44" & 52" Deck Parts Manual ······· Hustler Turf Equipment ····· P.O. Box 7000 ··· Hesston, Kansas · 67062-2097 365262 Rev. 6/06 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 enclosed Engine Owner's Manual is supplied for information regarding the U.S. Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance and warranty. Keep this 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 this manual. Table of Contents Chapter 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Chapter 2 Contents Tractor Frame Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . Idler Plate Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Guard Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 3 Contents Battery Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering and Brake Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydro Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Towlink Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 4 Contents Honda 18 & 20 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . Honda 16 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Briggs & Stratton 17.5 HP Engine Installation. . . . . . . . . . . . . . . . . Kohler 18 & 20 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . Fuel System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Panel Assembly/Installation . . . . . . . . . . . . . . . . . . . . . Honda 18 & 20 HP Electrical Schematic (784868) . . . . . . . . . . . . . Honda 16 HP Electrical Schematic (786178). . . . . . . . . . . . . . . . . Briggs & Stratton Electrical Schematic (786186) . . . . . . . . . . . . . . Kohler Electrical Schematic (792754) . . . . . . . . . . . . . . . . . . . . . . . Chapter 5 Contents Front Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Wheel Breakdown--768044 . . . . . . . . . . . . . . . . . . . . . . . . . Drive Wheel Assembly--783134 . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-Rollover Wheel Assembly--Honda and Briggs . . . . . . . . . . . . 2-2 2-3 2-4 2-5 3-2 3-4 3-6 3-8 3-10 4-2 4-4 4-6 4-8 4-12 4-14 4-16 4-18 4-20 4-22 5-2 5-3 5-4 5-5 Chapter 6 Contents 52" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 52" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 44" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 365262 6/06 c-1 44" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Blade Spindle Assembly Breakdown . . . . . . . . . . . . . . . . . . . . . . . 6-13 Chapter 7 Contents Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Deck Belt Routing and Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Chapter 8 Contents Tractor Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 8-4 8-5 i-1 c-2 365262 6/06 Chapter 1 General Information This Manual covers FasTrak 20/52 model 926501, FasTrak 18/44 model 926519, FasTrak 16/44 model 926527, FasTrak 18/52 model 926592, FasTrak 17.5/52 model 926600, FasTrak 17.5/44 model 926774, FasTrak 18/44 model 927442, & Fastrak 20/52 model 927459. Frequently Ordered Parts PART NO. 784231 784249 784322 785626 785600 785618 785634 787226 787234 786988 787002 794370 747303 068478 789511 DESCRIPTION Pump Drive A-Section Belt 52" Deck B-Section Belt 44" Deck B- Section, Belt Fuel Filter Honda 18 & 20 HP Air Filter Honda 18 & 20 HP Air Filter Precleaner Honda 18 & 20 HP Engine Oil Filter Honda 16 HP Air Filter Honda 16 HP Engine Oil Filter Air Cleaner Cartridge, Briggs & Stratton Oil Filter, Briggs & Stratton Engine Kohler Paper Air Filter Kohler Engine Oil Filter Kohler Fuel Filter In-line Filter Kit, C-IZT Service Literature PART NO. 365270 785642 787242 786962 794313 DESCRIPTION FasTrak Owner's Manual Honda 18 & 20 HP Engine Manual Honda 16 HP Engine Manual 17.5 HP Briggs & Stratton ELS Engine Manual Kohler Courage Engine Manual Options PART NO. 365668 365684 785428 785436 793331 784850 367425 367656 DESCRIPTION 52" FasTrak Mulch Kit 44" FasTrak Mulch Kit 16" CW Gator Blade 18" CW Gator Blade Armrest Kit (Michigan Seat) Armrest Kit (Milsco Seat) FasTrak Seat Spring Kit FasTrak Hour Meter Kit 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 365262 6/06 1-1 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. 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 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 NOTE: Loctite® 592 to be used on all pipe threads. Lubricate all grease zerks. 1-2 365262 6/06 Chapter 2 Contents Tractor Frame Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Idler Plate Rivet Nut Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Engine Guard Rivet Nut Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 365262 6/06 2-1 Tractor Frame Rivet Nut Installation 1 2 1 1 1 1 INDEX NO. 1 2 SERVICE PART NO. N/A 546044 545962 MFG. PART NO. 808485 365544 361667 QTY. 11 1 1 DESCRIPTION RIVET NUT, 5/16-18 THREAD 44" FASTRAK FRAME 52" FASTRAK FRAME NOTES: 2-2 365262 6/06 Idler Plate Rivet Nut Installation 1 2 INDEX NO. 1 2 SERVICE PART NO. N/A 363952 MFG. PART NO. 808485 363952 QTY. 3 1 DESCRIPTION RIVET NUT, 5/16-18 THREAD IDLER PLATE NOTES: 365262 6/06 2-3 Engine Guard Rivet Nut Installation 1 2 2 INDEX NO. 1 2 SERVICE PART NO. 364885 N/A MFG. PART NO. 364885 808485 QTY. 1 2 ENGINE GUARD DESCRIPTION RIVET NUT, 5/16-18 THREAD NOTES: 2-4 365262 6/06 Footrest Assembly 1 2 4 3 3 TRACTOR FRAME 5 6 6 5 6 5 INDEX NO. 1 2 3 4 5 6 SERVICE PART NO. 785493 785485 011320 355651 054502 767954 MFG. PART NO. 785493 785485 011320 355651 054502 767954 QTY. 2 2 4 1 4 4 DESCRIPTION LOWER STEP TREAD UPPER STEP TREAD CB .375-16 X .750 STD ZN FLOOR PLATE NT .375-16 HX GRD 5 ZNYC FW .406 X .812 X .060 SAE HD ZN NOTES: 365262 6/06 2-5 2-6 365262 6/06 Chapter 3 Contents Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Steering and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Hydro Transmission Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Towlink Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 365262 6/06 3-1 Battery Installation 1 2 3 4 5 5 7 6 5 4 9 6 10 8 11 12 11 2 2 12 13 11 2 14 IDLER PLATE 14 TRACTOR FRAME 3-2 365262 6/06 Battery Installation INDEX NO. 1 2 3 4 5 6 7 7 8 8 9 10 11 12 13 14 SERVICE PART NO. 058776 768523 348417 055939 029868 024927 785063 786632 793216 785071 786640 795146 740696 771428 034280 034272 364174 779850 MFG. PART NO. 058776 768523 348417 055939 029868 024927 785063 786632 793216 785071 786640 795146 740696 771428 034280 034272 364174 779850 QTY. 2 7 1 2 4 2 1 1 1 1 1 1 1 1 5 2 1 2 DESCRIPTION NT .312-18 HX NL ZNYC FW .343 X .687 X .051/.080 HD ZNYC BATTERY CLAMP STRAP CS .250-20 X .750 HX G5 ZNYC LW .250 INT-EXT TOOTH ZNYC NT .250-20 HX GR.5 ZNYC POSITIVE BATTERY CABLE POSITIVE BATTERY CABLE POSITIVE BATTERY CABLE NEGATIVE BATTERY CABLE NEGATIVE BATTERY CABLE NEGATIVE BATTERY CABLE BATTERY (VU1LH-8) BATTERY CABLE BOOT-RED CS .312-18 X .750 HX G5 ZNYC NT .312-18 HX G5 BATTERY SUPPORT CB .312-18 X 3.00 FUL ZN ZNYC 5 1 2 4 1 3 4 NOTES: 1. Used on mowers with Honda 18 & 20 HP engines. 2. Used on mowers with Briggs & Stratton engines, and Honda 16 HP engines. 3. Used on mowers with Honda 16 HP Engines. 4. Used on mowers with Kohler engines 5. Used on mowers with Briggs & Stratton engines. 365262 6/06 3-3 Deck Lift Assembly 1 2 3 4 5 11 3 4 12 6 10 16 1 14 1 3 4 16 8 16 1 3 4 7 7 6 13 3 8 15 3 5 8 8 6 16 1 4 8 7 9 7 8 3-4 365262 6/06 Deck Lift Assembly INDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 SERVICE PART NO. 348318 348284 781294 784686 782995 055749 360131 704643 781831 781229 784488 756270 034272 348458 767962 015495 MFG. PART NO. 348318 348284 781294 784686 018846 055749 360131 704643 781831 781229 784488 756270 034272 348458 767962 015495 QTY. 1 1 7 6 2 3 4 8 1 1 1 1 1 1 2 4 STOP HANDLE HEIGHT ADJUSTOR STOP CLIP E, 1.00 X .625 X .050 FW .812 X 1.469 X .134 THK ZNYC DECK LIFT SPRING CS .437-14 X 1.750 HX G5 ZNYC DECK LIFT CHAIN NT .437-14 HX FLG ZN CS.437-14 X 1.750 FULTH G5 ZNYC CE .750 X 2.25 X 1.75 HEADLESS DECK LIFT INDICATOR CS .312-18 X 1.50 FLTHR GR5 ZNYC NT .312-18 HX G5 ZNYC DECK LEVELER YOKE FW .531 X 1.063 X .090 SAE HD ZN GREASE FITTING STRAIGHT DESCRIPTION NOTES: 1. Apply grease to zerks (see owners manual). 365262 6/06 3-5 Steering and Brake Assembly 1 2 4 3 5 4 24 8 23 4 21 22 25 22 8 12 8 9 9 15 13 8 33 12 8 12 18 26 28 48 5 24 32 8 11 25 10 20 19 7 8 11 20 24 8 19 17 16 6 8 4 3 8 12 12 11 10 7 9 8 24 9 11 13 8 8 14 6 11 18 8 19 27 26 18 8 12 } 5 24 8 19 31 32 20 4 4 3 29 12 8 19 19 11 8 19 30 8 32 12 8 4 19 20 3 3-6 365262 6/06 Steering and Brake Assembly INDEX NO. 1 SERVICE PART NO. 781260 360487 086660 767954 705178 363812 360677 768523 768259 362251 036236 034272 784405 784355 784371 781211 063198 059832 770867 784439 359737 359745 784421 023655 017251 785162 787879 787887 363176 361550 783696 781922 361295 MFG. PART NO. N/A 360487 086660 767954 705178 363812 360677 768523 N/A 362251 036236 034272 784405 784355 784371 781211 063198 059832 770867 784439 359737 359745 784421 023655 017251 785162 787879 787887 363176 361550 783696 781922 361295 QTY. 2 2 6 14 6 2 2 31 4 2 9 12 2 1 1 2 4 6 8 4 2 2 2 6 2 2 1 1 1 1 2 4 1 DESCRIPTION STEERING BAR GRIP STEERING BAR NT .375-16 HX LK NY FW .406 X .812 X .060 SAE HD ZN CS ...