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Manual HUSTLER Truck Engine 108277

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  • HUSTLER Truck Engine 108277 - page 1

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

  • HUSTLER Truck Engine 108277 - page 2

    t-2 108277 10/08 IMP OR T AN T : Th i s e n gi ne i s n o t e q u i pped w i t h a s par k a r r est e r m u ffl er . I t i s a vi ola t i on of Ca li for nia Publ i c Re sour c e C od e S ec t i o n 4442 to us e o r op erate th i s eng ine o n an y fo res t-c o v ered , b rus h-co vered , o r grass -co ver ed uni mp r o ved l and . O t her sta te ...

  • HUSTLER Truck Engine 108277 - page 3

    108277 10/08 t-3 ...

  • HUSTLER Truck Engine 108277 - page 4

    t-4 108277 10/08 ...

  • HUSTLER Truck Engine 108277 - page 5

    108277 10/08 c-1 T able of Content s Chapter 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Chapter 2 Contents Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Engine Guard and Anti Rollover Wheels. . . . . . . . . . . . . . . . . . . . . 2-3 Footre ...

  • HUSTLER Truck Engine 108277 - page 6

    c-2 108277 10/08 Maintenance & Adjustment Safe ty . . . . . . . . . . . . . . . . . . . . . . . . . 9-14 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32 Index . . . . . . . . . . . . . . . . ...

  • HUSTLER Truck Engine 108277 - page 7

    108277 10/08 1 -1 Chapter 1 General Information This Manual covers Hustler FasT rak models 928267, 928275, 928291, 928502, & 928520 . Frequently Ordered Parts Service Literature Note: When ordering p arts, yo u must use the part numbe r as shown for each part, not the index numb er . Always give the model and seria l numb er to you r parts and ...

  • HUSTLER Truck Engine 108277 - page 8

    1-2 108 27 7 10/08 Options Available From Y our Dealer Hardware Description C odes & Abbreviations The following codes are used throu gho ut this part s manual. Refer to this list when ordering p arts. St an d a r d T o r qu e s The following chart list s the standard torque va lues for the threaded fasteners found in this manual. T orque all c ...

  • HUSTLER Truck Engine 108277 - page 9

    108277 10/08 2 -1 Chapter 2 Content s Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Engine Guard and Anti Rollover Wheels . . . . . . . . . . . . . . . . . . . . . . 2-3 Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 ...

  • HUSTLER Truck Engine 108277 - page 10

    2-2 108 27 7 10/08 Rivet Nut Installation NOTES: INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 548289 107819 1 54" F ASTRAK FRAME 548297 107890 1 48" F ASTRAK FRAME 2 N/A 600994 2 3/8-16 THREAD RIVET NUT 3 N/A 808493 8 3/8-16 THREAD RIVET NUT 4 N/A 808485 1 5/16-18 THREAD RIVET NUT 1 2 3 3 3 4 ...

  • HUSTLER Truck Engine 108277 - page 11

    108277 10/08 2 -3 Engine Guard and Anti Rollover Wheels NOTES: 1. Includes item s 2 through 5. INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 107840 107840 1 F ASTRAK ENGINE GUARD 2 781708 N/A 2 CS .500-13 X 4.25 HX G5 ZNYC 3 767962 N/A 4 FW .531 X 1.063 X .090 SAE ZNYC 4 031997 N/A 2 ANTI-SCALP WHEEL 5 053199 N/A 2 NT .500-13 H ...

  • HUSTLER Truck Engine 108277 - page 12

    2-4 108 27 7 10/08 Footrest Assembly NOTES: INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 107839 107839 1 FLOOR PLA TE 2 785485 785485 2 UPPER STEP TREAD 3 785493 785493 2 LOWER STEP TREAD 4 01 1320 01 1320 4 CB .375-16 X .750 STD ZNYC 5 767954 767954 4 FW .406 X .812 X .060 SAE ZNYC 6 054502 054502 4 NT .375-16 HX GRD 5 ZNYC 1 ...

  • HUSTLER Truck Engine 108277 - page 13

    108277 10/08 3 -1 Chapter 3 Content s Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Hydro Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Steering Sub-Ass ...

  • HUSTLER Truck Engine 108277 - page 14

    3-2 108 27 7 10/08 Battery Installation 1 2 3 4 5 6 6 7 7 7 7 8 10 9 11 11 12 13 ...

  • HUSTLER Truck Engine 108277 - page 15

    108277 10/08 3 -3 Battery Installation NOTES: 1. When performing servic e on mower , disconnect battery ground cable and do not reconnect to battery until engi ne is ready to be started. See Owners Manual. 2. Battery is not inst alled in export models. 3. Used on mowers using Kohler engine s with serial numbers prior to 07080126. Also used on mower ...

  • HUSTLER Truck Engine 108277 - page 16

    3-4 108 27 7 10/08 Deck Lift Assembly 1 2 3 4 4 4 4 4 5 5 5 5 5 6 6 6 6 6 6 6 7 7 8 8 8 9 10 10 10 10 11 12 13 14 15 15 15 15 ...

  • HUSTLER Truck Engine 108277 - page 17

    108277 10/08 3 -5 Deck Lift Assembly NOTES: 1. Apply grease to zerks. INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 348318 348318 1 STOP HANDLE 2 348284 348284 1 HEIGHT ADJUSTMENT STOP 3 784488 784488 1 DECK LIFT INDICA TOR 4 781294 781294 7 E CLIP 1.00 X.625 X.05 5 601681 601681 6 FW .812X1.50X.120 ZNYC 6 704643 704643 8 NT .4 ...

  • HUSTLER Truck Engine 108277 - page 18

    3-6 108 27 7 10/08 Hydro T ransmission Installation 1 19 13 18 1 3 2 3 4 5 6 7 8 4 17 9 10 11 10 9 12 14 13 14 3 3 16 15 20 21 25 28 24 22 24 23 26 28 26 26 27 27 29 2 ...

  • HUSTLER Truck Engine 108277 - page 19

    108277 10/08 3 -7 Hydro T ransmission Installation NOTES: 1. T orque to 17 f t-lbs. 2. T orque to 100 f t-lbs 3. Service part s available for the transaxles: INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 710087 710087 4 CS .312-18X2.500 HX G5 2 038828 038828 4 CS .312-18X2.250 HX G5 3 768523 768523 16 FW .343X.687X.051/.080H 4 ...

  • HUSTLER Truck Engine 108277 - page 20

    3-8 108 27 7 10/08 S teering Sub-Assembly NOTES: 1. Includes Item 1 (7 81260 S teering Bar Grip). ITEM NO. SE RVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 781260 N/A 2 STEERING BAR GRIP 2 360487 360487 2 STEERING BAR 3 767954 767954 12 FW .406 X .812 X .060 SAE HD ZN 4 705178 705178 4 CS .375-16X1.750 HX G5 5 086660 086660 6 NT .375-16 HX ...

  • HUSTLER Truck Engine 108277 - page 21

    108277 10/08 3 -9 This p age intentionally lef t blank. ...

  • HUSTLER Truck Engine 108277 - page 22

    3-10 108277 10/08 S teering and Brake Assembly 13 22 24 13 10 6 21 19 25 23 10 7 5 8 10 6 7 6 5 3 9 11 6 14 15 16 TRACTOR FRAME 33 6 32 28 5 4 29 26 30 HYDRO TRANSAXLE 19 20 31 18 13 31 22 ASSEMBLED BRAKE RODS 20 12 13 18 13 23 25 BELL CRANK DET AIL 22 21 20 23 12 13 27 13 3 25 6 1 BRAKE ARM 17 6 4 6 6 2 1 4 2 See “S teering Sub-Assembly” on pa ...

  • HUSTLER Truck Engine 108277 - page 23

    108277 10/08 3-11 S teering and Brake Assembly NOTES: 1. Supplied with transmissions. 2. For mowers with serial numbers prior to 07102604, to replace the dampener mount first remove the or iginal control arms from the transmissions–saving the hardware, and replace with items 1,2 3 and 4. INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRI ...

  • HUSTLER Truck Engine 108277 - page 24

    3-12 108277 10/08 ...

  • HUSTLER Truck Engine 108277 - page 25

    108277 10/08 4 -1 Chapter 4 Content s Honda 18 & 20 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . . . 4-2 Kawasaki 19 & 21 HP Engine Installation . . . . . . . . . . . . . . . . . . . . . 4-4 Kohler 19 HP Engine Inst allation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Instrument Panel Installation . . . . ...

  • HUSTLER Truck Engine 108277 - page 26

    4-2 108 27 7 10/08 Honda 18 & 20 HP Engine Installation 1 11 } 5 3 6 7 8 9 10 2 9 27 PA R T O F ENGINE YEL 1 26 12 17 14 15 16 9 12 18 20 19 21 22 23 24 25 9 12 29 BLK 1 RED/BLK 1 PUR BRN 1 GRA/PUR 1 31 30 27 9 28 PA R T O F ENGINE TA N / R E D 1 2 1 3 26 12 13 27 26 13 12 9 9 27 9 4 15 33 34 32 35 4 ...

  • HUSTLER Truck Engine 108277 - page 27

    108277 10/08 4 -3 Honda 18 & 20 HP Engine Installation NOTES: 1. Part of Item 28 (600998 FasT rak wire harness). 2. T wo wires. 3. Connected to Item 28 ( 600998 FasT rak wire harness). 4. T orque to 45-48 f t-lb. 5. Engine oil capacity: See engine manual. 6. Engine speed; High speed - 3450 ±50 RPM . 7. Nuts supplied with item 33 (U-Bolt s). IN ...

  • HUSTLER Truck Engine 108277 - page 28

    4-4 108 27 7 10/08 Kawasaki 19 & 21 HP Engine Installation 1 1 3 4 3 15 4 4 5 5 14 YEL 1 1 PUR 1 BLK NEGA TIVE BA TTER Y CABLE POSITIVE BA TTERY CABLE 1 RED 1 RED/BLK 17 18 20 21 18 22 26 27 27 29 30 28 } 35 39 32 4 33 34 { PA R T O F ENGINE 16 2 19 8 9 10 11 12 13 6 5 31 29 30 19 HP EXHAUST & CLAMP DET AIL 37 38 37 18 7 4 4 18 BRN TA N / R ...

  • HUSTLER Truck Engine 108277 - page 29

    108277 10/08 4 -5 Kawasaki 19 & 21 HP Engine Installation INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 601082 601082 1 21HP KA WASAKI ENGINE (USED ON 928291) 2 601081 601081 1 19HP KA WASAKI ENGINE (USED ON 928275) 3 058776 058776 4 NT .312-18 HX ZNYC NL 4 768523 768523 1 1 FW .343 X .687 X .051/.080 HD 5 050161 050161 4 C ...

  • HUSTLER Truck Engine 108277 - page 30

    4-6 108 27 7 10/08 NOTES: 1. Part of Item 16 (600999/601341 Fa sT rak Kawasaki Wire Harness). 2. Engine oil capacity:See engine manual. 3. Engine speed; High idle—3450 ±50 rpm. 4. Connected to item 16 (6009 99/601341 FasT rak Kawasaki Wire Harness). 5. T orque to 45-48 f t-lb 6. Supplied with item s 24 and 25 (U-Bolts). 7. Used on mowers with se ...

  • HUSTLER Truck Engine 108277 - page 31

    108277 10/08 4 -7 This p age intentionally lef t blank. ...

  • HUSTLER Truck Engine 108277 - page 32

    4-8 108 27 7 10/08 Kohler 19 HP Engine Installation 1 2 3 4 5 NEGA TIVE BA TTERY CABLE BLK 1 7 7 7 8 POSITIVE BA TTERY CABLE RED 1 10 12 11 RED/BLK 1 BLK 1 4 13 14 15 } 17 16 18 4 19 20 21 22 23 24 25 27 28 2 26 6 29 3 } 7 6 9 7 6 32 33 7 7 33 31 30 10 ...

  • HUSTLER Truck Engine 108277 - page 33

    108277 10/08 4 -9 Kohler 19 HP Engine Installation NOTES: 1. Part of Item 2 ( 601000/6013 42 Kohler Wire Harness). 2. T orque to 45-48 f t-lb 3. T orque to 30-35 f t-lbs . Do not reuse factory installed screw when performing service to mower requiring removal of engine, replace with 3/8-16 x 1.0 long grade 5 cap screw . 4. Engine oil capacity: See ...

  • HUSTLER Truck Engine 108277 - page 34

    4-10 108277 10/08 6. Connected to item 2 (601000/60 1342 FasT rak Kohler Wire Harness). 7. Bolt and washer supplied with engi ne. For replacement part, order 029710 (Cap Screw .312-18X .750 HXFLK). 8. Used on mowers with se rial numbers pr ior to 07080126. 9. On mowers with serial number s prior to 07062321, item 10 (starter solenoid) is located in ...

  • HUSTLER Truck Engine 108277 - page 35

    108277 10/08 4-11 This p age intentionally lef t blank. ...

  • HUSTLER Truck Engine 108277 - page 36

    4-12 108277 10/08 Instrument Panel Installation 2 1 1 3 5 6 7 1 8 12 10 9 13 1 14 14 15 15 FUSE SIZE AND LOCA TION 10a 20a 11 RIGHT FUEL TA N K 6 4 ...

  • HUSTLER Truck Engine 108277 - page 37

    108277 10/08 4-13 Instrument Panel Installation NOTES: 1. Part of 600998, 600999, 601000, 60 1341 or 601342 wire harness. INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 601095 601095 1 CHOKE CABLE (KAWASAKI ONLY) 601097 601097 1 CHOKE CABLE (KOHLER & HONDA ONLY) 2 776476 776476 1 PTO SWITCH 3 785808 785808 1 KEY SET 4 769166 ...

  • HUSTLER Truck Engine 108277 - page 38

    4-14 108277 10/08 Fuel System Installation (with S/N higher than 07102604) 1 1 2 3 4 4 5 5 6 6 7 12 7 7 8 9 10 4 1 1 11 13 12 13 13 13 14 14 15 15 ...

  • HUSTLER Truck Engine 108277 - page 39

    108277 10/08 4-15 Fuel System Installation (with S/N higher than 07102604) NOTES: 1. T orque to 20 f t-lbs. INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 779306 779306 2 3.5" FUEL CAP 2 601320 601320 1 RIGHT SIDE FUEL T A NK 3 601321 601321 1 LEFT SIDE FUEL T ANK 4 000323 000323 6 CLIP 5 712919 712919 8 FW .406 X 1.00 X .1 ...

  • HUSTLER Truck Engine 108277 - page 40

    4-16 108277 10/08 Fuel System Installation (with S/N prior to 07102604) 1 1 2 3 4 4 5 5 6 6 7 7 8 8 9 10 11 4 1 1 12 ...

  • HUSTLER Truck Engine 108277 - page 41

    108277 10/08 4-17 Fuel System Installation (with S/N prior to 07102604) NOTES: 1. T orque to 20 f t-lbs. 2. See “FasT raks with Honda engines” on page 9-4 for Honda fuel line routing. See “FasT raks with Kawasaki engines” on p age 9-6 for Kawasaki fuel line routing. See “F asT r aks with Kohler Engines” on page 9-1 1 for Kohler fuel lin ...

  • HUSTLER Truck Engine 108277 - page 42

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

  • HUSTLER Truck Engine 108277 - page 43

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

  • HUSTLER Truck Engine 108277 - page 44

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

  • HUSTLER Truck Engine 108277 - page 45

    108277 10/08 5 -1 Chapter 5 Content s Front Wheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Front Wheel Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Drive Wheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 ...

  • HUSTLER Truck Engine 108277 - page 46

    5-2 108 27 7 10/08 Front Wheel Assembly NOTES: 1. Apply grease to zer ks, see owners manual. 2. T orque to 75 f t.-lbs. 3. Assemble with ex tended inner race down. INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 705954 705954 2 CS .500-13 X 1.25 HX G5 ZNYC 2 344267 344267 2 FW .510 X 2.15 X .187 SPL ZNYC 3 712976 712976 2 FW .531 ...

  • HUSTLER Truck Engine 108277 - page 47

    108277 10/08 5 -3 Front Wheel Breakdown NOTES: 1. Inflate to 8-12 psi. INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 772814 N/A 1 3/4" ROLLER BEARING 2 772806 N/A 2 BEARING CAP 2 2 1 768044 ...

  • HUSTLER Truck Engine 108277 - page 48

    5-4 108 27 7 10/08 Drive Wheel Assembly NOTES: 1. Inflate tire to 8-12 p si. 2. T orque to 65-75 f t-lbs. INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 784264 784264 2 WHEEL/TIRE ASSY 18 X 9.50 (QTY PER 54" TRACTOR) 2 784272 N/A 1 TIRE 18 X 9.5 3 784280 N/A 1 WHEEL 4 019521 N/A 1 TIRE V AL V E 5 061077 061077 4 WHEEL NUT ( ...

  • HUSTLER Truck Engine 108277 - page 49

    108277 10/08 6 -1 Chapter 6 Content s 54" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 54" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 48" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 48&quo ...

  • HUSTLER Truck Engine 108277 - page 50

    6-2 108 27 7 10/08 54" Deck Assembly 2 9 14 8 10 6 12 6 5 7 4 4 11 5 5 5 5 17 17 12 12 12 13 13 13 14 14 13 15 15 16 16 16 15 15 11 17 11 6 5 14 1 3 ...

  • HUSTLER Truck Engine 108277 - page 51

    108277 10/08 6 -3 54" Deck Assembly NOTES: 1. Includes item s 12 through 15. 2. Service part deck includes decals (see “54" Deck Decals” on page 8-4 for listing of decals). INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 548305 108100 1 DECK W/A 54" F ASTRAK 2 6 01 1 17 601 1 17 1 DISCHARGE CHUTE ASSY 3 108537 ...

  • HUSTLER Truck Engine 108277 - page 52

    6-4 108 27 7 10/08 54" Deck Pulley Assembly 2 1 2 3 5 7 10 14 13 15 16 8 11 12 17 4 4 5 19 20 20 20 19 20 19 19 21 22 20 22 23 24 26 14 13 25 27 54" Deck Assy 1 1 18 14 4 6 3 3 9 18 5 ...

  • HUSTLER Truck Engine 108277 - page 53

    108277 10/08 6 -5 54" Deck Pulley Assembly NOTES: 1. T orque to 1 18 ft.-lbs. 2. See “Deck Belt Routin g and T ensioning” on page 7-5 for belt tensioning. INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 789388 789388 1 B-SECTION BELT 2 025007 025007 1 CS .625-1 1 X .75 HX G5 3 046821 046821 3 FW .656 X 2.00 X .078 ZNYC 4 ...

  • HUSTLER Truck Engine 108277 - page 54

    6-6 108 27 7 10/08 48" Deck Assembly 2 4 7 14 9 10 6 12 5 3 8 4 4 11 5 5 5 5 17 17 12 12 12 13 13 13 14 14 13 15 15 16 16 16 15 15 11 17 6 14 1 5 ...

  • HUSTLER Truck Engine 108277 - page 55

    108277 10/08 6 -7 48" Deck Assembly NOTES: 1. Includes item s 12 through 15. 2. Service part deck includes decals (see “48" Deck Decals” on page 8-5 for a listing of decals). INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 548313 108125 1 DECK W/A 48" FASTRAK 2 6 01 1 17 601 1 17 1 DISCHARGE CHUTE ASSY 3 108537 ...

  • HUSTLER Truck Engine 108277 - page 56

    6-8 108 27 7 10/08 48" Deck Pulley Assembly 2 1 2 3 5 10 14 13 15 16 8 11 12 17 18 18 3 4 5 19 20 20 20 19 20 19 19 21 22 20 25 22 23 24 26 14 13 14 27 48" Deck Assy 1 1 4 6 7 4 3 9 14 5 ...

  • HUSTLER Truck Engine 108277 - page 57

    108277 10/08 6 -9 48" Deck Pulley Assembly NOTES: 1. T orque to 1 18 ft.-lbs. 2. See “Deck Belt Routin g and T ensioning” on pa ge 7-5 for belt tensioning. INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 791335 791335 1 B-SECTION BELT 2 025007 025007 1 CS .625-1 1 X .75 HX G5 3 046821 046821 3 FW .656 X 2.00 X .078 ZNYC ...

  • HUSTLER Truck Engine 108277 - page 58

    6-10 108277 10/08 Blade Spindle Assembly Breakdown NOTES: INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 783548 N/A 1 BLADE SPINDLE RETAINING 2 783555 N/A 2 BEARING , BLADE S PINDLE 3 783530 N/A 1 SP ACER, BLADE SPINDLE 4 783514 N/A 1 HOUSING , BLADE SPINDLE 5 783522 N/A 1 SHAFT , BLADE SPINDLE 1 2 3 4 5 2 ...

  • HUSTLER Truck Engine 108277 - page 59

    108277 10/08 7 -1 Chapter 7 Content s Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Deck Belt Routing and Tensioni ng . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 ...

  • HUSTLER Truck Engine 108277 - page 60

    7-2 108 27 7 10/08 Seat Installation 1 1 6 7 8 3 9 10 11 3 12 4 6 2 3 5 3 13 ...

  • HUSTLER Truck Engine 108277 - page 61

    108277 10/08 7 -3 Seat Installation NOTES: 1. Do not torque, Item 7 ( 107861 Seat Pan) must pivot. 2. Service part s, (Michigan seat): INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 793661 793661 1 MICHIGAN ST ANDARD SEA T 2 034280 034280 1 CS .312-18X .750 HX G5 3 768523 768523 9 FW .343 X .687 X .051/.080 HD 4 108321 108321 1 ...

  • HUSTLER Truck Engine 108277 - page 62

    7-4 108 27 7 10/08 Deck Installation NOTES: INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 055749 055749 4 CS .437-14X1.750 HX G5 2 017616 017616 2 CS .500-13X1.750 HX G5 3 767962 767962 4 FW .531X 1.063X.090 SAE 4 704643 704643 8 NT .437-14 HX FLG ZN 5 008193 008193 2 NT .500-13 HX G5 ZNYC 5 3 3 2 4 4 1 ...

  • HUSTLER Truck Engine 108277 - page 63

    108277 10/08 7 -5 Deck Belt Routing and T ensioning NOTES: 1. S pring length after t ensioning new belt. S pri ng length measured from outside of hook to out si de of hook. T ension spring with deck in leveling position. 2. Route belt as shown. ...

  • HUSTLER Truck Engine 108277 - page 64

    7-6 108 27 7 10/08 ...

  • HUSTLER Truck Engine 108277 - page 65

    108277 10/08 8 -1 Chapter 8 Content s Tractor Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 54" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 48" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 ...

  • HUSTLER Truck Engine 108277 - page 66

    8-2 108 27 7 10/08 T ractor Decals 16 15 7 4 2 1 3 8 9 10 11 12 13 14 17 18 5 6 ...

  • HUSTLER Truck Engine 108277 - page 67

    108277 10/08 8 -3 T ractor Decals NOTES: INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 785121 785121 1 OPERA TION RIGHT DECAL 2 785139 785139 1 STEERING L.S. DECAL 3 N/A 083279 1 TURF PROD SERIAL NO PLATE 4 784710 784710 1 F AST RAK DECAL 5 727172 727172 1 'MADE IN U.S.A.' DECAL 6 782573 782573 1 FIRST ZERO TURN DECAL ...

  • HUSTLER Truck Engine 108277 - page 68

    8-4 108 27 7 10/08 54" Deck Decals NOTES: INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 799171 799171 1 54" DECK ID DECAL 2 727453 727453 2 BEL T & PULLEY DECAL 3 727438 727438 2 WHIRLING BLADES DECAL 4 727172 727172 1 'MADE IN U.S.A.' DECAL 5 785055 785055 1 STEP TREAD 3.70 X 9.00 6 781419 781419 1 BEL ...

  • HUSTLER Truck Engine 108277 - page 69

    108277 10/08 8 -5 48" Deck Decals NOTES: INDEX NO. SERVICE PA R T N O . MFG . P ART NO. QTY . DESCRIPTION 1 793976 793976 1 48" DECK ID DECAL 2 727453 727453 2 BEL T & PULLEY DECAL 3 727438 727438 2 WHIRLING BLADES DECAL 4 727172 727172 1 'MADE IN U.S.A.' DECAL 5 794503 794503 1 STEP TREAD MINI FST DECAL 6 781419 781419 1 BE ...

  • HUSTLER Truck Engine 108277 - page 70

    8-6 108 27 7 10/08 ...

  • HUSTLER Truck Engine 108277 - page 71

    108277 10/08 9 -1 Chapter 9 Content s Assembly Pictures and Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 General Information for al l models . . . . . . . . . . . . . . . . . . . . . 9-3 Wire harness routing (all models). . . . . . . . . . . . . . . . . . . . . . 9-3 FasTraks with Honda engines . . . . . . . . . . . . . . ...

  • HUSTLER Truck Engine 108277 - page 72

    9-2 108 27 7 10/08 Transaxle drive belt replacement . . . . . . . . . . . . . . . . . . . . . 9-29 Mower blade maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29 Mower blade removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • HUSTLER Truck Engine 108277 - page 73

    9-3 108 27 7 10/08 Assembly Pictures and Aids General Information for all models Instrument pane l layout (FIG . 1). Wire harness routing (all models). Front of wire harness (FIG . 2 & FIG . 3). FIG . 1 FIG . 2 FIG . 3 PTO CLUTCH SWITCH TO SEA T SWITCH TIE STRAP FROM SAFETY SWITCHES TIE STRAP ...

  • HUSTLER Truck Engine 108277 - page 74

    9-4 108 27 7 10/08 FasT raks with Honda engines Wire harness, battery cable, throttle cable, an d ch oke cable routing and tie strap s (FIG . 4 & FIG . 5). NOTE: Tie straps on rear seat support tie fuel line from L.S. fuel t ank. FIG . 4 FIG . 5 CHOKE & THROTTLE CABLES TIE STRAPS SEA T SWITCH WIRE SAFETY SWITCH WIRES TIE STRAP TIE STRAPS NE ...

  • HUSTLER Truck Engine 108277 - page 75

    9-5 108 27 7 10/08 Engine connec tio ns )FIG . 6, FIG . 7, FIG . 8, and FIG . 9). NOTE: Route oil sensor wire between oil file tube and engine block . Index ter- minal on wire in horizont al direct ion to hold wire off oil filter . NOTE: Tie carburetor drain tubes and c lutch pigtail together t o clutch anchor . Do not tighten tie strap enou gh to ...

  • HUSTLER Truck Engine 108277 - page 76

    9-6 108 27 7 10/08 FasT raks with Kawasaki engines FOR MOWERS WITH SERIAL N UMBER 07102604 AND HIGHER . Front of wire harness (FIG . 10). Route the 4" positive batt ery cable and the purple and r ed wires through the cable boot prior to fastening hardware to solenoid (FIG . 1 1). Route negative ba ttery cable and wireharness ( from seat an d s ...

  • HUSTLER Truck Engine 108277 - page 77

    9-7 108 27 7 10/08 Wire harness, battery cable, and throttle and choke cable, routing and tie str aps (FIG . 1 3 & FIG . 14) . Clutch pigtail to clutch anchor tie strap (FIG . 15). Safety switches and tie straps (FIG . 16) Engine connec tions (FIG . 17 & FIG . 18). FIG . 13 FIG . 14 FIG . 15 FIG . 16 FIG . 17 FIG . 18 FUEL LINE GROUND WIRE ...

  • HUSTLER Truck Engine 108277 - page 78

    9-8 108 27 7 10/08 Fuel line routing (FIG . 19, FIG . 20 & FIG . 21). Be sure fuel filter does not come in cont act with engine. FIG . 19 FIG . 20 FIG . 21 LEFT FUEL LINE LEFT FUEL LINE TIESTRAP FUEL FIL TER FUEL LINE FROM FUEL VA LV E FUEL V AL VE FUEL V AL VE LEFT FUEL LINE RIGHT FUEL LINE FUEL LINE TO F I L T E R ...

  • HUSTLER Truck Engine 108277 - page 79

    9-9 108 27 7 10/08 FasT raks with Kawasaki engines FOR MOWERS WITH SERIAL NUMBERS PRIOR TO 07102604: Wire harness, battery cable, and throttle and choke cabl e, routing and tie str aps (FIG . 22, FIG . 23, & FIG . 24) . NOTE: Route fuel line beneath both battery cables. T ie strap s on rear seat support tie fuel line from L.S. fuel t ank. FIG . ...

  • HUSTLER Truck Engine 108277 - page 80

    9-10 108277 10/08 Engine connections for 19 HP (FIG . 25 & FIG . 26). Engine connections for 21 HP (FIG . 27 & FIG . 28). FIG . 25 FIG . 26 FIG . 27 FIG . 28 THROTTLE CABLE CHOKE CABLE OIL SENSOR WIRE TIE STRAP CHOKE CABLE THROTTLE CABLE OIL SENSOR WIRE ...

  • HUSTLER Truck Engine 108277 - page 81

    9-11 108277 10/08 FasT raks with Kohler Engines FOR ENGINES WITH SERIAL NUMBER S PRIOR TO 07102604 (FIG . 29): FOR ENGINES WITH SERIAL NUMBERS 07102604 AND HIGHER: Front of wire harness (FIG . 30). Route the 4" positive batt ery cable and the purple and r ed wires through the cable boot prior to fastening hardware to solenoid (FIG . 31). Route ...

  • HUSTLER Truck Engine 108277 - page 82

    9-12 108277 10/08 Wire harness and battery cabl e, and thr ottle and choke cable, routing and tie strap s (FIG . 33, & FIG . 34) . NOTE: Tie strap on rear seat support (FIG . 33) ties fuel line from L.S. fuel t ank similar to Kawasaki engines. See Fue l line routing (FIG . 19, FIG . 20 & FIG . 21). on p age 9-8. Engine connectio n (FIG . 35 ...

  • HUSTLER Truck Engine 108277 - page 83

    9-13 108277 10/08 Clutch pigtail to clutch anchor tie strap (FIG . 36). FIG . 36 TIE STRAP CLUTCH PIGT AIL ...

  • HUSTLER Truck Engine 108277 - page 84

    9-14 108277 10/08 Maintenance & Adjustment Safety This safety alert symbol is used to call attention to a message inte nded to provide a reasonable degree of PER- SONAL SAFETY for operators and other persons dur i ng the normal operation and servicing of this equipme nt. DANGER — denotes immediate hazards wh ich WILL result in severe personal ...

  • HUSTLER Truck Engine 108277 - page 85

    9-15 108277 10/08 ? Except when changing or che cking belt, always keep belt covers on mower f or safety as well as cleanliness. ? S top the engine before removing the grass catcher or unclogging the discharge chu te . Never clear the discharge chute with the engine runn ing. T urn off the en gine and be sure the blades have stopped before cleaning ...

  • HUSTLER Truck Engine 108277 - page 86

    9-16 108277 10/08 The following illustration s show the various decals that are located on the machine. A brief explanation, for those requiring one, is shown to help the oper at or understand the meanin gs of these decals. Read Owner ’ s Manual and Quick Reference Decal befo re attempting to operate this machine. Avoid skin contact with ba ttery ...

  • HUSTLER Truck Engine 108277 - page 87

    9-17 108277 10/08 Keep shields or co v ers in pl ace while mach ine is in operation. Keep hands away from rot ating pulleys and belt s. If you lose steering cont rol while operating the machine, place the steering control levers in the park brake pos ition immediately . Ins pect the machine an d involve your Hustler dea ler to resolve the problem b ...

  • HUSTLER Truck Engine 108277 - page 88

    9-18 108277 10/08 Maintenance FIG . 37 13 Viewed from top of unit 12 14 14 1 3 2c 3b 8 15 11 11 10 10 6 6 5 7 7 16 2a 2b 9 4 Viewed from top of unit 1 Engine Oil Fill & Dipstick 2a. Fuel Filter (Honda) 2b. Fuel Filter (Kawasaki) 2c. Fuel Filter (Kohler) 3. Engine Air Cleaner 4. Engine Oil Drain Plug 5. Battery 6. Fuel T anks 7. Gauge Wheel Bear ...

  • HUSTLER Truck Engine 108277 - page 89

    9-19 108277 10/08 NOTES: 1. Initial oil change is after 5 hours of operation. Thereaf t er , change oil after every 40 hours operation. Ch ange more ofte n under dusty or dirty conditions and during hot weather periods. 2. T orque initially and after first 2 hours of operation. 3. Change engine oil filter per the engine man ufactur er’s recommend ...

  • HUSTLER Truck Engine 108277 - page 90

    9-20 108277 10/08 wear or damage. A good time to detect potentia l problems is while performing scheduled maintenance service. Cor- recting the problem as quickly as possible is the best insurance. Clear away he avy build-up of grea se, oil and dirt, espe cially in the engine and u nder the seat plat form ar eas; minute dust particle are a bra sive ...

  • HUSTLER Truck Engine 108277 - page 91

    9-21 108277 10/08 The battery is located under th e seat platform. FIG . 38 W ARNING: Battery posts, terminals, and related accessories conta in lead and lead compounds, chemicals known to the S tate of California to ca us e cancer and reproductive harm. W ash hands after handling. W ARNING: Avoid skin and clothing cont act with battery acid. Alway ...

  • HUSTLER Truck Engine 108277 - page 92

    9-22 108277 10/08 voltage. If the battery voltage is satisfactory , check the cleanliness and tightness of the terminals and ground connec- tions. A general underst anding of electrical servicing and us e of basic test equipment is necessary for troubleshooting and repair . Major overhaul or rep air of the startin g motor or charging system should ...

  • HUSTLER Truck Engine 108277 - page 93

    9-23 108277 10/08 W ARNING: When washing the m ower , direct the spray away (especially if us ing a power washer) from the Hydro-Gear ZT 2800 tr ansaxle’s seals to p revent water intrusion and to ensure component performance. W ARNING: Make sure the tra nsaxles are cool before perform ing service proc edures. Fluid changing proce dure 1. Park the ...

  • HUSTLER Truck Engine 108277 - page 94

    9-24 108277 10/08 13. Continue to fill the transaxles throug h the exp ansion tank until the “Full Cold” line is reac hed on the expansion tank. 14. Re-in st all the expansion tank cap by hand. Be careful not to ove rtighten. Fuel system DANGER: Observe usual fuel handling precautions: Do not smoke while refueling. Do not fill tank with engine ...

  • HUSTLER Truck Engine 108277 - page 95

    9-25 108277 10/08 Using a fuel stabilizer/condi tioner in the tractor can provide benefits such as: 1. Keeps gasoline fresh during stor age of 90 days or le ss. For longer storage, dr ain the fuel t anks. 2. Cleans the engine d uring operation. 3. Eliminates gum-like varnish buildup in the fuel system. IMPORT ANT : Never use methanol, gasolin e con ...

  • HUSTLER Truck Engine 108277 - page 96

    9-26 108277 10/08 T o drain a fuel tank use the following method: 1. Park the unit o n a flat surface. S top the engine and re move the ignition key . Make sure deck clutch switch is in the down (OFF) position . Place co ntrol levers in the park brake po sition. Disconnect n egative battery cable. 2. T urn t he fuel valve to t he closed posi tion ( ...

  • HUSTLER Truck Engine 108277 - page 97

    9-27 108277 10/08 Attach the oil drain hose, furn ished with the unit, to the oil drain valve when dr aining the engine oil. Oil drain hose must be removed af te r oil is drained. IMPORT ANT : All oil drips or spills must be cleaned of f of the exhaust system before operating the mach ine. The oil drain and oil filter are located at the rear of the ...

  • HUSTLER Truck Engine 108277 - page 98

    9-28 108277 10/08 Deck belt replacement 1. Park the unit o n a flat surface. S top the engine and re move the ignition key . Make sure deck clutch switch is in the down (OFF) position . Place control levers in th e park brake position. Disconnect nega tive battery cable. 2. Place the deck in th e lowe st posit ion . 3. Remove the deck belt cover s. ...

  • HUSTLER Truck Engine 108277 - page 99

    9-29 108277 10/08 6. Remove the existing belt and re place 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 sectio n located elsewhere in this manual. 9. Re-install the deck belt covers. 10. Re-a ttach the ne g at i ve ba tt er y cab le. T ransaxle drive belt replacement 1. Pa ...

  • HUSTLER Truck Engine 108277 - page 100

    9-30 108277 10/08 W ARNING: Never attempt to straighten a bent blade by heating, or weld a cracked o r broken blade as the blade may br ea k an d ca us e serious injury . Replace w orn or dam a ge d bla d es . W ARNING: Never work with blades while engine is runni ng or d eck clutch switch is engaged ( on). Always place deck clutch switch in t he d ...

  • HUSTLER Truck Engine 108277 - page 101

    9-31 108277 10/08 Mower blade removal Use a 15/16" wrench to remove the 5/8" cap screw ho lding the blade to the spindle shaf t from underneath. Blade Lock T ool, part num ber 381442, is available from your dealer to preven t the blades from turning while remov- ing or and inst alling the blade bolts . Sharpen th e blades on a grin der fo ...

  • HUSTLER Truck Engine 108277 - page 102

    9-32 108277 10/08 Adjustment Introduction Y our FasTrak 48/54 was adjusted before it left the factor y and was checked during pre delivery setup. Ho wever , after st art-up and cont inued use, a certain amount of break-in wear will cause some adjustments to change. Remain alert for unusual noises, they could be signaling a proble m. Visually inspec ...

  • HUSTLER Truck Engine 108277 - page 103

    9-33 108277 10/08 S teering linkage The neutral adjustment for the contro l levers in the neutral position is di scussed in this section. The tractor steering has been factory adjusted to eliminate creeping when the control levers are in the neutral p osi- tion (FIG . 61). However , should the tr actor begin to creep, the control lever linkage can ...

  • HUSTLER Truck Engine 108277 - page 104

    9-34 108277 10/08 5. Shut off th e machine. Loosen the jam nuts on each end of the transaxle control rod as shown in FIG . 62. 6. S tart the engine. M ove the contro l lever to just engag e the brake (n eutral) slot and ho ld it in that posit ion (Do not engage the control leve r far en ough to engage the brakes in the brake slot). W ARNING: This o ...

  • HUSTLER Truck Engine 108277 - page 105

    9-35 108277 10/08 8. Hold the transaxle control r od still and turn off the engine. 9. T ighten the jam nut s on each end of the transaxle contro l rod. NOTE : Do not let transaxle c ontrol rod turn while tightening the jam nut s (FIG . 62). 10. Neutral is now set. S tart the e ngin e a nd actuate th e b rak es a few times to co nfirm that the ZT 2 ...

  • HUSTLER Truck Engine 108277 - page 106

    9-36 108277 10/08 DRIVE STRAIGHT ADJUSTMENT: 1. Initially adjust cap screws all the way in so that th e steering levers may go fu lly forward. 2. Drive tractor in an open area with both steering handles fully forward. The tractor will likely drift slightly to the left or ri ght. 3. Whicheve r dire ction th e tra c tor turns is the slow side. Leave ...

  • HUSTLER Truck Engine 108277 - page 107

    9-37 108277 10/08 W ARNING: If the transaxle belt fails, loss of control w ill occur especially when operating on a slope. If you lose steering control while operating the mach ine, place the steering control le vers in t he park brake position immediate ly . Inspect the machine and involve your Hustler dealer to resolve the prob- lem before contin ...

  • HUSTLER Truck Engine 108277 - page 108

    9-38 108277 10/08 deck. The recommended pressures are as fo llows: W ARNING: S top engine. Make sure deck clutch switch is in the down (OFF) posit ion. Remove igni- tion key . Place control levers in the brake position before leaving machine. 2. Park the unit on a flat surface. 3. Raise deck and place 3" of blocking under all 4 corners of the ...

  • HUSTLER Truck Engine 108277 - page 109

    9-39 108277 10/08 18. Tighten the hardware holding the chain and adjuster onto the deck lift arm. 19. Go to the right rear of the tractor . 20. Mak e sure that there is still slack in the chain. If not, loosen the two nuts on the block holding the threaded rod un til there is slack in the deck lift chain (FIG . 75). 21. Tighten the appropriate nut ...

  • HUSTLER Truck Engine 108277 - page 110

    9-40 108277 10/08 27. Compress the deck lift assist springs so that there is ½” of sp ace between the front nut on the spring and the re ar nut on the deck lift block (FIG . 77). T ypical both sides. 28. When c ompleted, all chains will be tight, and deck cutting height will be set to the deck height indicato r . ...

  • HUSTLER Truck Engine 108277 - page 111

    108277 10/08 i-1 Numerical Index Part Page No. No. Part Page No. No. Part Page No. No. Index Part Numbers 000323 4-15 , 4-17 000331 3-3 , 3-7 , 3-11 , 4-3 , 4-5 , 4-9 , 4-15 , 4-17 , 7-3 000398 4-15 005108 3-11 005116 3-11 , 6-5 , 6-9 008193 7-4 011320 2-4 015495 3-5 015818 4-15 , 4-17 016253 4-3 , 4-5 016410 3-7 016523 4-9 016816 3-11 016972 6-5 , ...

  • HUSTLER Truck Engine 108277 - page 112

    Part Page No. No. Part Page No. No. Part Page No. No. i-2 108277 10/08 601095 4-13 601096 4-13 601097 4-13 601098 4-13 601099 8-3 601100 8-3 601117 6-3 , 6-7 601118 4-3 , 4-5 601123 1-1 , 6-9 601124 1-1 , 6-5 601131 3-11 601155 1-1 601156 1-1 601158 1-1 601206 3-7 601207 3-7 601221 3-7 601312 3-3 , 4-9 601319 4-5 , 4-9 601320 4-15 601321 4-15 60134 ...

  • HUSTLER Truck Engine 108277 - page 113

    108277 10/08 i-3 Part Page No. No. Part Page No. No. Part Page No. No. 797704 1-2 797712 1-2 797910 6-5 , 6-9 799171 8-4 799429 4-3 , 4-5 , 4-9 808485 2-2 , 7-3 808493 2-2 928267 1-1 928275 1-1 928291 1-1 928502 1-1 928520 1-1 ...

  • HUSTLER Truck Engine 108277 - page 114

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

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