Hustler FasTrak Super Duty CE Parts Manual

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Hustler FasTrak Super Duty CEParts Manual Excel Industries, Inc. P.O. Box 7000 Hesston, Kansas 67062-2097

Table of ContentsSection 1General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Section 2Frame CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Footrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Engine Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6Section 3Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Steering Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23-43-103-12Section 4Wheel and Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Drive Wheel Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Section 5Engine, 23 HP Kaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6Section 6Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4Electrical Schematic—601341 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6Section 754" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54" Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54" Deck Belt Routing and Tensioning . . . . . . . . . . . . . . . . . . . . .Deck Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Deck Mounting Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-27-47-87-107-127-14Section 8Seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1109188CE 0510c-1

c-2109188CE 0510

Section 1General InformationThis Manual covers Hustler Fastrak Super Duty model 928382CE.Frequently Ordered PartsPART 4DESCRIPTIONPART NO.Pump Drive BeltDeck Belt 48"Deck Belt 54"Deck Belt 60"Main Air Filter Element KawAir Filter Element KawPanel Air Filter HondaEngine Oil Filter CRIPTIONFuel Filter KawasakiEngine Oil Filter KawasakiOil Filter ZT 2800F20.50"-L-F-CW BladeF18.50"-L-F-CW BladeF16.50"-L-F-CW BladeFoam Outer Filter HondaService LiteraturePART NO.799411CE778423DESCRIPTIONCE Owner’s ManualKawasaki Engine ManualNote: When ordering parts, you must use the part number as shown for each part, not the index number. Always givethe 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 manualIllustrations used were current at the time of printing, but subsequent production changes may cause your machine tovary 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, seeyour Hustler dealer for current information and parts.Hardware Description Codes & AbbreviationsThe following codes are used throughout this parts manual. Refer to this list when ordering partsABBREVIATIONCBCECPCNCSCWFDRW109188CE 0510DESCRIPTIONABBREVIATIONCarriage BoltClevis PinCotter PinClip NutCap ScrewCup WasherFender WasherMBMSNTSCSHSBSS1-1DESCRIPTIONMachine BushingMachine ScrewNutSelf Tapping Cap ScrewSocket HeadShoulder BoltSet Screw

ABBREVIATIONFWHXLWDESCRIPTIONABBREVIATIONFlat WasherHex HeadLock WasherODIDDESCRIPTIONOutside DiameterInside DiameterStandard TorquesThe following chart lists the standard torque values for the threaded fasteners found in this manual. Torque all capscrews, nuts and set screws to these values unless a different torque is shown in the Notes section next to the 108.5215435750NOTE:Loctite 592 to be used on all pipe threads.Lubricate all grease zerks.1-2109188CE 0510

Section 2Frame CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Footrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Engine Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6109188CE 05102-1

Frame 9188CE 0510

Frame CEINDEX NO.PART NO.QTY.DESCRIPTION16020411HOT DECAL26019671ENGINE COMPARTMENT DECAL36010991TOW VALVE DECAL47271721MADE IN USA DECAL56014211FASTRAK SUPER DUTY DECAL67825731FIRST ZERO TURN DECAL7N/A1TURF PRODUCT SERIAL NO PLATE87763101CE MARK DECAL9789776CE1CE 105 DBA LIMIT DECAL106009942RIVET NUT, 3/8-16 THREAD118084938RIVET NUT, 3/8-16 THREAD126025621NO SERVICE DECAL137918481FUEL INDICATOR DECAL146010692CN .312-18 X .200 MAX THK156008991PUMP BELT WARNING DECAL168084851RIVET NUT, 5/16-18 THREAD177851391STEERING LS DECAL187852201STEERING RS DECAL19785154CE1DECK HEIGHT INDICATOR DECAL206019811SAFE OPERATION DECAL21548743CE1FRAME (USED ON 928382CE)NOTES:1. Service part frames include decals.109188CE 05102-3

567682-4109188CE 0510

FootrestINDEX NO.PART NO.QTYDESCRIPTION15487681FLOOR PAN27854852STEP TREAD, UPPER37854932STEP TREAD, LOWER40113202CB .375-16 X .750 STD ZN50866602NT .375-16 HXZY NL67679544FW .406 X .812 X .060 SAE70253952CB .375-16 X 1.000 STD CD80545022NT .375-16 HX G5 ZNNOTES:1. Item 1 (Floor Pan) includes Items 2 & 3(Step Treads).109188CE 05102-5

Engine Guard8109911411223657INDEX NO.PART NO.QTY.11085411HEAT SHIELD CEDESCRIPTION27881662WHEEL ASSY, ANTI SCALP33442674FW .510X 2.15X.187 SPL47815672NT .500-13 HX G8 ZY NL50528606CS .375-16X1.250 HX G567679546FW .406X .812 X.060 SAE71088471ENGINE GUARD87817082CS .500-13X4.250 HX G597679624FW .531X 1.063X.090 SAE100319972ANTI-SCALP WHEEL110531992NT .500-13 HX JAM ZNYCNOTES:1. Install Item 1 (Heat Shield) between the engine guard and the frame.2. Item 2 (Anti-scalp Wheel) includes (items 8–11).2-6109188CE 0510

Section 3Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5Steering Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13109188CE 05103-1

Hydraulic 0912 21933161141327262826283293-2109188CE 0510

Hydraulic SystemINDEX NO.PART NO.QTYDESCRIPTION17100874CS .312-18 X 2.500 HX G520388284CS .312-18 X 2.250 HX G5376852316FW .343 X .687 X .051/.080 HD ZN/YL47868482IDLER PULLEY 4.0 OD50281182FW .625 X 1.00 X .134 ZNYC67944461CS .625-11 X 1.500 HX G576009791BELT, FASTRAK PUMP DRIVE80250071CS .625-11 X 1.750 HX G590252962FW .760 X 1.625 X .08 ZNYC107811532UHMW BUSHING111078811PUMP IDLER W/A, FASTRAK126010841SB .750 X 2.000 SH .625-11130164102CS .375-16X2.00 G5 ZN147679542FW .406 X .812 X .060 SAE156009871ZT SPACER TUBE160342728NT .312-18 HX G5 ZN170363841SPRING 1/4 COIL PL 1.23186014041ZT3100 LH196014031ZT3100 RH206010882TOW LINK ROD210485532CP .062DX1.000 LG HML Z226007591OVERFLOW TANK230559392CS .250-20X.750 HX G5 ZN247685154FW .281X.625X.051/.080 HD ZN/YL250685512NT .250-20 HXZY NL266010014SPRING CLAMP 3/4" DIA276010182OVERFLOW HOSE286008802HYDRAULIC FITTING 45 DEG290003312WIRE TIE, SMALL/SHORTNOTES:1. Torque to 23 N-m.2. Torque to 136 N-m.3. Torque axle hub nuts to 373 N-m.4. Service parts available for the transaxles:PARTNUMBER109188CE 0510PARTNUMBERDESCRIPTIONDESCRIPTION600767OVERFLOW TANK CAP601941FAN/PULLEY KIT600972BRAKE ARM RETAINER CLIP601221ZT2800 BRAKE ARM - 2007600974RIGHT FILTER GUARD6014334-BOLT HUB KIT SDFST600975LEFT FILTER GUARD600976OIL FILTER ZT 28003-3

1014891612115193118203-4109188CE 0510

SteeringINDEX NO.PART NO.QTYDESCRIPTION17844392LOCK COLLAR .75020236552NT .312-24 HX NL ZN376852317FW .343 X .687 X .051/.080 HD ZN/YL46002212DAMPER, STEERING56009812PUMP ROD ASSEMBLY67819224BALL STUD, DAMPER77041632CS .250-20 X 2.000 HX G5 ZN876851512FW .281 X .625 X .051/.080 HD ZN/YL90685512NT .250-20 HX ZN NL101093182PUMP ARM110342724NT .312-18 HX G5 ZNYC120411522NT .312-24 HX ZNYC130559394CS .250-20 X .750 HX G5 ZN141089682STEER TUBE SUPPORT150051162CS .375-16 X 1.375 HX G5 ZN167061682NT .375-16 HX JAM GR5 ZN170362361CS .312-18 X 1.000 HX G5 ZN183612951PIVOT TUBE190298762LW .312 INT-EXT TOOTH ZN200249274NT .250-20 HX GR5 ZNNOTES:1. Supplied with transmission.CONTROL LEVER ADJUSTMENTThe control levers can be adjusted for operator comfort. By loosening the nuts that attach the uppercontrol lever to the lower lever (FIG. 1), the upper control lever can be pivoted to fit the operator’spersonal preference.The control levers can also be adjusted up and down. Remove the hardware and slide the uppercontrol lever up or down and align the holes in it with the holes in lower lever. Re-install the hardware and tighten.The control levers should be adjusted so that they align with each other when in the neutral position(FIG. ROLLEVERFIG. 1109188CE 0510FIG. 23-5

STEERING LINKAGEThe neutral adjustment for the control levers in the neutral position is discussed in this section.The tractor steering has been factory adjusted to eliminate creeping when the control levers are inthe neutral position (FIG. 3). However, should the tractor begin to creep, the control lever linkagecan be adjusted as follows:CONTROLLEVERCONTROL LEVER IN THENEUTRAL POSITIONFIG. 3CONTROL LEVER NEUTRAL ADJUSTMENTBefore considering any adjustment, check the tire air pressure. Unequal tire pressure will cause thetractor to drift to one side. Refer to tire pressure information in the section of this manual.NOTE:Proper park brake adjustment must be completed before the controllever neutral adjustment can be done.Fine adjustment to the unit’s steering is made with the transmission control rod. (FIG. 4).Neutral is properly adjusted when the control levers are in the park brake position and the transmissions do not “whine”.If this occurs, the control linkage may be adjusted as follows:1. Park the unit on a flat surface, raise the rear of the tractor and block with certified jackstands (FIG. 6). With the park brakes set, start the engine. Once the engine is started,if the transmissions whine while the park brake is engaged, then neutral needs to bereset. Turn off the engine.WARNING: Never work under the machine or attachment unless it is safely supported with jackstands. Make certain machine is secure when it is raised and placed on the jack stands. The jackstands should not allow the machine to move when the engine is running and the drive wheels arerotating. Use only certified jack stands. Use only appropriate jack stands, with a minimum weightrating of 2000 pounds to block the unit up. Use in pairs only. Follow the instructions supplied withthe vehicle stands.WARNING: This is a dangerous operation - keep hands, hair, clothing, etc., clear of the coolingfans on top of the transmissions! Exercise extreme caution.WARNING: .Never attempt to make any adjustments or repairs to the tractor drive system while theengine is running. The following procedures should be performed by trained maintenancepersonnel only.2. Loosen and back off the jam nuts on both ends of the steering control rod assembly(FIG. 4). Set the steering control lever in the neutral/brake position.3. Remove the female spade connectors from the seat switch (located under the seat).These will need to be connected together now to bypass the seat switch to perform thefollowing functions. This must only be done by a qualified authorized dealer.4. Make sure the steering damper ball studs attached to the frame at the rear of thedamper on either side are loose and allowed to slide in the slot.5. Both steering control levers need to be in the brake position when starting the engine,but need to quickly be moved out of the brake position once engine is started so the3-6109188CE 0510

CONTROL LEVER IN THENEUTRAL POSITIONJAM NUTCONTROL LEVERS IN PARK BRAKE POSITIONSTEERINGCONTROL RODJAM NUTFIG. 4FIG. 5brakes do not fight the transmissions since they have not yet been adjusted.6. Start the engine. Move the control lever to just engage the brake (neutral) slot and holdit in that position (Do not engage the control lever far enough to engage the brakes inthe brake slot) (FIG. 5).WARNING: This operation is extremely dangerous. Pay close attention when adjusting thetransmission control rod so you do not get your fingers, tools, or anything else close to the ZT 2800transmission’s cooling fans.7. Beginning with the RH side of the tractor, adjust the steering control rod so that the RHdrive axle just starts turning in the forward rotation while the steering lever remains inthe neutral position. Now, turn the steering rod back the opposite direction to the pointwhen the drive axle stops spinning. From that point, turn the steering rod back again ½turn. This ensures that the steering rod is adjusted so that the transmission control armis centered in the neutral band of the transmission.8. Move the lever forward and backward and make sure that the drive axle spins forwardand backward correctly. Return the steering lever to neutral and re-check to make surethe drive axle is stopped in the neutral position. Lock the steering control lever into thebrake position. You should not hear the transmission whine if neutral is properly set.9. Turn off the engine.10. With the engine off, move the RH steering control lever into the neutral position and pullthe lever all the way back to the rear of the tractor as if you were going full speed inreverse. Now, slowly bring the lever back to the neutral position and lock it into thebrake position. This sets the steering damper in the correct neutral position. Tighten theball stud at the rear of the damper that is attached to the frame side panel on the RHside (FIG. 7). Once this is tightened, you should be able to move the steering controllever to the reverse position, let it go, and the steering lever should return itself to theneutral position. This should finish the adjustment for the RH side steering control.Double check to make sure you have all fasteners tightened to the correct torquespecifications.11. Repeat steps 4 thru 9 for the LH side.12. Once both sides are properly adjusted, double check them together to make sureeverything is working properly.13. IMPORTANT: With the engine off, disconnect the two female spade connectors fromeach other (from step #3) and reconnect them to the seat switch. This must becompleted so the safety circuit is functioning properly. Refer to the machine’s owner’smanual for operation check.109188CE 05103-7

STEERINGDAMPENERENGINEGUARDREAR DAMPENERBALL STUD NUTJACK STANDSFIG. 6FIG. 7WARNING: Do not operate the tractor without plugging the tractor wiring harness into the seatswitch. This switch is an important part of the safety start interlock system. Serious injury can resultif the seat switch is not plugged into the tractor’s wiring harness.14. Check to make sure all tools or obstructions are removed from under the tractor.Assemble the drive wheels and wheel nuts. Torque the wheel nuts to 65-75 ft-lbs.15. Jack up the rear of the tractor and remove the jack stands. Lower the tractor to theground and remove the jack.16. The control levers should be adjusted so that they align vertically with each other whenin the neutral position (FIG. 2). Space between ends of control handles to be .50" .25".17. Check the hydraulic oil level after final adjustments. Make sure oil level is withinoperating range specified.STEERING DAMPERThe steering damper (FIG. 7) is spring loaded to return the control levers to the neutral positionfrom the reverse position. This gives the operator a sense of neutral during operation.If the tractor does not return to neutral from reverse then adjust as follows:To set the steering dampers in the correct operating position follow these steps:1. Shut engine off, place control levers in the park brake position, disengage deck clutch,remove ignition switch key and disconnect negative battery cable before doing anyadjustments.2. Place the control lever in the neutral position (FIG. 3).3. Loosen the steering damper’s rear ball stud (FIG. 7).4. Pull the damper spring housing, to the rear, past the point that the internal spring isengaged.5. Release the damper spring housing and allow the internal spring to bring the housingback to the neutral position.6. Tighten the nut on the steering damper’s rear ball stud.7. To check, move the control lever to the reverse position and release. The control levershould return to the neutral position. If not, repeat steps 1 through 6.DRIVE STRAIGHT ADJUSTMENT:1. Initially adjust cap screws (FIG. 8) all the way in so that the steering levers may gofully forward.2. Drive tractor in an open area with both steering handles fully forward. The tractor willlikely drift slightly to the left or right.3. Whichever direction the tractor turns is the slow side. Leave the slow side cap screwand jam nut so that they are flush with the frame. Holding the cap screw in place, lockthe jam nut.4. On the fast side, through several iterations, back out the cap screw gradually until thefast side is slowed to the same speed as the other side and the tractor drives straight.After adjustment is finished, hold the cap screw still and tighten the jam nut.3-8109188CE 0510

JAM NUTCAP SCREWFIG. 8109188CE 05103-9

Steering Sub-Assembly1235334365733478INDEX NO.PART NO.QTY.17812601STEERING BAR GRIP23604871STEERING BAR376795412FW .406 X .812 X .060 SAE HD ZN47051783CS .375-16 X 1.750 HX G550866606NT .375-16 HXZY NL61078431STEERING ARM LEFT (SHOWN)1078421STEERING ARM RIGHT77708672BUSHING, PLASTIC .750X181078481STEER PIVOT, LEFT (SHOWN)1078471STEER PIVOT RIGHT1DESCRIPTIONNOTES:1. Includes Item 1 (Steering Bar Grip).3-10109188CE 0510

This page intentionally left blank.109188CE 05103-11

18HydroTransmission3-12109188CE 0510

BrakeINDEX NO.PART NO.QTY.DESCRIPTION10866604NT .375-16 HX LK NY276795412FW .406 X .812 X .060 SAE HD ZN36010872PLUNGER SWITCH40051082CS .375-16X3.50 HX G5 Z56014102BRAKE ROD ASSEMBLY60545022NT .375-16 HX GRD 5 ZN70236554NT .312-24 HXZY NL87685238FW .34 3X .687 X .051/.080 HD ZN/YLBUSHING97653394101078931BRAKE BELL CRANK LS111078921BRAKE BELL CRANK RS120806552CS .375-16X1.500 HX G5136009912SHORT BRAKE LINK ROD146011312BRAKE ARM RET. SPRING151092031BRAKE SPRING LINK LS161092021BRAKE SPRING LINK RS (NOT SHOWN)170559392CS .250-20X .750 HX G5180168162NT .250-20 HX FL LK ZNY196010512OVERTRAVEL SPRINGNOTES:PARK BRAKE SPRING ADJUSTMENTOccasionally check the park brake spring adjustme

109188CE_0510 1-1. Section 1. General Information. This Manual covers Hustler Fastrak Super Duty model . 928382CE. Frequently Ordered Parts. PART NO. DESCRIPTION

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Refer to API RP 500 and NFPA 70 for guidance. When loading liquids that can accumulate static charges, refer to the precautions described in the International Safety Guide for Oil Tankers and Terminals, Safety of Life at Sea, API MPMS Ch. 3, and API RP 2003. Care must be taken with all liquid-in-glass thermometers to prevent breakage, which will result in a safety hazard. If the liquid in the .