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HUSTLER FasTrak SDX General Service Manual Download Page 3

121878

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REV C

Table of Contents

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-1

Hustler

®

 Service Program  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-1

Maintenance Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-1
Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-1

Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-1

Safe Servicing Practices  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-1
Understand Correct Service . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-1
Pre-Operation Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-1
Operation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-2
Operate Machine Safely. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-2
General Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . .  2-2
Maintenance Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-3

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-1

Standard Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-1
Special Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-1

Power Unit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-1

Steering Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-1
Park Brake Spring Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .  4-3
Steering Control Lever Stops   . . . . . . . . . . . . . . . . . . . . . . . . . .  4-4
Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-5
Hydraulic Pump Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . .  4-5
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-5
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-9

Engine Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-1

General Engine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . .  5-1
Engine Oil and Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-1
Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-2
Fuel Evaporation System Filter  . . . . . . . . . . . . . . . . . . . . . . . . .  5-4
Fuel & Evaporative System Line Routings . . . . . . . . . . . . . . . . .  5-4
Engine RPM Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-6

Deck Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-1

Deck Leveling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-1
Blades  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-2
Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-4
Deck Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-4

Summary of Contents for FasTrak SDX

Page 1: ...121878 REV C Hustler FasTrak SDX General Service Manual 200 South Ridge Road Hesston Kansas 67062 ...

Page 2: ... This equipment may create sparks that can start fires around dry vegetation California Public Resources Code Section 4442 6 provides that it is unlawful to use or operate an internal combustion engine on any forest covered brush covered or grass covered land unless the engine is equipped with a spark arrester maintained in effective working order A spark arrester is a device constructed of nonfla...

Page 3: ...ions 2 3 Torque 3 1 Standard Torques 3 1 Special Torques 3 1 Power Unit Maintenance 4 1 Steering Adjustments 4 1 Park Brake Spring Adjustment 4 3 Steering Control Lever Stops 4 4 Belts 4 5 Hydraulic Pump Belt Adjustment 4 5 Hydraulic System 4 5 Tires 4 9 Engine Maintenance 5 1 General Engine Maintenance 5 1 Engine Oil and Filter 5 1 Engine Air Filter 5 2 Fuel Evaporation System Filter 5 4 Fuel Eva...

Page 4: ...e Deck Belt Routing 6 5 Rear Discharge Deck Belt Routing 6 6 Electrical 7 1 Main Electrical Harness Schematic Kawasaki 7 1 Main Electrical Harness Schematic Kohler 7 2 Main Harness to Fuel Gauge Voltage Converter Schematic 7 3 Maintenance 8 1 Maintenance Locator Chart 8 2 Troubleshooting 9 1 ...

Page 5: ...as quickly as possible is the best insurance Clear away heavy build up of grease oil and dirt especially in the engine compartment and under the seat platform areas minute dust particles are abrasive to close tolerance engine and hydraulic assemblies Daily inspect mower for grass clippings and wire and string tangles The underside of the mower deck will collect a build up of grass clippings and di...

Page 6: ...REV C 1 2 121878 ...

Page 7: ...rk and store machine away from open flame or spark or pilot light such as on a water heater or appliances Refuel outdoors Never refuel or drain the gasoline from the machine indoors Never attempt to start the engine when there is a strong odor of gasoline fumes present Locate and correct the cause Store gasoline in an approved container and keep it out of the reach of children Never buy more than ...

Page 8: ...tion on safe machine operation Always maintain a safe distance from people and pets when mowing Always be aware of what is behind the machine before backing up Never leave machine unattended with ignition key in switch especially with children present Follow daily and weekly checklists making sure hoses are tightly secured and bolts are tightened Always keep engine and machine clean removing accum...

Page 9: ...ng batteries Do not smoke near battery Never check fuel level with an open flame Never use an open flame to look for leaks anywhere on the equipment Never use an open flame as light anywhere on or around the equipment When preparing engine for storage remember that fuel stabilizer is volatile and therefore dangerous Seal and tape openings after adding the inhibitor Keep container tightly closed wh...

Page 10: ...connecting the negative black cable s Avoid Acid Burns Sulfuric acid in battery electrolyte is poisonous It is strong enough to burn skin eat holes in clothing and cause blindness if splashed in eyes Avoid the hazard by Filling batteries in a well ventilated area Wearing eye protection and rubber gloves Avoiding breathing fumes when electrolyte is added Avoiding spilling or contacting dripped elec...

Page 11: ...r Size ft lbs N m Size ft lbs N m 10 32 4 IN LBS 3 6 M3 12 IN LBS 1 3 250 98 4 IN LBS 11 1 M4 26 4 IN LBS 3 312 204 IN LBS 23 M5 54 IN LBS 6 1 375 30 40 M6 92 4 IN LBS 10 4 438 48 65 M8 222 IN LBS 25 500 73 99 M10 37 50 562 105 143 M12 64 87 625 145 200 M14 103 140 750 260 350 M16 160 215 875 420 565 M20 320 435 Size ft lbs N m Wheel lug nuts 1 70 95 Blade spindle bolt top 70 95 Blade spindle bolt...

Page 12: ...REV C 3 2 121878 ...

Page 13: ... connecting the two mower harness female spade connectors together Figure 4 1 Re attach the seat platform to the mower frame 4 Loosen the jam nuts on each end of the steering control rod assemblies Figure 4 4 5 Set both steering control levers in the park brake position Figure 4 2 NOTE Both steering control levers need to be in the park brake position when starting the engine but need to be moved ...

Page 14: ...eel rotates forward and backward correctly Return the steering control lever to neutral and re check to make sure the wheel has stopped in the neutral position Place the steering control lever in the park brake position If neutral is set properly you should not hear the transmission whine 8 Repeat steps 4 through 10 for the left side 9 Once both sides are properly adjusted check them together to m...

Page 15: ...e spring adjustment using the following method 1 This procedure does not require engine power therefore Park the mower on level ground Disengage the deck clutch Place the steering control levers in the park brake position Stop the engine Remove the ignition key Disconnect the negative battery cable 2 On one side measure the park brake spring It should be compressed to 1 43 1 48 36 3 37 6mm If it i...

Page 16: ...re rotating at the same speed Figure 4 8 8 Tighten the side cap screws on both the left and right sides to lock the drive straight brackets in place Snug the top cap screws to prevent loosening during operation Figure 4 8 9 IMPORTANT Unbolt the seat platform from the mower frame Disconnect the two female spade connectors from each other from step 3 This procedure will require that the unit to be r...

Page 17: ... is the primary enemy of any hydraulic system Each transaxle has its own hydraulic expansion tank The tanks are located in front of the engine and behind the operator s platform Figure 4 10 Check the oil level in the hydraulic system after every 50 hours of operation or weekly whichever occurs first Check more often if the system appears to be leaking or otherwise malfunctioning The mower ships fr...

Page 18: ...ilter 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 Figure 4 12 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 IMPORTANT Remove the t...

Page 19: ...an open area free of any objects or bystanders 1 Raise the rear of the mower and block with certified jack stands The rear wheels need to be able to rotate freely and clear of all obstructions 2 Chock the front tires 3 Unbolt the seat platform from the mower frame Disconnect the mower harness from the seat switch Bypass the seat switch by connecting the two mower harness female spade connectors to...

Page 20: ...se at normal speeds then the transaxle is considered purged 9 Unbolt the seat platform from the mower frame Disconnect the two female spade connectors from each other from step 3 Reconnect them to the seat switch This must be completed so that the safety circuit is functioning properly Figure 4 14 Re attach the seat platform to the mower frame A Seat switch B Female spade connector C Mower harness...

Page 21: ...air pressure The recommended pressures are Drive wheels 8 12 psi 55 83 KPa Front wheels 8 12 psi 55 83 KPa If you wish to use non pneumatic tires on your Hustler mower the tire must be a Hustler approved tire Warranty claims will be denied on any mower equipped with unapproved non pneumatic tires ...

Page 22: ...REV C 4 10 121878 ...

Page 23: ...er has been installed clean up any oil which may have spilled onto the engine plate engine exhaust system and muffler guard Draining the Engine Oil 1 Locate the oil drain valve on the lower right side of the engine Figure 5 1 Figure 5 2 2 Position a suitable oil drain container under the oil drain valve to catch the oil as it drains from the engine 3 Use a 10 mm wrench or socket and open the valve...

Page 24: ...es or tears in the paper Also check gaskets for cuts or tears Do not attempt to use a damaged element which will allow abrasive particles to enter the engine 3 Kawasaki engines Reinstall the dust cap Make sure it seals all the way around the air cleaner canister then tighten the clamps Figure 5 7 Kohler engines Reinstall the top of the canister housing Make sure it seals all the way around the low...

Page 25: ... warranty consideration if the air filter element has been cleaned or serviced in any manner A partially dirty air filter element works better than a new element Therefore a dirty filter element is not bad for the engine unless it is excessively restricting the air flow and engine performance is affected The reason is simple The media in the filter must be porous to allow air to pass through it Wh...

Page 26: ...ystem installed There are two different types of rubber hoses that are connected to the fuel tank One is the fuel hose that is part of the fuel system The other is the vapor line that is part of the fuel evaporative system The fuel hose is connected to the fuel tank as shown It connects the fuel tank to the engine s fuel pump Figure 5 12 Figure 5 13 A Carbon canister B Fuel evaporation system filt...

Page 27: ...own A Fuel tank B Fuel line Figure 5 13 Kawasaki engine shown A Fuel tank B Vapor lines C Fuel evaporation system filter Figure 5 14 A B B A B B B B C Kawasaki engine shown A Fuel tank B Vapor lines C Fuel evaporation system filter D Carbon canister Figure 5 15 Kohler engine shown A Fuel tank B Vapor lines C Fuel evaporation system filter Figure 5 16 A B B B B C B D A B B B B C ...

Page 28: ...re are several different extensions that may be shown i e EX AU or CE Example 922222 no extension 922222 EX 922222 CE 922222 US 922222 AU Kawasaki FX691 FX730 ENGINE SPEEDS MODEL NO ENDING WITH HIGH IDLE Model NO without extension Model NO with EX extension Model NO with US extension 3600 50 rpm Model NO with CE extension 2800 50 rpm Kohler ZT730 ZT740 ENGINE SPEEDS MODEL NO ENDING WITH HIGH IDLE ...

Page 29: ...the indicator hole marked 3 25 82 6 mm and release the pedal 8 Unscrew the nut from the eyebolt and slide the eyebolt out of the mount This removes the tension from the deck lift assist spring Figure 6 4 9 Pull the pedal rearward so that the transport latch is held firmly against the deck height adjusting stop pin and the play in the pivot joint is removed secure the pedal in this position a bunge...

Page 30: ... blade on an inverted line punch or 5 8 bolt A commercial balancing tool is also available through most hardware supply stores The blade should not lean or tilt When spinning the blade slowly it should not wobble Balance the blade before reinstalling Lay the blade on a flat surface and check for distortion Replace any distorted blade Figure 6 6 Figure 6 7 A Transport latch B Deck lift pedal C Deck...

Page 31: ... blades Replace the cup washers if they are cracked or flattened IMPORTANT The blade sail curved part must be pointing upward toward the inside of the deck to ensure proper cutting A Re sharpening pattern B Original edge Figure 6 5 Comparison of Warped and Straight Blades A Warped blade replace B Straight blade C Cutting plane Figure 6 6 Do not sharpen to original pattern below It is easier to get...

Page 32: ...grease away from belts and never use belt dressings Any of these will destroy the belt composition in a very short time Deck Belt Adjustment The deck belt tension remains constant by means of a tension idler and spring There is no tension adjustment of this belt Figure 6 8 Deck Belt Installation When replacing a deck belt use the following procedure 1 Route the belt around all the pulleys except t...

Page 33: ... Belt Routing and Tensioning The following notes are the same for the different decks that are available 1 There is no tension adjustment of this belt 2 Route belt as shown Side Discharge Deck Belt Routing Figure 6 11 ...

Page 34: ...REV C 6 6 121878 Rear Discharge Deck Belt Routing Figure 6 12 ...

Page 35: ...121878 7 1 REV C ELECTRICAL Main Electrical Harness Schematic Kawasaki ...

Page 36: ...G R K S CLUTCH NEUTRAL SWITCH NEUTRAL SWITCH SEAT SWITCH RED BLK 18 RED 14 BRN 18 ORG RED 16 TAN 18 TAN RED 18 TAN ORG 18 ORG GRN 18 BRN 18 AUX ORG 16 ORG 18 ORG 18 BLK 18 BLK 18 TAN 18 BLK 16 ORG 16 ORG 20 ORG 12 BLK 16 IGNITION SWITCH CLUTCH SWITCH START RELAY 30A MASTER FUSE ORG 14 OIL PRESS ORG 18 A B C YEL BLK 18 START OIL PRESS CHARGE FUEL SOL ENG KILL CHARGE GROUND SPLICE BLK 12 1 2 3 4 ORG...

Page 37: ...rter Schematic PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 24 12V DC 5V DC CONVERTER ORG 20 ORG 20 ORG 20 BLK 20 GRN 20 YEL BLK BLK BLK 20 FUEL GAUGE CONNECTOR HARNESS CONNECTOR 3A FUSE BLK 16 BLK 16 RED 20 ...

Page 38: ...REV C 7 4 121878 ...

Page 39: ...often under dusty or dirty conditions and during hot weather Maintenance Schedule Figure 8 1 Figure 8 2 Figure 8 3 Figure 8 4 Figure 8 5 Figure 8 6 SERVICE AT INTERVALS INDICATED WEEKLY OR 50 HOURS MONTHLY OR 100 HOURS ANNUALLY OR 300 HOURS Verify safety start interlock system Prior to each use Visually inspect unit for loose hardware and or damaged parts Prior to each use Visually inspect tires P...

Page 40: ...ck 2 Fuel Filter 3 Engine Air Cleaner 4 Engine Oil Drain Valve 5 Battery 6 Fuel Tank 7 Engine Oil Filter 8 Deck Lift Pivot Zerks 4 9 Park Brake Switch 2 10 Drive Tire 11 Pump Belt 12 Engine Air Intake Screen 13 Front Wheel Tires 14 Front Wheel Zerks 2 15 Deck Belt 16 Blades 17 Hydraulic Oil Expansion Tank 18 Hydraulic Oil Filter 19 Fuel Evaporation System Filter 20 Carbon Canister Figure 8 1 Figur...

Page 41: ... Oil Filter 8 Deck Lift Pivot Zerks 4 9 Park Brake Switch 2 10 Drive Tire 11 Pump Belt 12 Engine Air Intake Screen 13 Front Wheel Tires 14 Front Wheel Zerks 2 15 Deck Belt 16 Blades 17 Hydraulic Oil Expansion Tank 18 Hydraulic Oil Filter 19 Fuel Evaporation System Filter 20 Carbon Canister Figure 8 3 Figure 8 4 15 16 16 16 15 16 16 16 ...

Page 42: ...e Oil Filter 8 Deck Lift Pivot Zerks 4 9 Park Brake Switch 2 10 Drive Tire 11 Pump Belt 12 Engine Air Intake Screen 13 Front Wheel Tires 14 Front Wheel Zerks 2 15 Deck Belt 16 Blades 17 Hydraulic Oil Expansion Tank 18 Hydraulic Oil Filter 19 Fuel Evaporation System Filter 20 Carbon Canister Figure 8 5 Figure 8 6 11 10 10 18 18 19 20 ...

Page 43: ...ion only Steering control linkage needs adjustment Adjust linkage Loose steering linkage Tighten linkage Transaxle component faulty Contact your Dealer Mower creeps when steering control levers are in neutral Steering linkage needs adjustment Adjust linkage Mower circles or veers in one direction Steering linkage needs adjustment Adjust linkage Loose steering linkage Tighten linkage Tires improper...

Page 44: ...REV C 9 2 121878 ...

Page 45: ...age Convertor Schematic 7 3 Maintenance Introduction 1 1 Maintenance Locator Chart 8 2 Maintenance Precautions 2 3 Maintenance Schedule 8 1 Mower Blade Maintenance 6 2 Mower Blade Removal 6 3 Operate Machine Safely 2 2 Operation Precautions 2 2 Park Brake Spring Adjustment 4 3 Pre Operation Precautions 2 1 Prepare for Emergencies 2 3 Prevent Battery Explosions 2 3 Purging Procedure 4 7 Rear Discha...

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