Hustler Super Mini Z Parts Manual ••••••• Hustler Turf Equipment ••••• P.O. Box 7000 ••• Hesston, Kansas • 67062-2097 302620 Rev.
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.
Table of Contents Chapter 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Chapter 2 Contents Rivet-nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Chapter 3 Contents Hydraulic System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Chapter 4 Contents Battery Installation. . . . . . . . . . . .
Chapter 11 Contents Maintenance & Adjustments Safety Precautions . . . . . . . . . . . . . . 11-2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-15 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 1 General Information This Manual covers Hustler Super Mini Z 23/44 model 927269, Super Mini Z 25/52 model 927277, Super Mini Z 24/52 model 927285, and Super Mini Z 27/52 model 927533. Frequently Ordered Parts PART NO. 027912 027920 783936 786533 791335 789388 785626 068478 785261 785279 785634 772079 747303 784256 783753 DESCRIPTION Lubrizol 7 oz. Bottle Lubrizol 10 oz.
sary, 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.
Chapter 2 Contents Rivet-nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rivet-nut Installation 1 2 INDEX NO. 1 2 SERVICE PART NO. MFG. PART NO. QTY.
Footrest Assembly 2 1 3 4 5 6 5 INDEX NO. 7 1 SERVICE PART NO. MFG. PART NO. QTY. 1 388884 388884 1 MINI Z FLOOR PLATE 2 785485 785485 2 UPPER STEP TREAD 3 785493 785493 1 LOWER STEP TREAD 4 086660 086660 2 NT .375-16 HX LK NY 5 767954 767954 4 FW .406 X .812 X .060 SAE HD ZN 6 781880 781880 2 RUBBER BUMPER 7 052860 052860 2 CS .375-16 X 1.25 HX G5 ZNYC DESCRIPTION NOTES: 1.
2-4 302620 8/06
Chapter 3 Contents Hydraulic System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic System Installation 3 2 4 5 11 6 7 14 8 10 9 2 3 12 1 19 18 15 21 13 24 16 22 26 27 17 23 2 20 28 19 29 30 21 32 22 25 33 26 34 27 31 35 28 27 29 27 31 30 37 38 36 39 41 42 44 40 43 3-2 302620 8/06
Hydraulic System Installation INDEX NO. 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 302620 8/06 SERVICE PART NO. MFG. PART NO. QTY. 1 068551 068551 2 NT .250-20 HX NL ZNYC 2 768515 768515 8 FW .281 X .625 X .051/.080 HD ZNYC 3 055939 055939 4 CS .250-20 X .
NOTES: 1. Add 3.5 oz. Lubrizol® (027912) to new system or when hydraulic oil is changed (see Owner’s Manual). 2. Hydraulic system capacity is 5 US quarts. Fill reservoir to within 1" of top of Item 8 (032771 Strainer). 3. Included in Hydro Kit (791160).
Chapter 4 Contents Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Steering and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Pump Belt and Pulley Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Installation 1 2 3 5 6 4 7 8 6 7 9 7 8 10 1 2 12 11 13 14 4-2 302620 8/06
Battery Installation INDEX NO. SERVICE PART NO. MFG. PART NO. QTY. 1 058776 058776 2 NT .312-18 HX NL ZNYC 2 768523 768523 3 FW .343 X .687 X .051/.080 HD ZNYC 3 348417 348417 1 BATTERY CLAMP STRAP 4 785063 785063 1 POSITIVE BATTERY CABLE 5 771428 771428 1 RED BATTERY CABLE BOOT 6 055939 055939 2 CS .250-20 X .750 HX G5 ZNYC 7 029868 029868 4 LW .250 INT-EXT TOOTH ZNYC 8 024927 024927 2 NT .250-20 HX GR.
Deck Lift Assembly 1 2 3 5 4 6 4 6 14 1 12 4 15 11 10 4 7 6 4 6 8 13 14 1 4 14 1 7 6 5 7 6 8 8 1 6 14 9 8 4-4 302620 8/06
Deck Lift Assembly INDEX NO. SERVICE PART NO. MFG. PART NO. QTY. 1 348318 348318 1 STOP HANDLE 2 348284 348284 1 HEIGHT ADJUSTMENT STOP 3 784488 784488 1 DECK LIFT INDICATOR 4 781294 781294 7 CLIP E, 1.00 X.625X .050 5 782995 782995 2 DECK LIFT SPRING 6 704643 704643 8 NT .437-14 HX FLG ZN 7 055749 055749 3 CS .437-14 X 1.750 HX G5 ZNYC 8 348391 348391 4 DECK LIFT CHAIN 9 781831 781831 1 CS .437-14 X 1.750 FULTH G5 ZNYC 10 756270 756270 1 CS .312-18 X 1.
Steering and Brake Assembly 1 2 5 4 7 6 3 8 6 9 14 12 10 13 19 17 12 20 18 15 12 12 13 21 13 24 16 11 6 12 7 25 28 27 6 26 12 23 20 22 30 24 12 29 31 15 6 5 26 44 1 2 12 13 21 40 43 42 32 37 41 12 38 36 35 45 12 47 34 26 46 26 33 21 6 33 39 4-6 302620 8/06
Steering and Brake Assembly INDEX NO. 5 SERVICE PART NO. MFG. PART NO. QTY. 1 781260 781260 2 STEERING BAR GRIP 2 368704 N/A 2 STEERING BAR 3 367128 367128 1 CONTROL PANEL 4 368670 368670 2 STEERING ARM MOUNT 5 055822 055822 6 CS .375-16 X .750 HX G5 ZNYC 6 767954 767954 26 FW .406 X .812 X .060 SAE HD ZN 7 781716 781716 4 SS .500-13 X 1.75 SH ZN 8 053199 053199 2 NT .500-13 HX JAM ZNYC 9 036244 036244 4 CS .375-16 X 1.
NOTES: 1. 2. 3. 4. 5. 6. Torque to 280-310 ft.-lbs. Included with wheel motor. Torque brake assembly mounting bolts to 24 ft.-lbs. 783118 used on left wheel. 783126 used on right wheel. Includes Item 1 (781260 Steering Bar Grip). Used on mowers with serial numbers prior to 06071186.
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Pump Belt and Pulley Installation For mowers with serial numbers prior to 04040580 35 1 14 27 2 28 30 25 2 31 32 33 34 5 26 28 LOCATION FOR RUBBER BUMPER 13 1 29 12 8 2 2 9 3 8 2 4 10 5 9 13 15 14 6 16 1 4 11 17 7 20 21 22 18 19 3 23 24 4-10 302620 8/06
Pump Belt and Pulley Installation INDEX NO. SERVICE PART NO. MFG. PART NO. QTY 1 783761 783761 1 SUPER Z SINGLE PULLEY 2 212076 212076 1 KEY 1/4 SQ X 1.50 LONG DESCRIPTION 3 797654 797654 1 FW 1.156 X 1.750 X .250 ZY 4 791251 791251 1 CLUTCH PIGTAIL HARNESS (DIODE) 5 787366 787366 1 WARNER Z CLUTCH 6 783829 783829 1 FW .460X 1.750X .250 ZNYC 7 785659 785659 1 CS .437-20 X 2.50 HX G5 ZNYC 8 083196 083196 4 SS .312-18 X .
Cycle the deck clutch on for 15 seconds, and then off for 15 seconds. Repeat this operation 10 times - it will require about 5 minutes to complete.
Chapter 5 Contents Kawasaki Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Honda Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Kohler Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Fuel System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 Instrument Panel Installation/Assembly. . . . . . . . . . . . . . . . . . . . . .
Kawasaki Engine Installation 2 1 2 5 6 3 4 7 8 10 7 9 11 12 13 14 18 15 6 7 16 3 19 3 YEL 3 P/O ENGINE 11 24 21 TO BULLET TERMINALS 3 (MALE-BRN) (FEMALE-ORG) 6 7 23 20 TO SPADE TERMINAL 3 PUR 17 22 1 10 11 25 27 26 28 30 29 28 36 37 11 31 11 33 11 34 3 39 38 40 35 32 RED/BLK 41 POSITIVE BATTERY CABLE 3 PUR 42 7 43 44 45 46 47 5-2 7 47 302620 8/06
Kawasaki Engine Installation 7 INDEX NO. SERVICE PART NO. MFG. PART NO. QTY. 1 786673 786673 1 DONALDSON AIR CLEANER CAP 2 785741 785741 1 MOUNTING BAND 3 057661 057661 2 HOSE CLAMP 4 788943 788943 1 AIR FILTER INDICATOR 5 782763 782763 1 AIR CLEANER 6 034272 034272 10 NT .312-18 HX G5 ZNYC 7 768523 768523 18 FW .343 X .687 X .051/.080HD ZNYC 8 370270 370270 1 MINI Z DEFLECTOR SCOOP 9 036236 036236 2 CS .312-18 X 1.00 HX G5 ZNYC 10 055939 055939 6 CS .
NOTES: 1. Includes mounting hardware. 2. Includes one (1) of Item 3 (057661 Hose Clamp). 3. Part of Item 30 (783894 Tractor Wire Harness). 4. Engine oil capacity; 2 US quarts. 5. Engine RPM to be set at 3600±50. 6. When installing lower hose clamp on air cleaner hose, install as low as possible (against carburetor inlet). 7. Used on mowers with serial numbers 05031839 and higher. This part replaces “O” ring , drain extension, and drain plug, on mowers with serial numbers prior to 05031839, 8.
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Honda Engine Installation 2 2 4 6 3 7 5 32 8 9 7 11 10 1 10 12 33 9 13 14 6 7 15 3 39 16 34 1 38 37 45 35 36 6 7 YEL 3 PART OF ENGINE 17 18 BRN 3 ORG 3 41 20 19 GRA/PUR 3 POSITIVE BATTERY CABLE 36 3 RED/BLK 40 PUR 3 21 26 22 43 42 24 23 10 10 25 7 42 ANTI-ROLLOVER WHEEL BRACKET 28 27 29 30 7 31 5-6 302620 8/06
Honda Engine Installation INDEX NO. SERVICE PART NO. MFG. PART NO. QTY. 1 785014 785014 1 HONDA 24 HP ENGINE (USED ON 927285) 2 775353 775353 1 CENTRIFICAL AIR CLEANER CAP 3 057661 057661 2 HOSE CLAMP 4 785741 785741 1 MOUNTING BAND 5 782763 782763 1 AIR CLEANER 6 034272 034272 10 NT .312-18 HX G5 ZNYC 7 768523 768523 18 FW .343 X .687 X .051/.080HD ZNYC 8 370270 370270 1 MINI Z DEFLECTOR SCOOP 9 055939 055939 6 CS .250-20 X .
3. Part of Item 41 (787200 Tractor Wire Harness). 4. Engine oil capacity; 2 US quarts. 5. Engine RPM to be set at 3600±50. 6. When installing lower hose clamp on air cleaner hose, install as low as possible (against carburetor inlet). 7.
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Kohler Engine Installation 8 1 12 11 13 9 14 10 2 9 3 15 4 14 7 2 20 1 6 16 17 18 19 21 13 14 22 9 4 5 13 14 23 25 26 24 27 39 POSITIVE BATTERY CABLE PUR (P/O ENGINE) 2 3 RED/BLK 28 29 33 31 30 34 32 14 ANTI-ROLLOVER WHEEL BRACKET 35 36 37 5-10 14 38 302620 8/06
Kohler Engine Installation 4 7 INDEX NO. SERVICE PART NO. MFG. PART NO. QTY. 1 788216 788216 1 KOHLER CV740 ENGINE (27 HP) 2 788018 788018 1 KOHLER MUFFLER 3 029751 029751 2 CS .375-16 X 1.00 HXFLK ZNYC 4 705137 705137 4 FW .391 X 1.250 X .060 ZNYC 5 016899 016899 2 NT .375-16 HXFLK ZNYC 6 785378 785378 1 MUFFLER 1.
7. Used on mowers with serial number 05031280 and higher.
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Fuel System Installation 1 2 SEAT SUPPORT CROSSMEMBER 10 6 5 1 6 4 2 7 9 6 3 1 12 11 6 8 8 1 6 9 4 2 8 9 5-14 1 302620 8/06
Fuel System Installation ITEM NO. SERVICE PART NO. MFG. PART NO. 1 784181 784181 2 FUEL TANK CAP 2 796318 796318 1 RIGHT SIDE FUEL TANK 3 796326 796326 1 LEFT SIDE FUEL TANK 4 791277 791277 2 FITTING, FUEL TANK 90° 5 745059 745059 1 3-WAY FUEL VALVE 6 000323 000323 6 CLIP 7 000331 000331 3 BLACK CABLE TIE 8 767954 767954 12 FW .406 X .812 X .060 SAE HD ZN QTY DESCRIPTION 9 055822 055822 12 CS .375-16 X .75 HX G5 ZNYC 10 015818 015818 1 FUEL LINE 12.
Instrument Panel Installation/Assembly 1 2 3 4 1 6 10 5 8 7 8 5 1 12 9 13 1 10 14 1 8 11 6 RIGHT SIDE FUEL TANK 15a 13 12 5a KAWASAKI 10a HONDA 15a KOHLER 20a FUSE SIZE AND LOCATIONS 5-16 302620 8/06
Instrument Panel Installation/Assembly ITEM NO. SERVICE PART NO. MFG. PART NO.
Electrical Schematic - Kawasaki Engines (783894) 5-18 302620 8/06
Electrical Schematic - Kawasaki Engines (783894) 302620 8/06 5-19
Electrical Schematic - Honda Engines (787200) 5-20 302620 8/06
Electrical Schematic - Honda Engines (787200) 302620 8/06 5-21
Electrical Schematic—Kohler (788000) 5-22 302620 8/06
Electrical Schematic—Kohler (788000) 302620 8/06 5-23
5-24 302620 8/06
Chapter 6 Contents Front Wheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Front Wheel Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Drive Wheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Anti-Rollover Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Wheel Assembly 1 2 3 TRACTOR FRAME 4 2 5 1 2 6 2 2 3 5 4 5 7 8 9 10 10 6 11 5 2 7 8 10 9 10 12 1 12 6-2 1 302620 8/06
Front Wheel Assembly SERVICE PART NO. MFG. PART NO. QTY 1 705954 705954 2 CS .500-13 X 1.25 HX G5 ZN 2 344267 344267 2 FW .510 X 2.15 X .187 SPL ZN 3 798603 798603 2 FW .515 X 1.65 X .125 HD ZY 4 263517 263517 2 BEARING DISC 5 784223 784223 4 BEARING W/O COLLAR 6 784603 784603 2 SPACER 7 045765 045765 2 FW 1.030 X 1.500 X.134 ZN 8 366625 366625 2 FORK 9 786731 786731 2 CS .750-10 X 8.00 HX GR5 ZYNC 10 025296 025296 4 FW .760 X 1.625 X .08 INDEX NO.
Front Wheel Breakdown - 786061 2 1 3 1 5 4 ITEM NO. 2 2 SERVICE PART NO. MFG. PART NO. QTY DESCRIPTION 1 786103 N/A 2 WHEEL BEARING 2 747402 N/A 1 TIRE 13 X 5.00 3 786079 N/A 1 WHEEL 4 019521 N/A 1 TIRE VALVE 5 015511 N/A 1 GREASE FITTING 45 DEG 1/4 NOTES: 1. Inflate tire to 8-10 psi. 2. Service parts for 795245 (Optional Semi-Pneumatic Tire/Wheel Assembly), also.
Drive Wheel Assembly/Installation 1 6 2 4 3 5 1 SERVICE PART NO. MFG. PART NO. QTY 1 782078 782078 2 2 782284 N/A INDEX NO. DESCRIPTION WHEEL/TIRE ASSEMBLY 23 X 9.50 TIRE 23 X 9.50-12 3 782086 N/A WHEEL 10 X 7.5 4 019521 N/A TIRE VALVE 5 061077 061077 5 WHEEL NUT (QTY PER WHEEL) 6 770859 N/A 5 1/2" WHEEL LUG STUD (QTY PER WHEEL) NOTES: 1. Torque to 65-75 ft. lbs. 2. Inflate tire to 8-10 psi.
Anti-Rollover Wheel Assembly 4 3 5 1 6 1 5 5 2 1 7 5 2 4 7 8 SERVICE PART NO. MFG. PART NO. QTY 1 034272 034272 6 NT .312-18 HX G5 ZNYC 2 768523 768523 6 FW .343 X .687 X .051/.080 HD ZNYC 3 350835 350835 2 ANTI ROLLOVER WHEEL BRACKET 4 068239 068239 2 CS .500-13 X 4.500 HX G5 ZN 5 767962 767962 4 FW .531 X 1.063 X .090 SAE HD ZN 6 781567 781567 2 NT .50-13 HX LK NY 7 016253 016253 6 CB .312-18 X .750 FUL ZN 8 031997 031997 2 ANTI-SCALP WHEEL INDEX NO.
Chapter 7 Contents Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Blade Spindle Assembly Breakdown . . . . . . . . . . . . . . . . . . . . . . . . .
Deck Assembly 2 4 3 1 3 5 7 8 9 17 4 10 4 9 6 2 15 16 1 17 11 12 14 17 13 11 12 2 15 12 17 13 15 4 2 14 13 12 18 2 15 12 11 4 14 5 2 15A 13 12 11 1A 11A 12A 13A 44" DECK 14A 7-2 302620 8/06
Deck Assembly 5 INDEX NO. SERVICE PART NO. MFG. PART NO. QTY. 1 546408 367730 1 52" MINI-Z DECK 1A 546382 367946 1 44" MINI-Z DECK DESCRIPTION 2 357111 357111 1 DISCHARGE CHUTE 3 063297 063297 2 SB .375 X .50 SH .312-18 TD ZN 4 767954 767954 20 FW .406 X .812 X .060 SAE HD ZN 5 054502 054502 8 NT .375-16 HX GRD 5 ZNYC 6 357103 357103 1 DISCHARGE CHUTE MOUNT BRACKET 7 058776 058776 2 NT .
Deck Pulley Assembly 1 2 4 3 2 11 5 12 6 7 8 13 9 7 22 10 14 13 7 21 14 15 16 1 23 17 23 19 19 23 20 17 27 23 26 24 19 25 28 29 16 15 7-4 1 302620 8/06
Deck Pulley Assembly INDEX NO. SERVICE PART NO. MFG. PART NO. QTY. 1 789388 789388 1 52" DECK BELT 791335 791335 1 44" DECK BELT 2 784199 784199 6 CS .312-18 X 1.25 FLT SH ZNYC 3 017129 017129 6 FW .440 X 1.00 X .083 ZNYC 4 785832 785832 2 DECK IDLER UHMW CLAMP 5 787069 787069 2 DECK IDLER UHMW RISER 6 025007 025007 1 CS .625-11 X1.75 HX G5 ZNYC 7 028118 028118 4 FW .62 X 1.00 X.134 ZNYC 8 781856 781856 1 IDLER NHI 5.
4. Used on mower with serial number prior to 05050800. 31 34 2 32 4 3 12 5 6 7 13 8 7 14 33 5. Used on mowers with serial number 05050800 and higher, mowers with serial number pior to 05050800, use 786889. 6.
Blade Spindle Assembly Breakdown 1 2 3 4 2 5 INDEX NO. SERVICE PART NO. MFG. PART NO. QTY.
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Chapter 8 Contents Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Deck Belt Routing and Tensioning. . . . . . . . . . . . . . . . . . . . . . . . . . .
Deck Installation TRACTOR ASSEMBLY 1 1 2 4 3 5 DECK ASSEMBLY 5 INDEX NO. SERVICE PART NO. MFG. PART NO. QTY. 1 055749 055749 4 CS .437-14 X 1.750 HX G5 ZNYC CS .750-10X3.000 HX G5 ZNYC DESCRIPTION 2 051169 051169 2 3 025296 025296 4 FW .760 X 1.625 X.08 ZNYC 4 061101 061101 2 NT .750-10 HX NL ZN 5 704643 704643 8 NT .437-14 HX FLG ZN NOTES: 1. 52" Deck installation shown, 44" Deck installation is similar.
Deck Belt Routing and Tensioning 1 NOTES: 1. Spring length after tensioning new beltmeasured from outside of hook to outside of hook. 2. Route belt as shown.
8-4 302620 8/06
Chapter 9 Contents Tractor Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 52" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 44" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tractor Decals 2 3 SECTION A-A 4 5 SEE DETAIL A DETAIL A 6 SECTION B-B 7 8 11 13 9 TOP OF SEAT PAN 10 12 14 15 17 16 BOTTOM OF SEAT PAN 9-2 302620 8/06
Tractor Decals INDEX NO. SERVICE PART NO. MFG. PART NO. QTY. 1 784702 784702 1 INSTRUMENT PANEL DECAL 2 782128 782128 1 Z SERVICE DECAL 3 779280 779280 1 HOT & HYD OIL DECAL 4 727008 727008 1 HYD PRESSURE DECAL 5 791848 791848 1 FUEL INDICATOR DECAL 6 782573 782573 1 FIRST ZERO TURN DECAL 7 786822 786822 1 HUSTLER SUPER MINI-Z ID DECAL 8 727172 727172 1 "MADE IN U.S.A.
52" Deck Decals 1 2 3 8 7 4 3 5 5 6 INDEX NO. SERVICE PART NO. MFG. PART NO. QTY. 1 781419 781419 1 BELT ROUTING DECAL 2 760637 760637 1 MOWER DECK QUICK REF DECAL 3 727438 727438 2 WHIRLING BLADES DECAL 4 727420 727420 1 DEFLECTOR SHIELD DECAL 5 727453 727453 2 BELT & PULLEY DECAL 6 785535 785535 1 DECK I.D. 52" DECAL 7 727172 727172 1 "MADE IN U.S.A.
44" Deck Decals 1 2 3 8 4 7 3 5 5 6 INDEX NO. SERVICE PART NO. MFG. PART NO. QTY. 1 781419 781419 1 BELT ROUTING DECAL 2 760637 760637 1 MOWER DECK QUICK REF DECAL DESCRIPTION 3 727438 727438 2 WHIRLING BLADES DECAL 4 727420 727420 1 DEFLECTOR SHIELD DECAL 5 727453 727453 2 BELT & PULLEY DECAL 6 784801 784801 1 DECK 44" ID DECAL 7 727172 727172 1 "MADE IN U.S.A.
9-6 302620 8/06
Chapter 10 Contents Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Installation 3 19 18 3 5 6 4 7 9 1 2 10 11 8 12 13 15 9 1 14 16 16 2 17 10-2 302620 8/06
Seat Installation INDEX NO. SERVICE PART NO. MFG. PART NO. QTY. 1 036244 036244 1 CS .375-16 X 1.00 HX G5 ZNYC 2 767954 767954 5 FW .406 X .812 X .060 SAE HD ZN 3 748756 748756 1 SPRING PLUNGER LATCH 4 389940 389940 1 SEAT LATCH BRACKET 5 781617 781617 3 RUBBER BUMPER 6 722199 722199 1 2" WIDE SCOTCH POLYURETHANE 6" 7 792051 792051 1 SEAT 8 000331 000331 3 SMALL/SHORT WIRE TIE 9 086660 086660 3 NT .
10-4 302620 8/06
Chapter 11 Contents Maintenance & Adjustments Safety Precautions . . . . . . . . . . . . . . .11-3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-7 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-2 302620 8/06
SAFETY PRECAUTIONS ▲ ▲ This safety alert symbol is used to call attention to a message intended to provide a reasonable degree of PERSONAL SAFETY for operators and other persons during the normal operation and servicing of this equipment. DANGER – denotes immediate hazards which WILL result in severe personal injury or death. WARNING - denotes a hazard or unsafe practice which COULD result in severe personal injury or death. This manual uses two other words to highlight information.
Using a ramp ▲ Grass collection system components are subject to wear, damage and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check components and replace with manufacturer’s recommended parts, when necessary. ▲ Use only genuine Hustler replacement parts to ensure that original standards are maintained ▲ Use extreme caution when loading and unloading a unit with a ramp. ▲ Use only a single, full width ramp; do not use individual ramps for each side of the unit.
Safety and Instruction Decals ▲ Specific safety warning decals are located on the equipment near the immediate areas of potential hazards. These decals should not be removed or obliterated. Replace them if they become non-readable. The following illustrations show the various safety decals that are located on the machine. A brief explanation is shown to help the operator understand the meanings of these decals. Do not smoke while refueling. Do not fill tank with engine running, or while the engine is hot.
11-6 302620 8/06
MAINTENANCE MAINTENANCE LOCATOR CHART 3 6 7 13 5 12 12 10 2B 16 19 2C 11 4 1A 1B 6 2A 13 12 12 1A. Engine Oil Fill & Dipstick (Kawasaki & Honda) 1B. Engine Oil Fill & Dipstick (Kohler) 2A. Fuel Filter (Kawasaki) 2B. Fuel Filter (Honda) 2C. Fuel Filter (Kohler) 3. Engine Air Cleaner 4. Engine Oil Drain Plug 5. Battery 6. Fuel Tanks 7. Hydraulic Oil Reservoir 8. Deck Pusher Arm Zerks (2) 9. Hydraulic Oil Filter 10. Gauge Wheel Bearing Zerks (2) 11. Engine Oil Filter 12.
SERVICE AT INTERVALS INDICATED Verify safety start interlock system Visually inspect unit for loose hardware and/or damaged parts Visually inspect tires Check oil level, engine (1) Clean air intake screen (5) Clean oil heat exchanger (5) Check fuel level Blades - sharpen & securely fastened Discharge chute - securely in place & in lowest position Clean engine and pump compartments Replace air cleaner paper element (5) Grease deck pusher arms Grease pump idler Grease deck height pivots Grease gauge wheel bea
multi-purpose grease. 3. Grease the pump idler per the Maintenance Schedule. Use SAE multi-purpose grease. 4. Grease the two deck pusher arm pivots per the Maintenance Schedule. Use SAE multi-purpose grease. Battery Electrical system The electrical system is a 12 volt, negative ground. Recommended battery size is a garden tractor BCI group U1R with 225 or better cranking AMP rating. A maintenance-free battery is recommended.
Seat platform catch Cooling fan Engine Heat exchanger Seat platform Control lever Figure 11-7 Figure 11-5 Hydraulic reservoir Hydraulic filter Figure 11-6 Hydraulic system IMPORTANT: Never use hydraulic or automatic transmission fluid in this system; use only motor oil as specified. Remember, dirt is the primary enemy of any hydraulic system. WARNING: Hydraulic oil escaping under pressure can penetrate skin. Hydraulic oil may cause infection in a minor cut or opening in the skin.
Fuel tank Fuel filter Honda engine Figure 11-8 Figure 11-9B WARNING: Gasoline is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness. Avoid prolonged breathing of vapors. Keep face away from nozzle and gas tank or conditioner opening. Keep gas away from eyes and skin. The fuel tanks are located in the tractor’s fenders. (Fig. 11-8) Total capacity for the fuel tanks is 12 U.S. gallon (45.
Kawasaki Engine Engine oil filler tube Pre-cleaner Engine oil drain plug Engine oil filter Canister Figure 11-11A Figure 11-12 Engine oil filler tube Honda Engine 3. Damaged filter, seals or canister. 4. Incorrect air filter element size. 5. Use of poorly designed aftermarket air filter elements. Air cleaner servicing is an inexpensive maintenance check that can prevent costly non-warrantable premature engine damage.
Viewed from bottom for unit 1. Pump belt 2. Engine pulley 3. Pump idler pulley 4. Pump idler arm 5. Pump pulley 6. Electric deck clutch 7. Pump idler spring Reset button 1 5 5 Indicator 4 Figure 11-13 Incorrect air cleaner element 2, 6 7 Use only the correct Donaldson air filter element, Hustler part number 785261, which is designed to fit the canister properly. Hustler air filter elements have the correct media composition, filter area, micron size and dimensions.
control levers in the park brake position immediately. Inspect the machine and involve your Hustler dealer to resolve the problem before continuing to operate. Inspect the belt pulley grooves and flanges for wear. A new belt, or one in good condition, should never run against the bottom of the groove. Replace the pulley when this is the case, otherwise belt will lose power and slip excessively. Never pry a belt to get it on a pulley as this will cut or damage the fibers of the belt covering.
ADJUSTMENTS Introduction Your Super Mini Z was adjusted before it left the factory and was checked during predelivery setup. However, after start-up and continued use, a certain amount of break-in wear will cause some adjustments to change. Remain alert for unusual noises, they could be signaling a problem. Visually inspect the machine for any abnormal wear or damage. A good time to detect potential problems is while performing scheduled maintenance service.
Upper control lever Spring housing Front ball stud Cap screw Steering dampener with spring Lower control lever Figure 11-22 Control lever stops The control lever stops (Fig. 11-21) are designed to do two things: First, and most important, they must keep the pumps from bottoming out internally. Secondly, the stops may be adjusted to help drive straight when the control levers are pushed forward against the stops. To keep the pumps from bottoming out internally use the following procedure: 1.
NOTE: The front brake link is not adjustable. Fig. 11-24 2. Raise and block the tractor up so the drive wheels are off of the floor. 3. Open the hydraulic pump’s bypass valve (Fig. 11-25), on the side that is being adjusted, by turning bypass valve counter clockwise one-half to one revolution. The valve stems on each hydraulic pump are located near the top and are identified as a hex stud. 4. Rotate the tire. The tire should rotate.
Spring Tension idler Pump drive belt Blocks Figure 11-33 Figure 11-30 Stop handle Spring Height adjusting stop Tension idler Chain Figure 11-34 Figure 11-31 Deck lift threaded rod Spring Extension 7.75” Normal Spring Length 6.0” 1.75” Nut Nut Figure 11-32 excessively worn or damaged. As belt stretches and wears in, adjustment may become necessary. To increase belt tension, move the spring chain one (or more) link(s) at the anchor bracket (Fig. 11-31). Installed spring length should be 7.
18. Tighten the hardware holding the chain and adjuster onto the deck lift arm. 19. Go to the right rear of the tractor. 20. Make sure that there is still slack in the chain. If not, loosen the two nuts on the block holding the threaded rod until there is slack in the deck lift chain. Fig. 11-36 21. Tighten the appropriate nut until the chain just becomes tight, making sure that the deck stays tight against the 3" block. 22.
11-20 302620 8/06
INDEX PAGE Access to engine and hydraulic pump............................11-9 Adjustment introduction...............................................11-15 Belt replacement...........................................................11-13 Burnishing the electric clutch.........................................11-9 Control lever adjustment ..............................................11-16 Control lever stops .......................................................11-16 Decals....................................
Numerical Index Part No. Page No. Part No. Page No. Part No. Page No.
Part No. 727016 727172 727420 727438 727453 740696 742684 745059 747303 747402 748681 748756 756270 762195 763318 765339 767954 767962 768127 768515 768523 768820 769166 770859 771428 771436 772079 775353 776476 777656 778217 778365 778423 778738 779280 779850 780841 781153 781211 781229 781260 781286 781294 781302 781385 781419 781526 781542 Page No.
Part No. Page No. Part No. Page No. Part No. Page No.
