUEL FILTER
LEFT FUEL LINE
LEFT FUEL LINE
TIESTRAP
FUEL VALVE
FUEL LINE FROM FUEL VALVE FIG. 19 FIG. 20
LEFT FUEL LINE FUEL VALVE
FUEL LINE TO FILTER
RIGHT FUEL LINE
FIG. 21
108277 05/10
9-7
FasTraks with Kawasaki enginesFOR MOWERS WITH SERIAL NUMBERS PRIOR TO 07102604: Wire harness, battery cable, and throttle and choke cable, routing and tie straps (FIG. 22, FIG. 23, & FIG. 24) . FUEL LINE TIE STRAP
GROUND WIRE
CHOKE AND THROTTLE CABLES
TIE STRAPS
FIG. 22 SAFETY SWITCH WIRES TIE STRAP
FIG. 23
SEAT SWITCH WIRE TIE STRAPS
NOTE:
FIG. 24 Route fuel line beneath both battery cables. Tie straps on rear seat support tie fuel line from L.S. fuel tank.
9-8
108277 05/10
Engine connections for 19 HP (FIG. 25 & FIG. 26). OIL SENSOR WIRE
CHOKE CABLE THROTTLE CABLE TIE STRAP
FIG. 25 Engine connections for 21 HP (FIG. 27 & FIG. 28). CHOKE CABLE
FIG. 26 OIL SENSOR WIRE
THROTTLE CABLE
FIG. 27
FIG. 28
108277 05/10
9-9
FasTraks with Kohler EnginesFOR ENGINES WITH SERIAL NUMBERS PRIOR TO 07102604 (FIG. 29):
TIE STRAPS
FIG. 29 FOR ENGINES WITH SERIAL NUMBERS 07102604 AND HIGHER: Front of wire harness (FIG. 30). Route the 4" positive battery cable and the purple and red wires through the cable boot prior to fastening hardware to solenoid (FIG. 31). TIE STRAP POS. BAT. CABLE
TIE STRAP
TO SEAT SWITCH FROM SAFETY SWITCHES NEG. BATTERY CABLE BOOT PUR/RED WIRES
FIG. 30 FIG. 31 Route negative battery cable and wireharness (from seat and safety switches) through hole in the right side of frame (FIG. 32). RIGHT SIDE
NEG. BATTERY CABLE
WIREHARNESS
FIG. 32 Wire harness and battery cable, and throttle and choke cable, routing and tie straps (FIG. 33, & FIG. 34) . 9-10 108277 05/10
FROM BATTERY
TIE STRAP
TIE STRAP
TIE STRAP
NOTE:
FIG. 33 FIG. 34 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 & FIG. 21). on page 9-6.
Engine connection (FIG. 35).
CHOKE CABLE
THROTTLE CABLE
FIG. 35
108277 05/10
9-11
Clutch pigtail to clutch anchor tie strap (FIG. 36).
TIE STRAP
CLUTCH PIGTAIL
FIG. 36
9-12
108277 05/10
Maintenance & Adjustment Safety
This safety alert symbol is used to call attention to a message intended to provide a reasonable degree of PERSONAL SAFETY for operators and other persons during the normal operation and servicing of this equipment. DANGERdenotes immediate hazards which WILL result in severe personal injury or death. WARNINGdenotes a hazard or unsafe practice which COULD result in severe personal injury or death. This manual uses two other words to highlight information. IMPORTANT calls attention to special mechanical information and NOTE: emphasizes general information worthy of special attention. All operators should read this manual, or be instructed about safe operating and maintenance procedures. This is the owners responsibility. Improper use or maintenance by the operator, mechanic, or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert s symbol, which means DANGER or WARNINGpersonal 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 setup, 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 owners responsibility to make certain that the operator/mechanic reads and understands this manual and all decals before operating this machine. It is also the owners responsibility to make certain that the operator/ mechanic is a qualified and physically able individual, properly trained in the operation of this equipment. Local regulations may restrict the age of the operator/mechanic. 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 & Adjustment PracticesThis product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death. s 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 operated in an enclosed area.s s
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 operators station clean of accumulated trash, grass clippings, 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. 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! 9-13
s
s
s s s
108277 05/10
s s s s s s s s s s
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 grinding mower blades and removing accumulated debris. Use extra caution when handling gasoline and other fuels. They are flammable and vapors are explosive. 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 appropriate jack stands, with a minimum weight rating of 2000 pounds to block the unit up. Use in pairs only. Follow the instructions supplied with the vehicle stands. Before working on or under the deck, make certain engine cannot be accidentally started. Shut engine off and remove ignition switch key for maximum safety. Repairs or maintenance requiring engine power should be performed by trained personnel only. Use a stick or similar instrument to clean under the mower making sure that no part of the body, especially arms and hands are under mower. Exercise caution when working under the deck as the mower blades are extremely sharp. 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 manufacturers recommended parts, when necessary. Use only genuine Hustler replacement parts to ensure that original standards are maintained
s
s
s s s s s s
s
Using a ramps s
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. It also reduces the risk of a wheel going off and the machine tipping over. Do not exceed a 15 degree angle between the ramp and the ground or between the ramp and the trailer or truck. When on a ramp avoid sudden acceleration
s s
Safety and Instruction Decalss
Specific safety warning decals are located on the equipment near the immediate areas of potential hazards. These decals should not be removed or obliterated. Replace them if they become non-readable.
The following illustrations show the various 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. 9-14 108277 05/10
Read Owners Manual and Quick Reference Decal before attempting to operate this machine.
Part Number 727016
Avoid skin contact with battery acid. Always wear eye protection when checking the battery, acid can cause serious injury to skin and eyes. If contact occurs, flush area with clean water and call physician immediately. Acid will also damage clothing. Do not allow open flame near the battery when charging. Hydrogen gas forms inside the battery. This gas is both toxic and flammable and may cause an explosion if exposed to flame. Always remove the negative ground first and replace it last. Do not overfill battery. Electrolyte may overflow and damage paint, wiring or structure. When cleaning the battery, use soap and water. Be careful not to get soap and water into the battery. Use soda mixed in water to clean corrosion off the terminals. Do not remove or modify stabilizer wheels or rear engine guard or injury can result.
Part Number 771436
Keep engine and pump compartment(s) clean (especially in exhaust area) to prevent fire and provide maximum engine and hydraulic cooling.Part Number 788968
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.
Part Number 727420
Whirling blades! Keep hands and feet away. Beware of thrown objects.
Part Number 727438
Keep shields or covers in place while machine is in operation. Keep hands away from rotating pulleys and belts.
Part Number 727453
108277 05/10
9-15
Part Number 600899
If you lose steering control while operating the machine, place the steering control levers in the park brake position immediately. Inspect the machine and involve your Hustler dealer to resolve the problem before continuing to operate. If pump belt fails, steering control will be lost. Refer to owners manual for inspection and replacement intervals and refer to above paragraph for emergency procedures.
9-16
108277 05/10
MaintenanceMaintenance Locator Chart 113
6
5
10
7 9
2a 3b 8
16
1 4
2c
15 11 6 1 2a. 2b. 2c. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Engine Oil Fill & 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 2b 10 9 7
14 12
14
Viewed from top of unit
13 Viewed from top of unit
FIG. 37 108277 05/10 9-17
SERVICE AT INTERVALS INDICATED VERIFY SAFETY START INTERLOCK SYSTEM VISUALLY INSPECT UNIT FOR LOOSE HARDWARE AND/OR DAMAGED PARTS VISUALLY INSPECT TIRES CHECK OIL LEVEL, ENGINE (1) CLEAN AIR INTAKE SCREEN (4) CLEAN FOAM ELEMENT (4) CHECK FUEL LEVEL BLADES - SHARPEN & SECURELY FASTENED DISCHARGE CHUTE - SECURELY IN PLACE & IN LOWEST POSITION CHECK HYDRAULIC OIL LEVEL CLEAN ENGINE AND TRANSAXLE COMPARTMENT CHANGE TRANSAXLE OIL AND FILTER (7) GREASE DECK HEIGHT PIVOTS GREASE GAUGE WHEEL BEARINGS CHANGE ENGINE OIL AND FILTER (1) (3) CLEAN CYLINDER AND HEAD FINS(A) CHECK BATTERY CONNECTIONS CHECK TIRE PRESSURE WITH A GAUGE CHECK HYDRAULIC OIL LEVEL CLEAN ENGINE EXTERIOR (A) CLEAN & RE GAP SPARK PLUGS (A) CHECK PUMP AND DECK BELT TENSION AND CONDITION (5) CHECK FUEL AND HYDRAULIC LINES (6) CHECK FUEL VALVE AND GROMMET (6) TIGHTEN LUG NUTS ON WHEELS (2) CHANGE FUEL FILTER REPLACE SPARK PLUGS
WEEKLY OR 50 HOURS
MONTHLY OR 100 HOURS
ANNUALLY OR 300 HOURS
PRIOR TO EACH USE PRIOR TO EACH USE PRIOR TO EACH USE PRIOR TO EACH USE OR EVERY 4 HOURS PRIOR TO EACH USE OR EVERY 4 HOURS PRIOR TO EACH USE OR EVERY 4 HOURS PRIOR TO EACH USE PRIOR TO EACH USE PRIOR TO EACH USE DAILY DAILY EVERY 200 HOURS OR 2 YEARS X X X X X X X X X X X X X X 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 manufacturers recommendations. Refer to Engine Owners Manual for recommendations and other maintenance items. 4. Service more often under dusty or dirty conditions. 5. Pump drive belt only - Inspect every 6 months or 100 hours and replace if worn or cracking is noticed. Otherwise, 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 must be 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. REFERENCES:
a-- Refer to Engine Owners ManualNOTE: After completing maintenance cycle (300 hours), repeat cycle.
IntroductionRegular 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 wear or damage. A good time to detect potential problems is while performing scheduled maintenance service. Correcting the problem as quickly as possible is the best insurance. Clear away heavy build-up of grease, oil and dirt, especially in the engine and under the seat platform areas; minute dust particle are abrasive to close-tolerance engine and hydraulic assemblies. 9-18 108277 05/10
Daily inspect mower for grass clippings and wire and string tangles. The underside of the mower deck will collect a build-up of grass clippings and dirt, especially when grass is wet or has high moisture content. This build-up will harden, restricting blade and air movement and will probably show a poorer quality of cutting. Therefore it should be removed routinely. To do this it will be necessary to raise and block the deck, using jack stands or blocks, in the full up position and scrape the build-up from underneath. Some repairs require the assistance of a trained service mechanic and should not be attempted by unskilled personnel. Consult your Hustler service center when assistance is needed.
Torque valuesTorque values are given below:WHEEL (LUG) NUTS BLADE SPINDLE BOLT TOP BLADE SPINDLE BOLT BOTTOM 65-75 FT.-LBS. 118 FT.-LBS. 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 owners manual.
TiresIt is important for level mowing that the tires have the same amount of air pressure. The recommended pressure are:DRIVE WHEELS FRONT WHEELS 8-12 PSI 8-12 PSI
Solid fill tires are not recommended for Hustler turf equipment. On any machine, with solid filled tires, the warranty claim will be denied. WARNING: Explosive separation of a tire and rim can cause serious injury or death. Do not attempt to mount a tire without the proper equipment and experience to perform the task. Always maintain the correct tire pressure and never over inflate. Never weld or heat a wheel and tire assembly as an explosion may occur. Welding can weaken or deform a wheel. When inflating tires stand to one side and not in front of or over the tire assembly. Check tires for low pressure, blemishes, damaged rims or missing lug bolts and nuts.
Lubrication1. 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 operators footrest per the Maintenance Schedule. Use SAE multi-purpose grease.
Electrical systemThe 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 manufacturers maintenance, safety, storing and charging specifications.
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The battery is located under the seat platform. (FIG. 38) ZT2800 BATTERY
EXPANSION TANK
FIG. 38 WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. WARNING: Avoid skin and clothing contact with battery acid. Always wear eye protection when checking the battery, acid can cause serious injury to skin and eyes. If contact occurs, flush area with clean water and call physician immediately. Acid will also damage clothing. Do not drink the battery electrolyte. Do not allow open flame near the battery when charging. Hydrogen gas forms inside the battery. This gas is both toxic and flammable and may cause an explosion if exposed to flame. Always remove the negative ground first and replace it last. Do not overfill battery. Electrolyte may overflow and damage paint, wiring or structure. When cleaning the battery, use soap and water. Be careful not to get soap and water into the battery. Clean the battery terminals with a solution of four parts water and one part baking soda when they become corroded. WARNING: Shorts caused by battery terminals or metal tools touching metal tractor components can cause sparks. Sparks can cause a battery gas explosion which will result in personal injury. Prevent the battery terminals from touching any metal tractor parts when removing or installing the battery. Do not allow metal tools to short between the battery terminals and metal tractor parts. WARNING: Incorrect battery cable routing could cause damage to the tractor and battery cables. This can cause sparks which can cause a battery gas explosion which will result in personal injury. Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. 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 electrical system is protected by fuses located on the right fuel tank instrument panel. FIG. 39 The fuses are as follows:FUNCTION MAIN CLUTCH/AUX SIZE 20 AMP, 10 AMP, TYPE BLADE-TYPE BLADE-TYPE
Before attempting any failure diagnosis of the electrical system, use a test light or voltmeter to check the battery voltage. If the battery voltage is satisfactory, check the cleanliness and tightness of the terminals and ground connections. A general understanding of electrical servicing and use of basic test equipment is necessary for troubleshooting and repair. 9-20 108277 05/10
FUSES
FIG. 39 Major overhaul or repair of the starting motor or charging system should be performed by trained technicians only.
Access to ZT2800 transaxlesThe 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 systemThe 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 hydraulic expansion tank is located in front of the engine and under the operators 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 transaxles 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.
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ZT2800
ZT2800 FILTER
FILTER GUARD FIG. 41
FIG. 40
FIG. 42 WARNING: When washing the mower, direct the spray away (especially if using a power washer) from the Hydro-Gear ZT 2800 transaxles seals to prevent water intrusion and to ensure component performance. WARNING: Make sure the transaxles are cool before performing service procedures.
Fluid changing procedure1. Park the unit on a level surface. Place control levers in the park brake position, disengage deck clutch, remove ignition switch key and disconnect negative battery cable. 2. Remove the three 1/4 filter guard screws and filter guard. Clean any loose debris from around the filter (FIG. 42). 3. 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. 4. 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. 5. Install the new filter by hand, turn 3/4 to one full turn after the filter gasket contacts the filter base surface. 6. Re-install the filter guard with three 1/4 screws. Torque the screws to 65 in.-lbs. each. 7. Repeat steps 2 - 6 for the opposite side transaxle. 8. Drain oil filters of all free flowing oil prior to disposal. Place used oil in appropriate containers. 9. 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 (FIG. 42). 10. 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 transaxles top port (approximately 2 qts. per transaxle, 4 qts. total). Install the top port plug into each transaxle as the oil level reaches this port. 9-22 108277 05/10
12. Install and torque the top port plugs to 180 in. lbs. 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. 15. Proceed to the purge procedure.
Purging ProceduresThe following procedures are best performed with the vehicle drive wheels off the ground. Then repeated under normal operating conditions. If this is not possible, then the procedure should be performed in an open area free of any objects or bystanders. 1. Disengage the brake if activated. 2. With the bypass valve open and the engine running, slowly move the directional control in both forward and reverse directions (5 or 6 times). 3. With the bypass valve closed and the engine running, slowly move the directional control in both forward and reverse directions (5 to 6 times). Check the oil level, and add oil as required after stopping the engine. 4. It may be necessary to repeat Steps 2 and 3 until all the air is completely purged from the system. When the transaxle operates at normal noise levels and moves smoothly forward and reverse at normal speeds, then the transaxle is considered purged.
Fuel systemDANGER: Observe usual 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 explosive. 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 correct cause. Store gasoline in an approved container and keep it out of the reach of children. Never buy more than a 30 day supply of gasoline. Always place gasoline containers on the ground away from your vehicle before filling. Do not fill gasoline containers inside a vehicle or on a truck or trailer 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 container and not a gasoline dispenser nozzle. If a gasoline dispenser nozzle must be used, keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.
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 tractors fenders (FIG. 43). Total capacity for the fuel tanks is 10 U.S. gallons (38 liter). When filling the fuel tanks disengage deck clutch, place control levers in park brake position, and stop tractor engine. Clean around the fuel tank cap and remove the cap and begin filling. When finished, screw the cap on securely and wipe up any spilled gasoline. Use regular unleaded gasoline with an octane rating of 87 or higher. IMPORTANT: Never use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with gasoline. Using a fuel stabilizer/conditioner in the tractor can provide benefits such as: 1. Keeps gasoline fresh during storage of 90 days or less. For longer storage, drain the fuel tanks. 2. Cleans the engine during operation. 3. Eliminates gum-like varnish buildup in the fuel system. 108277 05/10 9-23
FUEL TANK
FIG. 43 IMPORTANT: Never use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with gasoline. Using a fuel stabilizer/conditioner in the tractor can provide benefits such as: 1. Keeps gasoline fresh during storage of 90 days or less. For longer storage, drain the fuel tanks. 2. Cleans the engine during operation. 3. Eliminates gum-like varnish buildup in the fuel system. IMPORTANT: Do not use fuel additives containing methanol or ethanol. Add the correct amount of gas stabilizer/conditioner to the gas. Follow the gas stabilizer/conditioner manufacturers directions for best results. The fuel filter (FIG. 44, FIG. 45 & 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 owners manual HONDA KAWASAKI
FUEL FILTER FUEL FILTER
FIG. 44
FIG. 45
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FUEL FILTER
FIG. 46 When replacing the fuel filter, check the fuel line hoses for any cracks or leaks. Replace as needed.
Fuel Shut-off ValvesThe 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 valves two other positions are front and rear. To drain a fuel tank use the following method: FUEL FILTER
CLOSED POSITION FUEL VALVE (RIGHT TANK POSITION SHOWN) 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. Place control levers in the park brake position. Disconnect negative battery cable. 2. Turn the fuel valve to the closed position (middle position) (FIG. 47). 3. Disconnect the tank to fuel valve line from the valve and clamp or cap the end of it. 4. Remove the fuel tank from the tractor. 5. Remove the fuel tanks fill cap and pour the fuel out of the fill spout into a clean certified fuel container. 6. 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. 7. Fill fuel tank with proper grade of gasoline and open shut-off valve.
Engine oil and filterCheck 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 & FIG. 50. Tractor must be setting level when checking oil. Refer to engine manual and maintenance schedule for oil recommendation and capacities. Change the engine oil and filter after the first 5 hours of operation, per the engine manufacturers recommendations after that. If tractor is being operated in extremely dirty conditions, then it is recommended oil be changed more 108277 05/10 9-25
frequently. IMPORTANT: When removing the oil filter take precautions to minimize oil spillage on the exhaust system. HONDA DIPSTICK & ENGINE OIL FILLER TUBE DIPSTICK & ENGINE OIL FILLER TUBE ENGINE OIL DRAIN VALVE KAWASAKI
ENGINE OIL FILTER ENGINE OIL FILTER ENGINE OIL DRAIN VALVE FIG. 49 DIPSTICK & ENGINE OIL FILLER TUBE KOHLER
FIG. 48
ENGINE OIL FILTER ENGINE OIL DRAIN VALVE 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 of the exhaust system before operating the machine. The oil drain and oil filter are located at the rear of the engine (FIG. 48, FIG. 49 & FIG. 50).
Belt replacementFIG. 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, separation, weather checking and cracking, or burns caused by slipping. Slight raveling of belt covering does not indicate failure, trim ravelling with a sharp knife. WARNING: If the pump belt fails, loss of control will occur especially when operating on a slope. If you lose steering control while operating the machine, place the steering control levers in the park brake position immediately. Inspect the machine and involve your Hustler dealer to resolve the problem before continuing to operate. Inspect the belt pulley grooves and flanges for wear. A new belt, or one in good condition, should never run against the bottom of the groove. Replace the pulley when this is the case, otherwise belt will lose power and slip excessively. Never pry a 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.
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Viewed from bottom of unit
5
2
2 3 6 5 4 2
1 Transaxle belt 2. Engine pulley 3. Transaxle idler pulley 4. Transaxle idler arm 5. Transaxle pulley 6. Electric deck clutch 7. Transaxle idler spring 5 8. Fixed idler pulley
5
3 1
Deck Belt Drive Layout 1 2. 3. 4. Spindle drive belt Deck blade spindle pulley Spindle belt tension idler Spindle belt tension idler spring 7.5 at operation) 5. Deck belt idler pulley 6. Idler arm
7 8 2, 6 1 4
FIG. 51 SPRING ANCHOR BRACKET TENSION IDLER
FIG. 52
CHAIN
FIG. 53
Deck belt replacement1. Park the unit on a flat surface. Stop the engine and remove the ignition key. Make sure deck clutch switch is in the down (OFF) position. Place control levers in the park brake position. Disconnect negative battery cable. 2. Place the deck in the lowest position. 3. Remove the deck belt covers.
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4. Release 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 5. Pull the idler to the left of the machine to provide maximum belt clearance. 6. Remove the existing belt and replace with a new belt. 7. Route the new belt per FIG. 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 replacement1. 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 & FIG. 54).
BELT
ENGINE PULLEY
CLUTCH PULLEY 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 position (FIG. 52). 6. Slide the belt off the engine pulley. The belt will have to be slid above the engine pulley to allow the belt to be removed from the other pulleys (FIG. 54). 7. Slide the belt over the transaxle pulleys. 8. Slide the belt off of the fixed idler pulley. 9. The belt can now be removed from above the engine pulley. 10. 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. 1