36" & 42" Deck Parts Manual ···· P.O. Box 7000 ··· Hesston, Kansas · 67062-2097 333559 Rev. 8/06 WARNING: The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. IMPORTANT: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate this engine on any forest-covered, brush-covered, or grass-covered unimproved land. Other states or federal areas may have similar laws. This spark ignition system complies with Canadian ICES-002. The Engine Owner's Manual provides information regarding the U.S. Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance and warranty. Keep Engine Owner's Manual with your unit. Should the Engine Owner's Manual become damaged or illegible, replace immediately. Replacements may be ordered per the information found in the Product Information section of the owner's manual. Table of Contents Chapter 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Chapter 2 Contents Tractor Frame Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Engine Guard and Anti-rollover Bracket Assemblies . . . . . . . . . . . 2-3 Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Chapter 3 Contents Battery Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydro Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering and Brake Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 4 Contents Honda 16 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Kohler 15 & 17 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . Fuel System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Panel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Honda 16HP Electrical Schematic (793083). . . . . . . . . . . . . . . . . . Kohler 15 & 17 HP Electrical Schematic (793117) . . . . . . . . . . . . . 3-2 3-3 3-4 3-6 4-2 4-4 4-6 4-8 4-10 4-12 Chapter 5 Contents Front Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Front Wheel Breakdown -768044 . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Drive Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Chapter 6 Contents Deck Assembly 36" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deck Pulley Assembly 36" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deck Assembly 42" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deck Pulley Assembly 42" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6-4 6-8 6-10 Chapter 7 Contents Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Belt Routing and Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Seat Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Chapter 8 Contents Tractor Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 42" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 36" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Chapter 9 Contents Maintenance & Adjustment Safety Precautions . . . . . . . . . . . . . . . .9-2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1 333559 8/06 c-1 c-2 333559 8/06 Chapter 1 General Information This Manual covers "Mini" FasTrak 15/36 model 927343, "Mini" FasTrak 17/42 model 927350, "Mini" FasTrak 16/42 model 927368, & "Mini" FasTrak 16/36 model 927376, Frequently Ordered Parts PART NO. 793836 793828 793893 068478 785626 794370 787226 747303 787234 793794 793802 DESCRIPTION Pump Drive Belt Deck Belt 36" Deck Belt 42" Fuel Filter Kohler Fuel Filter Honda Air Filter, Kohler Air Filter, Honda Engine Oil Filter, Kohler Engine Oil Filter, Honda 20.50" 42D X 0.631 CW Blade 13.75" 42D X 0.631 CW Blade Service Literature PART NO. 107612 794313 787242 DESCRIPTION Common Consumers Owners Manual Kohler Engine Manual Honda 16 HP Engine Manual Options PART NO. 793331 338442 DESCRIPTION Armrest Kit Mulch Kit, 36/42" Note: When ordering parts, you must use the part number as shown for each part, not the index number. Always give the model and serial number to your parts and service representative. Note: Items sold in bulk such as seals and hoses are sold by the foot. Using this manual Illustrations used were current at the time of printing, but subsequent production changes may cause your machine to vary slightly in detail. Excel Industries, Inc. reserves the right to redesign and change the machine as deemed necessary, without notification. If a change has been made to your machine which is not reflected in this parts manual, see your Hustler dealer for current information and parts. 333559 8/06 1-1 Hardware Description Codes & Abbreviations The following codes are used throughout this parts manual. Refer to this list when ordering parts. ABBREVIATION CB CE CP CS CW FDRW FW HX LW MB MS NT SC SH SB SS OD ID DESCRIPTION Carriage Bolt Clevis Pin Cotter Pin Cap Screw Cup Washer Fender Washer Flat Washer Hex Head Lock Washer Machine Bushing Machine Screw Nut Self Tapping Cap Screw Socket Head Shoulder Bolt Set Screw Outside Diameter Inside Diameter Standard Torques The following chart lists the standard torque values for the threaded fasteners found in this manual. Torque all cap screws, nuts and set screws to these values unless a different torque is shown in the Notes section next to the fastener SIZE .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 NOTE: SIZE M3 M4 M5 M6 M8 M10 M12 M16 M20 M24 FT-LBS 1 2.2 4.5 7.7 18.5 37 64 160 320 555 NM 1.3 3 6.1 10.4 25 50 87 215 435 750 Loctite 592 to be used on all pipe threads. Lubricate all grease zerks. 1-2 333559 8/06 Chapter 2 Contents Tractor Frame Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Engine Guard and Anti-rollover Bracket Rivet Nuts. . . . . . . . . . . . . . 2-3 Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 333559 8/06 2-1 Tractor Frame Rivet Nut Installation 2 1 INDEX NO. 1 2 SERVICE PART NO. 546911 546895 N/A MFG. PART NO. 315440 320242 808493 QTY. 1 1 2 DESCRIPTION FASTRAK 36 FRAME FASTRAK 42 FRAME 3/8-16 THREAD RIVET NUT NOTES: 2-2 333559 8/06 Engine Guard and Anti-rollover Bracket Assemblies 1 3 4 2 3 3 8 5 6 7 9 INDEX NO. 1 2 3 4 5 6 7 8 9 SERVICE PART NO. 316836 320580 808493 781567 344267 053199 767962 031997 781708 788166 MFG. PART NO. 316836 320580 808493 781567 344267 N/A N/A N/A N/A 788166 QTY. 1 2 8 2 4 2 4 2 2 2 DESCRIPTION ENGINE GUARD ANTI ROLLOVER BRACKET 3/8-16 THREAD RIVET NUT NT .50-13 HX LK NY ZNYC FW .510 X 2.15 X .187SPL ZNYC NT .500-13 HX JAM ZNYC FW .531 X 1.063 X .090 SAE HD ZN ANTI-SCALP WHEEL CS .500-13 X 4.25 HX G5 ZNYC ANTI SCALP WHEEL ASSEMBLY 1 10 NOTES: 1. Includes items 6 through 9. 333559 8/06 2-3 Footrest Assembly 3 1 4 2 1 6 7 6 5 7 INDEX NO. 1 2 3 4 5 6 7 SERVICE PART NO. 011320 785485 793844 320267 316844 767954 076422 054502 MFG. PART NO. 011320 785485 793844 320267 316844 767954 076422 054502 QTY. 4 2 2 1 1 2 2 4 DESCRIPTION CB .375-16 X .75 STD ZN UPPER STEP TREAD LOWER STEP TREAD FLOOR PLATE 36" MOWERS FLOOR PLATE 42" MOWERS FW .406 X .812 X .060 SAE HD ZN FW.406X 1.000X.06 ZNYC NT .375-16 HX GRD 5 ZNYC NOTES: 2-4 333559 8/06 Chapter 3 Contents Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Hydro Transmission Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Steering and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 333559 8/06 3-1 Battery Installation 1 5 3 7 4 4 8 PART OF WIRE HARNESS (BLK) 2 3 4 6 2 2 9 INDEX NO. 1 2 3 4 5 6 7 8 9 SERVICE PART NO. 314989 024927 055939 029868 740696 771428 785063 786632 786640 793489 MFG. PART NO. 314989 024927 055939 029868 740696 771428 785063 786632 786640 793489 QTY. 1 3 2 4 1 1 1 1 1 1 DESCRIPTION BATTERY CLAMP STRAP NT .250-20 HX GR.5 ZNYC CS .250-20 X .75 HX G5 ZNYC LW .250 INT-EXT TOOTH ZNYC BATTERY VU1LH-8 RED BATTERY CABLE BOOT POSITIVE BATTERY CABLE (KOHLER) POSITIVE BATTERY CABLE (HONDA) NEGATIVE BATTERY CABLE BATTERY CLAMP ROD NOTES: 3-2 333559 8/06 Deck Lift Assembly 1 2 3 6 78 9 5 4 9 8 9 10 7 8 1 7 11 1 12 13 14 9 7 17 16 15 11 9 5 16 7 INDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 SERVICE PART NO. 348318 348284 793505 782995 055749 334045 704643 025296 781294 781229 015495 756270 034272 348458 781831 360131 767962 MFG. PART NO. 348318 348284 793505 782995 055749 334045 704643 025296 781294 781229 015495 756270 034272 348458 781831 018846 767962 QTY. 1 1 1 1 2 1 6 4 5 1 3 1 1 1 1 2 2 DESCRIPTION STOP HANDLE HEIGHT ADJUSTMENT STOP DECK HEIGHT INDICATOR DECK LIFT SPRING CS .437-14 X 1.75 HX G5 ZNYC DECK LIFT LINK NT .437-14 HX FLG ZN FW .760 X 1.625 X .08 ZNYC E CLIP 1.00 X.625X .050 CE .750 X 2.25 X 1.75 HEADLESS STRAIGHT GREASE FITTING CS .312-18 X 1.50 FLTHR GR5 ZNYC NT .312-18 HX G5 ZNYC DECK LEVELER YOKE CS .437-14 X 1.75 FULTH G5 ZNYC DECK LIFTCHAIN FW .531 X 1.063 X .090 SAE HD ZN NOTES: 1. Apply grease to zerks (see owners manual). 333559 8/06 3-3 Hydro Transmission Installation 1 12 1 2 3 4 5 6 8 9 10 7 21 12 4 12 1 12 13 1 13 11 19 14 2 15 17 16 18 20 3-4 333559 8/06 Hydro Transmission Installation INDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 SERVICE PART NO. 710087 028118 794404 025007 793836 792911 792895 718288 035238 794552 335695 768523 034272 784827 781153 025296 324046 061101 036384 364315 335893 MFG. PART NO. 710087 028118 794404 025007 793836 792911 792895 718288 035238 794552 335695 768523 034272 784827 781153 025296 324046 061101 036384 059931 335893 QTY. 8 3 1 2 1 1 1 1 1 1 1 12 8 1 2 2 1 1 1 1 2 DESCRIPTION CS .312-18 X 2.50 HX G5 ZNYC FW .62 X 1.00 X .134 ZNYC PULLEY CS .625-11 X 1.75 HX G5 ZNYC A-SECTION PUMP BELT EZT LEFT PUMP/MOTOR COMBO EZT RIGHT PUMP/MOTOR COMBO FW .516 X .875 X .09 ZNYC LW .437 MED SPRING ZNYC CS .438-14 X 6.5 HX ZN G5 SPACER TUBE-EZT MINI FST FW .343 X .687 X .051/.080 HD ZNYC NT .312-18 HX G5 ZNYC 4.00"OD, 5/8"ID IDLER PULLEY UHMW BUSHING FW .760 X 1.625 X .08 ZNYC PUMP BELT IDLER ARM NT .750-10 HX NL ZN IDLER SPRING SPRING CHAIN BELT DEFLECTOR NOTES: 1. Torque to 17 ft.-lbs. 333559 8/06 3-5 Steering and Brake Assembly 1 2 3 8 9 12 14 13 15 8 16 11 8 17 21 22 18 8 23 11 7 8 24 13 11 6 20 4 10 4 19 10 4 5 7 8 11 4 4 5 9 13 13 25 27 28 29 21 8 10 40 37 38 39 21 28 41 SEE NOTE 3 41 35 36 29 8 26 11 29 28 30 31 32 33 11 34 8 3-6 333559 8/06 Steering and Brake Assembly INDEX NO. 1 2 3 SERVICE PART NO. 781260 360487 600221 783696 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 767954 086660 705178 034272 768523 781922 797779 041152 325464 768259 718288 793059 793646 794396 793612 797753 079186 079186 768515 797761 781567 795625 796615 793174 048553 068551 797050 795229 352112 352054 024927 781211 060731 315382 315101 794883 793182 089789 MFG. PART NO. N/A 360487 600221 783696 767954 086660 705178 034272 768523 781922 797779 041152 325464 768259 718288 793059 793646 794396 793612 797753 079186 079186 768515 797761 781567 795625 796615 793174 048553 068551 797050 795229 352112 352054 024927 781211 060731 N/A N/A 794883 793182 089789 QTY. 2 2 2 2 10 6 4 4 20 4 8 12 2 8 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 4 2 2 1 1 2 2 4 1 1 2 2 4 DESCRIPTION STEERING BAR GRIP STEERING BAR CENTERING DAMPER CENTERING DAMPER FW .406 X .812 X .060 SAE HD ZN NT .375-16 HX LK NY CS .375-16 X 1.75 HX G5 ZNYC NT .312-18 HX G5 ZNYC FW .343 X .687 X .051/.080 HD ZNYC DAMPER BALL STUD IGUS® BUSHING NT .312-24 HX ZNYC STEERING CONTROL ARM IGUS® BUSHING FW .516 X .875 X .09 ZNYC E CLIP .80X.396X.042 PUMP ROD ADJUSTER ASSEMBLY STEERING LINK ROD STEERING DRIVE ARM STEERING ARM CS .312-18 X 1.250 HX G5 CS .312-18 X 1.25 HX G5 Z ...