HUSTLER FasTrak General Service Manual Download

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121363

8-3

REV C

Figure 8-4

Engine Oil Fill & Dipstick

Fuel Filter

Engine Air Cleaner

Engine Oil Drain Plug

Battery

Fuel Tank

Hydraulic Oil Expansion Tank

Hydraulic Oil Filter

Front Wheel Bearing Zerks (2)

10.

Engine Oil Filter

11.

Deck Height Pivot Zerks (4)

12.

Park Brake Switch

13.

Drive Tire

14.

Deck Belt

15.

Pump Belt

16.

Blades

17.

Fuel Evaporation System Filter

Rear Discharge Deck Shown

Summary of Contents for FasTrak

Page 1: ...121363 REV C Hustler FasTrak General Service Manual 200 South Ridge Road Hesston Kansas 67062 ...

Page 2: ...t contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm NOTICE OF REQUIREMENT OF SPARK ARRESTER MUFFLER 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 g...

Page 3: ...3 1 Standard Torques 3 1 Special Torques 3 1 Power Unit Maintenance 4 1 Steering Adjustments 4 1 Steering Control Lever Stops 4 4 Belts 4 5 Hydraulic Pump Belt Adjustment 4 5 Hydraulic System 4 5 Fluid Changing Procedure 4 6 Tires 4 8 Engine Maintenance 5 1 General Engine Maintenance 5 1 Engine Oil and Filter 5 1 Engine Air Filter 5 1 Fuel Evaporation System Filter 5 1 Fuel and Evaporative System ...

Page 4: ...lt Routing Tensioning 6 6 Electrical 7 1 Main Electrical Harness Schematic 7 1 Main Harness to Fuel Gauge Voltage Convertor Schematic 7 2 Maintenance 8 1 Maintenance Schedule 8 1 Maintenance Locator Chart 8 2 Troubleshooting 9 1 ...

Page 5: ...uickly 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 dirt e...

Page 6: ...REV C 1 2 121363 ...

Page 7: ... ances Refuel outdoors Never refuel or drain the gaso line 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 a 30 day supply of gasoline Do not fill fuel containers inside a vehicle or on a truck or trailer ...

Page 8: ...sent Follow daily and weekly checklists making sure hoses are tightly secured and bolts are tightened Always keep engine and machine clean removing accumulated dirt trash and other material from machine Never put hands or feet under any part of the machine while it is running Never attempt to start engine when there is a strong odor of gasoline fumes present Locate and correct cause Keep all safet...

Page 9: ...ings after adding the inhibitor Keep con tainer tightly closed when not in use Inspect electrical wiring for worn or frayed insulation Install new wiring if wires are damaged Prepare for Emergencies Be prepared if a fire starts Keep a first aid kit and fire extinguishers available Keep emergency numbers for doctor ambulance ser vice hospital and fire department near the telephone Prevent Battery E...

Page 10: ... 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 dripped electrolyte If you spill acid on yourself Flush your skin with water Apply baking soda or lime to help neutralize the acid Flush your eyes with water for 10 15 minutes Get medical attention immedia...

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 121363 ...

Page 13: ...itch by connecting the two mower harness female spades together Figure 4 1 Re attach the seat platform to the mower frame 4 Loosen the jam nuts on each end of the steering con trol rod assemblies Figure 4 4 5 Set both steering control levers in the park brake posi tion 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 r...

Page 14: ...ral 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 make sure everything is working properly 10 IMPORTANT Unbolt the seat platform from the mower frame Disconnect the two female spade connectors from ...

Page 15: ...e 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 If it is not adjust the nylock nut until the proper spring compression is achieved Figure 4 6 3 Repeat for other side 4 Reconnect the negative battery cable Do not operate the mower wi...

Page 16: ...ide 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 opera tion 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 Reconnect them to the seat switch This must be completed so that the safety circuit is function ing prop...

Page 17: ...aulic 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 When the hydraulic system oil is cold the fluid level should be at the Full Cold line on the expansion tank Use only SAE 20W50 service motor oil Initial system oil and filter change must be after the first 75 hours of use or 1 year whichev...

Page 18: ...allow the tran saxles to vent during oil fill Figure 4 13 10 Remove the cap from the transaxle s expansion tank 11 Fill with 20W50 motor oil until oil just appears at the bottom of each transaxles top port approximately 2 qts per transaxle Install the top port plug into each transaxle Torque plugs to 180 in lbs Clean up any oil that leaked from the ports Figure 4 13 12 Continue to fill the transax...

Page 19: ...pass the seat switch by connecting the two mower harness female spades together Figure 4 14 Re attach the seat platform to the mower frame 4 Start the engine A Top port plug Figure 4 13 Exercise extreme caution when the transmissions are engaged Keep hands hair clothing etc clear of the cooling fans on top of the transmissions to prevent entanglement A WARNING Never work under the machine or attac...

Page 20: ... other from step 3 Reconnect them to the seat switch This must be completed so that the safety circuit is function ing properly Figure 4 14 Re attach the seat platform to the mower frame Tires It is important for level mowing that the tires have the same amount of 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 pneum...

Page 21: ... container under the machine below the oil drain valve 3 Twist the valve counterclockwise to open the valve Allow 10 minutes for engine oil to adequately drain 4 After oil is drained close the valve by twisting it clock wise 5 Once the valve is closed clean up any spilled oil IMPORTANT All oil drips or spills must be cleaned off of the engine plate engine exhaust system and muf fler guard before o...

Page 22: ...k and adjust the settings The idle speeds should be set as follows NOTE Model numbers may or may not end with an extension after the number There 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 A Fuel tank B Fuel line Figure 5 3 A B B A Fuel tank B Vapor lines C Fuel evaporation system filter Figure 5 4 A B B B ...

Page 23: ... 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 bung...

Page 24: ...lade on an inverted line punch or 5 8 bolt A commercial balancing tool is also avail able 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 rein stalling 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 25: ...the blades Replace the cup washers if they are cracked or flattened IMPORTANT The blade sail curved part must be point ing 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...

Page 26: ... 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 Deck Belt Adjustment The deck belt tension remains constant by means of a ten sion idler and spring There is no tension adjustment of this belt Figure 6 8 Figure 6 9 Deck Belt Installation When replacing a deck belt use the following proc...

Page 27: ...EV C Side Discharge Deck Shown A Grasp belt here Figure 6 10 Rear Discharge Deck Shown A Grasp belt here Figure 6 11 A A Grasp the belt here and pull over the pulley A A Grasp the belt here and pull over the pulley ...

Page 28: ...ioning 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 Rear Discharge Deck Belt Routing Figure 6 12 Figure 6 13 ...

Page 29: ...121363 7 1 REV B ELECTRICAL Main Electrical Harness Schematic ...

Page 30: ...REV B 7 2 114241 Main Harness to Fuel Gauge Voltage Convertor Schematic ...

Page 31: ... operation or yearly whichever comes first 10 Refer to engine owner s manual for engine service information After completing maintenance cycle 300 hours repeat cycle Maintenance Schedule Figure 8 1 Figure 8 2 Figure 8 3 Figure 8 4 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...

Page 32: ...draulic Oil Expansion Tank 8 Hydraulic Oil Filter 9 Front Wheel Bearing Zerks 2 10 Engine Oil Filter 11 Deck Height Pivot Zerks 4 12 Park Brake Switch 13 Drive Tire 14 Deck Belt 15 Pump Belt 16 Blades 17 Fuel Evaporation System Filter Figure 8 1 Figure 8 2 Figure 8 3 1 2 3 4 5 6 7 7 9 9 10 12 12 17 11 11 14 16 16 16 Side Discharge Deck Shown 13 13 8 8 15 ...

Page 33: ...ain Plug 5 Battery 6 Fuel Tank 7 Hydraulic Oil Expansion Tank 8 Hydraulic Oil Filter 9 Front Wheel Bearing Zerks 2 10 Engine Oil Filter 11 Deck Height Pivot Zerks 4 12 Park Brake Switch 13 Drive Tire 14 Deck Belt 15 Pump Belt 16 Blades 17 Fuel Evaporation System Filter 14 16 16 16 Rear Discharge Deck Shown ...

Page 34: ...REV C 8 4 121363 ...

Page 35: ...e belt Air in system Check filter and fittings For additional causes See engine manual Air cooled engine over heating Air intake screen or clean ing fins clogged Clean screen and fin For additional causes See engine manual Low engine oil pressure Low oil level Add oil Oil diluted or too light Change oil and check for source of contamination Failed oil pump Contact your Dealer High oil consumption ...

Page 36: ... Deck leveling and height adjust ment section of the General Service Manual An anti scalp wheel is not set correctly Adjust the height of the anti scalp wheel The underside of the deck is dirty Clean the underside of the deck Tires improperly inflated Adjust air pressure to 8 12 psi 55 83 KPa A blade spindle mount is bent Contact your Dealer SYMPTOMS PROBABLE CAUSES SUGGESTED REMEDIES ...

Page 37: ... 7 1 Main Harness to Fuel Gauge Voltage Convertor Schematic 7 2 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...

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