Hustler 302612 User Manual

Hustler Mini Z

Parts Manual

302612 Rev. 5/05

•••••••

Hustler Turf Equipment

•••••

P.O. Box 7000

•••

Hesston, Kansas

•

67062-2097

WARNING:

The engine exhaust from this p rod uct

contains chemicals known to the State

of Cal if orn ia to c au se c an cer, bir t h

defects or other reproductive harm.

IMPORTANT: This engine is not equipped with a spark arrest er muffler. It is a v io lation o f California Public Resourc e Code
Section 4442 to use or operate t his engi n e on any f orest-covered, b r ush-c overe d, or grass-co ve red u nimproved land . Other
states or federal areas may have similar laws.

This spark ignition system complies with Canadian ICES-002.

The Engine Owner’s Manual provides information regarding the U.S. Environmental Protection Agency (EPA) and the
California Emission Control Regulation of emission systems, maintenan ce and warranty.

Keep E ngine Owner’ s Ma nual with your unit. Should the Engine Owner’s Ma nual beco me damaged or i l legible, re­place immedia tely. Re pl acements may be orde red per the information found in the Product Informati on sec tion of t he

owne r ’ s manual.

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Steering and Brake Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Pump Belt and Pulley Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

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 . . . . . . . . . . . . . . . . . . . . . 5-16

Electrical Schematic–Kawasaki Engines (783894). . . . . . . . . . . . . 5-18

Electrical Schematic–Honda Engines (787200) . . . . . . . . . . . . . . . 5-20

Electrical Schematic–Kohler Engines (788000) . . . . . . . . . . . . . . . 5-22

Table of Contents

Chapter 6 Contents

Front Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Front Wheel Breakdown - 786061 . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Drive Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Anti-Rollover Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Chapter 7 Contents

Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Deck Pulley Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Blade Spindle Assembly Breakdown . . . . . . . . . . . . . . . . . . . . . . . 7-7

Chapter 8 Contents

Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Deck Belt Routing and Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Chapter 9 Contents

Tractor Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

52" Deck Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

44" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

Chapter 10 Contents

Seat Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

302612 5/05 c-1

Chapter 11 Contents

Maintenance & Adjustments Safety Precautions. . . . . . . . . . . . . . 11-3

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-7

Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15

Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1

c-2 302612 5/05

Chapter 1

General Information

This Manual covers Hustler Mini Z 19/44 model 927228, Mini Z 19/52 model 927236, Mini Z 23/52
model 927244, Mini Z 24/52 model 927251, Mini Z 20/44 model 927483, Mini Z 20/52 model

927491, & Mini Z 27/52 model 927525.

Frequently Ordered Parts

PART NO. DESCRIPTON

027912
027920
768341
786533
791335
789388
785626
068478
785261
785279
785634
772079
747303
784256
783753

Service Literature

PAR T NO. DESCRIPTION

302638
778423
785642
742684

Lubrizol 7 oz. Bottle
Lubrizol 10 oz. Bottle
Hydraulic Oil Filter
Pump Drive Belt
44" Deck Belt
52" Deck Belt
Honda Fuel Filter
Kawasaki & Kohler Fuel Filter
Main Air Filter
Safety Air Filter Element
Honda 20/24HP Engine Oil Filter
Kawasaki Engine Oil Filter
Kohler Engine Oil Filter
16" X 2.5" X 0.204 .631 Dia. Hole Blade
18" X 2.5" X 0.204 .631 Dia. Hole Blade

Hustler Mini Z Owner’s Manual
Kawasaki 19/23HP Engine Manual
Honda 18/20/24HP Engine Manual
Kohler Engine Manual

Note: When ordering parts, you must use the part number as shown for each part, not the index number. Always give
the 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 manual

Illustrations used were current at the time of printing, but subsequent production changes may cause your machine to
vary slightly in detail. Excel Industries, Inc. reserves the right to redesign and change the machine as deemed neces
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.

302612 5/05 1-1

-

Hardware Description Codes & Abbreviations

The following codes are used throughout this parts manual. Refer to this list when ordering parts.

ABBREVIATION DESCRIPTION

CB
CE
CP
CS

CW

FDRW

FW

HX
LW
MB
MS
NT
SC
SH
SB
SS
OD

ID

Carriage Bolt
Clevis Pin
Cotter Pin
Cap Screw
Cup Washer
Fender Washer
Flat Washer
Hex Head
Lock Washer
Machine Bushing
Machine Screw
Nut
Self Tapping Cap Screw
Socket Head
Shoulder Bolt
Set Screw
Outside Diameter
Inside Diameter

Standard Torques

The following chart lists the standard torque values for the threaded fasteners found in this manual. Torque all cap
screws, nuts and set screws to these values unless a different torque is shown in the Notes section next to the fastener

SIZE FT-LBS NM SIZE FT-LBS NM

.250 8.2 11.1 M3 1 1.3
.312 17 23 M4 2.2 3
.375 30 40 M5 4.5 6.1
.438 48 65 M6 7.7 10.4
.500 73 99 M8 18.5 25
.562 105 143 M10 37 50
.625 145 200 M12 64 87
.750 260 350 M16 160 215
.875 420 565 M20 320 435

1.00 625 850 M24 555 750

NOTE:

Loctite 592 to be used on all pipe threads.
Lubricate all grease zerks.

1-2 302612 5/05

Chapter 2 Contents

Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Footrest Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

302612 5/05 2-1

Rivet Nut Installation

1

2

INDEX

NO.

SERVICE

PART NO.

1 546630 387936 1 52" MINI Z FRAME

546648 392449 1 44" MINI Z FRAME

2 N/A 808493 2 3/8-16 THREAD RIVET NUT

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

2-2 302612 5/05

Footrest Assembly

1

3

4

2

5

6

5

1

7

INDEX

NO.

SERVICE

PART NO.

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

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Do not tighten, Item 1 ( 388884 Mini Z Floor Plate) must be able to pivot
on these bolts.

302612 5/05 2-3

2-4 302612 5/05

Chapter 3 Contents

Hydraulic System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

302612 5/05 3-1

Hydraulic System Installation

1

2

3

6

9

10

11

15

31

32

11

12

3

8

15

16

14

17

16

5

4

7

12

8

17

13

23

18

20

24

19

22

21

19

18

20

25

21

30

34

33

26

16

27

28

29

3-2 302612 5/05

Hydraulic System Installation

INDEX

NO.

10 768523 768523 3 FW .343 X .687 X .051/.080 HD ZNYC
11 787648 N/A 2 FILTER TO PUMP HOSE ASSEMBLY
12 779132 N/A 2 FITTING, STR-6MORB/-6JIC
13 781062 781062 1 HYDRO-GEAR BDP-10A-300 PUMP
14 781047 781047 1 HYDRO-GEAR BDP-10A-400 PUMP
15 041707 041707 4 NT .437-14 HX G5 ZNYC
16 704742 704742 8 FW .453 X .812 X .060 ZNYC
17 781559 N/A 4 FITTING, 45-8MORB/-8MSL
18 791152 791152 2 WHITE MOTOR CE14
19 008573 008573 8 CS .500-13 X 2.500 HX G5 ZNYC
20 767962 767962 8 FW .531 X 1.063 X .090 SAE HD ZN
21 781526 N/A 3 FITTING, 90-10MORB/-8MSL
22 787440 N/A 1 FITTING, 45-10MORB/-8MSL
23 79 1111 N/A 1 HYDRO TUBE, MINI-Z RLOOP/RP-BM
24 791129 N/A 1 HYDRO TUBE, MINI-Z RLOOP/LP-TM
25 791145 N/A 1 HYDRO TUBE, MINI-Z LLOOP/LP-TM
26 791137 N/A 1 HYDRO TUBE, MINI-Z LLOOP/RP-BM
27 705186 705186 4 CS .437-14 X 1.375 HX G5 ZNYC
28 787630 N/A 1 RESERVOIR TO FILTER HOSE ASSEMBLY
29 779447 N/A 1 ADAPTER T,-6JIC/-60RB/-6JIC
30 763946 N/A 1 FITTING 90, -6 O-RING/-6 JIC
31 055947 055947 2 CS .250-20 X .500 HX G5 ZNYC
32 768515 768515 2 FW .281 X .625 X .051/.080 HD ZNYC
33 768341 768341 1 FILTER ELEMENT
34 768333 768333 1 ZINGA BF SERIES FILTER HEAD

SERVICE

PART NO.

1 032763 032763 1 BREATHER CAP
2 032771 032771 1 STRAINER
3 368803 368803 1 HYDRAULIC OIL RESERVOIR
4 787614 N/A 1 FITTING, -12MORB/-6FORB
5 787473 N/A 1 FITTING, -6MORB/-6 BEADED TUBE
6 781658 N/A 1 FITTING, STR-8MORB/HEX PLUG
7 787655 N/A 2 CASE DRAIN HOSE ASSEMBLY
8 787465 787465 2 FITTING, 90-6MORB/-6BEADEDTUBE
9 034272 034272 3 NT .312-18 HX G5 ZNYC

MFG. PART

NO.

QTY. DESCRIPTION

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 2 (032771 Strainer).

Note:

Seal Kit for hydraulic pump; 780718 (BDP10 Overhaul Seal Kit)

302612 5/05 3-3

3-4 302612 5/05

Chapter 4 Contents

Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Steering and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Pump Belt and Pulley Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

302612 5/05 4-1

Battery Installation

1

2

3

5

8

7

6

4

7

6

12

9

10

1

11

2

13

7

8

14

4-2 302612 5/05

Battery Installation

INDEX

NO.

10 034272 034272 2 NT .312-18 HX G5 ZNYC
11 768820 768820 1 BATTERY GROUND CABLE
12 034280 034280 1 CS .312-18 X .750 HX G5 ZNYC
13 029876 029876 1 LW .312 INT-EXT TOOTH ZNYC
14 779850 779850 2 CB .312-18 X 3.00 FUL ZN

SERVICE

PART NO.

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.5 ZNYC
9 740696 740696 1 BATTERY

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. When perfoming service, disconnect battery ground cable and black
wire of harness,and do not reconnect them until engine is ready to be
started (See owners manual).

302612 5/05 4-3

Deck Lift Assembly

1

3

2

4

6

4

6

10

15

11

4

13

1

14

6

5

7

8

9

12

4

6

7

6

8

11

4

14

14

1

5

4

6

1

14

7

6

8

8

4-4 302612 5/05

Deck Lift Assembly

INDEX

NO.

10 756270 756270 1 CS .312-18 X 1.50 FLTHR GR5 ZNYC
11 034272 034272 1 NT .312-18 HX G5 ZNYC
12 348458 348458 1 DECK LEVELER YOKE
13 781229 781229 1 CE .750X2.25 X1.75 HEADLESS
14 015495 015495 4 STRAIGHT GREASE FITTING
15 784686 784686 1 FW .812 X 1.469 X .134 THK ZNYC

SERVICE

PART NO.

1 348318 348318 1 STOP HANDLE
2 784488 784488 1 DECK LIFT INDICATOR
3 348284 348284 1 HEIGHT ADJUSTMENT STOP
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

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Apply grease at zerks (see owner’s manual).

302612 5/05 4-5

Steering and Brake Assembly

1

2

4

7

8

6

9

14

10

12

13

11

6

31

12

2728

6

29

5

6

13

15

26

17

16

7

30

3

24
12

25

24

12

18

20

12

23

19

12

13

21

12

22

20

15

6

5

32

26

40

21

37

42

43

2

41

44

1

45

47

12

26

46

13

12

38

12

21

33

34

6

26

33

39

3536

4-6 302612 5/05

Steering and Brake Assembly

INDEX

NO.

10 781583 781583 2 BRAKE ROD ASSEMBLY
11 705178 705178 6 CS .375-16 X1.75 HX G5 ZNYC
12 768523 768523 26 FW .343 X .687 X .051/.080 HD ZNYC
13 041152 041152 8 NT .312-24 HX ZNYC
14 348862 348862 4 STEERLEVER BUSHING
15 781153 781153 4 .750 X 1.00 X .50 PLASTIC BUSHING
16 784439 784439 2 LOCK COLLAR
17 368910 368910 1 STEERING CENTER PIVOT TUBE
18 781286 781286 2 PUMP ROD ADJUSTER ASSEMBLY
19 704163 704163 2 CS .250-20 X 2.00 HX G5 ZNYC
20 768515 768515 4 FW .281X.625X.051/.080HD ZNYC
21 034272 034272 8 NT .312-18 HX G5 ZNYC
22 367557 367557 2 PUMP ARM
23 068551 068551 2 NT .250-20 HX NL ZNYC
24 781922 781922 4 DAMPER BALL STUD
25 783696 783696 2 CENTERING DAMPENER
26 086660 086660 12 NT .375-16 HX LK NY
27 367573 367573 1 LH STEERLEVER SUPPORT
28 367565 367565 1 RH STEERLEVER SUPPORT (NOT SHOWN)
29 063198 063198 4 CS 10-24 X .750 HXFLK ZNYC
30 782979 782979 2 CS .375-16 X 4.75 HX G5 ZNYC
31 781211 781211 2 PUSH BUTTON SWITCH
32 059832 059832 4 NT #10-24 HX NL ZN
33 060541 060541 4 SB .500 X .625 SH .375-16 ZN
34 765339 765339 4 INGUS#MFI-0608_05 BUSHING
35 302943 302943 1 LEFT BRAKE PIVOT ARM
36 302935 302935 1 RIGHT BRAKE PIVOT ARM (NOT SHOWN)
37 367169 367169 2 BRAKE LEVER EXTENSION
38 783852 N/A 2 KEY
39 791327 791327 2 BRAKE LINKAGE ASSEMBLYY
40 017004 017004 4 LW .312 MED SPRING ZNYC
41 048876 048876 8 CS .312-18 X .75 HX G8 ZNYC
42 783118 783118 1 BRAKE ASSEMBLY

3

43 783126 783126 1 BRAKE ASSEMBLY (NOT SHOWN)

4

44 782953 782953 2 HUB ASSEMBLY
45 783845 N/A 2 NUT
46 064014 064014 4 CS .312-18 X .875 HX G5 ZNYC
47 712927 712927 8 FW .344 X 1.00 X .12 HRD ZNYC

SERVICE

PART NO.

1 781260 781260 2 STEERING BAR GRIP
2 368704 368704 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 1.00 HX G5 ZNYC

MFG. PART

NO.

QTY. DESCRIPTION

302612 5/05 4-7

NOTES:

1. Torque to 280-310 ft.-lbs. Included with wheel motor.

2. Torque brake assembly mounting bolts to 24 ft.-lbs.

3. 783118 used on left wheel.

4. 783126 used on right wheel.

4-8 302612 5/05

This page intentionally left blank.

302612 5/05 4-9

Pump Belt and Pulley Installation

For mowers with serial
numbers prior to
04040580

35

1

1

14

LOCATION FOR
RUBBER BUMPER

2

25

5

2

26

28

29

27

28

34

30

33

32

31

12

1

12

12

9

2

8

9

17

2

8

2

3

4

10

5

13

14

15

6

1

7

16

4

20

21

22

23

24

4-10 302612 5/05

18

19

3

Pump Belt and Pulley Installation

INDEX

NO.

1 779876 779876 1 ENGINE SC SINGLE PULLEY
2 212076 212076 1 KEY 1/4 SQ X 1.50 LONG
3 797654 797654 1 FW 1.156 X 1.750 X .250 ZY

5

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 785048 785048 1 CS .437-20 X 3.00 HX G5 ZNYC

5
6

8 083196 083196 4 SS .312-18 X .750 SQ-HD ZN

9 325308 325308 2 PULLEY & FAN
10 768127 768127 2 KEY 5MM X 30MM RADIUS ENDS
11 366765 366765 1 CLUTCH ANCHOR ANGLE
12 016527 016527 2 CS .500-13 X 1.00 HX G5 ZNYC
13 767962 767962 4 FW .531 X 1.063 X .090 SAE HD ZN
14 008193 008193 2 NT .500-13 HX G5 ZNYC
15 784918 784918 1 RUBBER BUMPER
16 015495 015495 1 STRAIGHT GREASE FITTING
17 368860 368860 1 PUMP IDLER ARM
18 025296 025296 1 FW .760 X 1.625 X .08 ZN
19 061101 061101 1 NT .750-10 HX NL ZN
20 786848 786848 1 IDLER PULLEY
21 028118 028118 1 FW .62 X 1.00 X.134 ZN
22 781872 781872 1 CS .625-11 X 1.25 HX G5 ZN
23 781302 781302 1 IDLER SPRING
24 786533 786533 1 A-SEC PUMP IDLER BELT
25 787408 N/A 1 CLUTCH
26 778217 N/A 1 CS .437-20 X 2.25 G5 ZNYC
27 036244 N/A 1 CS .375-16 X 1.000 HX G5 ZN
28 767954 N/A 2 FW .406 X .812 X .060 SAE HD ZN
29 054502 N/A 1 NT .375-16 HX GRD 5 ZN
30 055939 N/A 1 CS .250-20 X .750 HX G5 ZN
31 362392 N/A 1 CLUTCH ANCHOR BRACKET
32 778738 N/A 1 .312 WIRING CLAMP
33 768515 N/A 1 FW .281 X .625 X .051/.080 HD ZN/YL
34 024927 N/A 1 NT .250-20 HX GR.5 ZN

SERVICE

PART NO.

785659 N/A 1 CS .437-20 X 2.50 HX G5 ZNYC

748681 N/A 1 GM .75 X 1.35 X 1.06 X .18 GROMMET

MFG.

PART NO.

QTY DESCRIPTION

NOTES:

1. Torque to 45-48 ft.-lbs.

2. Torque to 12-15 ft.-lbs.

3. Do not torque Item 18 (NT .750-10 HX NL ZN), Item 17 (368860 Pump Idler
Arm) should pivot freely.

4. Apply grease at zerks (see owner’s manual).

5. Used on mowers with serial number 05040948 and higher.

6. Used on mower with serial number prior to 05040948.

302612 5/05 4-11

7. Electric clutch burnishing procedure: After installing a new clutch, it is

important to burnish the clutch to insure maximum deck clutch life. In an
open area with no bystanders, set the engine speed to half throttle. 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.

4-12 302612 5/05

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. . . . . . . . . . . . . . . . . . . . . . 5-16

Electrical Schematic–Kawasaki Engines (783894) . . . . . . . . . . . . . 5-18

Electrical Schematic–Honda Engines (787200) . . . . . . . . . . . . . . . 5-20

Electrical Schematic–Kohler Engines (788000). . . . . . . . . . . . . . . . 5-22

302612 5/05 5-1

Kawasaki Engine Installation

2

1

2

13

12

PART OF
WIRE HARNESS

41

15

1

14

16

11

7

17

18

19

3

4

5

8

7

9

6

7

3

10

3

6

7

YEL

6

7

TO BULLET

3

TERMINALS
(MALE-BRN)
(FEMALE-ORG)

21

22

24

22

TO SPADE

3

TERMINAL
PUR

23

3

21

25

31

32

33

43

30

27

21

29

20

7

36

37

P/O ENGINE

3

RED/BLK

34

28

35

40

42

3

PUR

22

26

POSITIVE
BATTERY
CABLE

38

39

5-2 302612 5/05

40

7

Kawasaki Engine Installation

INDEX

NO.

10 786038 786038 1 REMOTE AIR FILTER HOSE

11 779611 779611 1 KAWASAKI 19 HP ENGINE (FH601V, 3600 RPM) (USED ON 927228& 927236)
12 786863 786863 1 19/23/25 KAWASAKI MUFFLER
13 720177 720177 2 CS M 8-1.25 X 20 10.9 HXFLZNYC
14 786566 786566 1 1.375" MUFFLER CLAMP
15 780841 780841 2 KAW (23) MUFFLER GASKET
16 786871 786871 1 KAWASAKI MUFFLER MANIFOLD
17 360693 360693 1 HEAT SHIELD
18 017004 017004 4 LW .312 MED SPRING ZNYC
19 782664 782664 4 NT M8-1.25 HX STAINLESS STEEL
20 796524 796524 1 M20 X 2.5 OIL DRAIN VALVE

8

21 768515 768515 5 FW .281 X .625 X .051/.080HD ZNYC
22 024927 024927 3 NT .250-20 HX GR.5 ZNYC
23 768820 768820 1 BATTERY CABLE
24 783894 783894 1 TRACTOR WIRE HARNESS
25 044255 044255 1 NT #10-32 HX ZN
26 771428 771428 1 RED BATTERY CABLE BOOT
27 030817 030817 1 STARTER SOLENOID
28 055947 055947 2 CS .250-20 X .50 HX G5 ZNYC
29 769166 769166 1 HOUR METER
30 388892 388892 1 SEAT SUPPORT CROSSMEMBER
31 055822 055822 8 CS .375-16 X .750 HX G5 ZNYC
32 767954 767954 8 FW .406 X .812 X .060 SAE HD ZN
33 034280 034280 4 CS .312-18 X .75 HX G5 ZNYC
34 369132 369132 1 MUFFLER GUARD
35 300053 300053 1 ENGINE GUARD
36 029876 029876 4 LW .312 INT-EXT TOOTH ZNYC
37 052837 052837 4 CS .312-18 X1.50 HX G5 ZNYC
38 016527 016527 6 CS .500-13 X1.00 HX G5 ZNYC
39 767962 767962 6 FW .531 X 1.063 X.090 SAE HD ZN
40 064006 064006 2 CS .312-18 X .625 HX G5 ZNYC
41 789131 789131 1 HUSTLER Z FAN CONNECTION CAP
42 792192 792192 1 STARTER RELAY GROUND WIRE
43 808493 808493 10 RIVET NUT, 3/8-16 THREAD
44

SERVICE

PART NO.

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 370288 370288 1 MINI Z REMOTE AIR CLEANER BRACKET
9 036236 036236 2 CS .312-18 X 1.00 HX G5 ZNYC

777656 777656 1 KAWASAKI 23 HP ENGINE (FH680V, 3600 RPM) (USED ON 927244)

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Includes mounting hardware.

2. Includes one (1) of Item 3 (057661 Hose Clamp).

302612 5/05 5-3

3. Part of Item 24 (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. This connector used for optional hydraulic oil cooler fan.

8. 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,

9. Air filter service parts:

785261 MAIN AIR FILTER ELEMENT
763318 VACUATOR VALVE

5-4 302612 5/05

This page intentionally left blank.

302612 5/05 5-5

5-6

302612 5/05

Honda Engine Installation

1

2

3

4

5

4

6

3

34

35

7

8

37

35

36

2

9

10

12

15

16

14

15

10

18

11

13

14

15

17

PART OF
WIRE HARNESS

40

13

14

1

YEL

PART OF
ENGINE

7

1

RED/BLK

19

20

22

23

24

ORG

39

BRN

GRA

7

38

1

PUR

POSITIVE
BATTERY
CABLE

25

14

1

1

32

33

21

ANTI-ROLLOVER
WHEEL BRACKET

26
27

31

30

14

28

29

30

Honda Engine Installation

INDEX

NO.

10 057661 057661 1 HOSE CLAMP
11 797670 N/A 1 HONDA AIRCLEANER HOSE CLAMP
12 782763 782763 1 AIR CLEANER
13 785741 785741 1 MOUNTING BAND
14 034272 034272 10 NT .312-18 HX G5 ZNYC
15 768523 768523 18 FW .343 X .687 X .051/.080HD ZNYC
16 036236 036236 2 CS .312-18 X 1.00 HX G5 ZNYC
17 370288 370288 1 MINI Z REMOTE AIR CLEANER BRACKET
18 785675 785675 1 REMOTE AIR FILTER HOSE
19 787689 787689 1 HONDA OIL DRAIN VALVE
20 787713 787713 1 0.50" LOW PRESSURE HOSE, 3.00" LONG
21 769166 769166 1 HOUR METER
22 388892 388892 1 SEAT SUPPORT CROSSMEMBER
23 767954 767954 8 FW .406 X .812 X .060 SAE HD ZN
24 055822 055822 8 CS .375-16 X .75 HX G5 ZNYC
25 034280 034280 4 CS .312-18 X .75 HX G5 ZNYC
26 029876 029876 4 LW .312 INT-EXT TOOTH ZNYC
27 052837 052837 4 CS .312-18 X1.50 HX G5 ZNYC
28 369132 369132 1 MUFFLER GUARD
29 300053 300053 1 ENGINE GUARD
30 064006 064006 2 CS .312-18 X .625 HX G5 ZNYC
31 767962 767962 6 FW .531 X 1.063 X.090 SAE HD ZN
32 016527 016527 6 CS .500-13 X1.00 HX G5 ZNYC
33 377994 377994 1 MMZ ROLLER HEAT SHIELD
34 056077 056077 2 CS .250-20 X 1.00 HX G5 ZNYC
35 768515 768515 4 FW .281 X.625 X .051/.080 HD ZNYC
36 024927 024927 2 NT .250-20 HX GR.5 ZNYC
37 785477 N/A 1 HONDA 20 AMP RECTIFIER
38 077545 N/A 1 NT M8-1.25 10 HX ZNYC
39 787200 787200 1 TRACTOR WIRE HARNESS

SERVICE

PART NO.

1 785014 785014 1 HONDA 24 HP ENGINE (USED ON 927251)
2 784843 784843 1 HONDA MUFFLER
3 720177 720177 2 CS M 8-1.25 X 20 10.9 HXFLZNYC
4 785543 N/A 2 HONDA MUFFLER GASKET
5 784959 784959 1 MUFFLER MANIFOLD
6 785378 785378 1 1.50" MUFFLER CLAMP
7 017004 N/A 5 LW .312 MED SPRING ZNYC
8 782664 N/A 4 NT M8-1.25 HX STAINLESS STEEL
9 786673 786673 1 DONALDSON AIR CLEANER CAP

789131 789131 1 HUSTLER Z FAN CONNECTION CAP

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Part of Item 39 (787200 Tractor Wire Harness).

2. Includes one (1) of Item 10 (057661 Hose Clamp).

3. Engine oil capacity; 2 US quarts.

4. Includes mounting hardware.

5. Engine RPM to be set at 3600±50.

302612 5/05 5-7

6. When installing lower hose clamp on air cleaner hose, install as low as
possible (against carburetor inlet).

7. This connector used for optional hydraulic oil cooler fan.

8. Air filter service parts:

785261 MAIN AIR FILTER ELEMENT
763318 VACUATOR VALVE

5-8 302612 5/05

This page intentionally left blank.

302612 5/05 5-9

Kohler Engine Installation

1

2

3

4

7

2

1

6

4

5

10

16

8

9

9

13

14

21

11

14

15

17

9

12

13

14

13

14

18

35

PART OF

7

WIRE HARNESS

3

RED/BLK

23

24

34

POSITIVE
BATTERY
CABLE

PUR (P/O ENGINE)

2

25

22

14

33

30

20

27

26

31

19

28

29

14

32

5-10 302612 5/05

Kohler Engine Installation

INDEX

NO.

4

10 788943 788943 1 AIR FILTER INDICATOR
11 782763 782763 1 AIR CLEANER
12 785741 785741 1 MOUNTING BAND
13 034272 034272 10 NT .312-18 HX G5 ZNYC
14 768523 768523 18 FW .343 X .687 X .051/.080 HD ZNYC
15 036236 036236 2 CS .312-18 X 1.00 HX G5
16 370288 370288 1 REMOTE A/C BRACKET
17 795310 795310 1 REMOTE AIR FILTER HOSE
18 796672 796672 1 3/8-18 OIL DRAIN VALVE

8

19 787713 787713 1 0.50" LOW PRESSUR HOSE

8

20 769166 769166 1 HOUR METER
21 388892 388892 1 MINI Z CROSSMEMBER
22 808493 808493 4 RIVET NUT, 3/8-16 THREAD
23 767954 767954 8 FW .406 X .812 X .060 SAE ZN
24 055822 055822 8 CS .375-16 X .750 HX G5 ZNYC
25 034280 034280 4 CS .312-18 X .750 HX G5 ZNYC
26 029876 029876 4 LW .312 INT-EXT TOOTH ZNYC
27 052837 052837 4 CS .312-18X1.500 HX G5 ZNYC
28 369132 369132 1 MINI Z MUFFLER GUARD
29 300053 300053 1 ENGINE GUARD
30 016527 016527 6 CS .500-13X1.00 HX G5 ZNYC
31 767962 767962 6 FW .531X 1.063X.090 SAE ZN
32 064006 064006 2 CS .312-18X .625 HX G5 ZNYC
33 377994 377994 1 MMZ ROLLER HEAT SHIELD
34 788000 788000 1 WIRE HARNESS
35 789131 789131 1 HUSTLER Z FAN CONNECTION CAP

SERVICE

PART NO.

1 788216 788216 1 KOHLER CV740 ENGINE (27 HP) USED ON 927527

794925 794925 1 KOHLER V20S ENGINE (20HP) USED ON 927483 & 927491
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 1.50" CLAMP
7 788026 788026 1 KOHLER 27-2 MANIFOLD
8 786673 786673 1 DONALDSON AIR CLEANER CAP
9 057661 057661 HOSE CLAMP

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Includes mounting hardware

2. Supplied with engine.

3. Part of 788000 Wire Harness.

4. Includes one (1) of Item 9(057661 Hose Clamp).

5. Engine oil capacity: 2 US quarts.

6. Engine RPM to be set at 3600±50.

7. This connector used for optional hydraulic oil cooler fan.

8. Used on mowers with serial number 05031280 and higher. These parts

302612 5/05 5-11

replace drain hose, 90° fitting, and drain plug, on mowers with serial
numbers prior to 05031280,

9. Air filter service parts:

785261 MAIN AIR FILTER ELEMENT
763318 VACUATOR VALVE

5-12 302612 5/05

This page intentionally left blank.

302612 5/05 5-13

Fuel System Installation

1

2

10

6

2

4

6

7

12

8

1

9

SEAT SUPPORT
CROSSMEMBER

5

6

6

1

3

1

9

8

11

6

2

4

8

1

9

5-14 302612 5/05

Fuel System Installation

ITEM 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 N/A 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

9 055822 055822 12 CS .375-16 X .75 HX G5 ZNYC
10 015818 015818 1 FUEL LINE 12.5” TOTAL
11 015818 015818 1 FUEL LINE 29" TOTAL
12 015818 015818 1 FUEL LINE 7.5” TOTAL KAWASAKI
12 015818 015818 1 FUEL LINE 22” TOTAL HONDA

SERVICE

PART NO.

MFG. PART

NO.

1. Torque to 20 ft.-lbs.

2. Supplied with new fuel tank.

QTY DESCRIPTION

NOTES:

302612 5/05 5-15

Instrument Panel Installation/Assembly

1

2

3

4

1

6

7

1

9

5

8

5

10

8

12

13

14

10

15a

11

1

8

6

5a KAWASAKI
10a HONDA

1

RIGHT SIDE
FUEL TANK

13

12

FUSE SIZE AND LOCATIONS

20a

5-16 302612 5/05

Instrument Panel Installation/Assembly

ITEM NO.

1 785030 785030 1 Z CHOKE CABLE (KAWASAKI ENGINES)

1 786657 786657 1 Z CHOKE CABLE (HONDA ENGINES)

2 776476 776476 1 PTO SWITCH

3 712257 712257 1 RED INDICATOR LIGHT

4 083022 N/A 2 IGNITION KEY

5 045898 045898 1 KEY SWITCH

6 059832 059832 6 NT #10-24 HX NL ZN

7 026237 N/A 3 RELAY

8 704932 704932 6 FW .219 X .500 X .048 ZN

9 762195 N/A 1 DELAY MODULE
10 714998 714998 3 MS #10-24 X .625 HX ZN
11 778365 778365 1 THROTTLE/CHOKE CABLE
12 055947 055947 3 CS .250-20 X .500 HX G5 ZN
13 768515 768515 3 FW .281 X .625 X .051 /.080 HD ZN/YL
14 349308 349308 1 INSTRUMENT PANEL

SERVICE

PART NO.

785808 785808 1 INDAK COATED KEY

MFG. PART

NO.

1. Part of Tractor Wire Harness.

QTY DESCRIPTION

NOTES:

302612 5/05 5-17

Electrical Schematic–Kawasaki Engines (783894)

5-18 302612 5/05

Electrical Schematic–Kawasaki Engines (783894)

302612 5/05 5-19

Electrical Schematic–Honda Engines (787200)

5-20 302612 5/05

Electrical Schematic–Honda Engines (787200)

302612 5/05 5-21

Electrical Schematic–Kohler Engines (788000)

5-22 302612 5/05

Electrical Schematic–Kohler Engines (788000)

302612 5/05 5-23

5-24 302612 5/05

Chapter 6 Contents

Front Wheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Front Wheel Breakdown - 786061. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Drive Wheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Anti-Rollover Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

302612 5/05 6-1

Front Wheel Assembly

1

2

3

4

2

5

TRACTOR
FRAME

1

2

3

6

2

2

5

7

8

9

10

10

2

11

10

5

6

5

7

4

8

10

9

12

1

1

12

6-2 302612 5/05

Front Wheel Assembly

INDEX NO.

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 712976 712976 2 FW .531 X 1.375 X .125 ZNYC
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 ZN
11 061101 061101 2 NT .750-10 HX NL ZN
12 786061 786061 2 WHEEL & TIRE ASSEMBLY

SERVICE

PART NO.

795245 N/A 2 OPTIONAL SEMI-PNEUMATIC TIRE/WHEEL ASSEMBLY

MFG. PART

NO.

QTY DESCRIPTION

NOTES:

1. Apply grease to zerks (see owner’s manual).

2. Assemble with extended inner race down.

302612 5/05 6-3

Front Wheel Breakdown - 786061

1

2

3

1

5

ITEM NO.

1 786103 N/A 2 WHEEL BEARING

2

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

2

SERVICE

PART NO.

MFG. PART

NO.

QTY DESCRIPTION

NOTES:

1. Inflate tire to 8-10 psi.

2. Service parts for 795245 (Optional Semi-Pneumatic Tire/Wheel
Assembly), also.

4

6-4 302612 5/05

Drive Wheel Assembly

1

6

2

4

1

5

INDEX NO.

1 782078 782078 2 WHEEL/TIRE ASSEMBLY 23 X 9.50
2 782284 N/A 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)

PART NO.

1. Torque to 65-75 ft. lbs.

SERVICE

MFG. PART

NO.

3

QTY DESCRIPTION

NOTES:

2. Inflate tire to 8-10 psi.

302612 5/05 6-5

Anti-Rollover Wheel Assembly

4

3

1

2

5

1

5

2

4

INDEX NO.

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

SERVICE

PART NO.

MFG. PART

NO.

QTY DESCRIPTION

5

1

6

5

7

7

8

NOTES:

1. Do not torque, wheel must turn freely.

2. Mowers with serial number prior to 04110938 will have anti rollover
wheel brackets as part of tractor frame.

6-6 302612 5/05

Chapter 7 Contents

Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Blade Spindle Assembly Breakdown. . . . . . . . . . . . . . . . . . . . . . . . . 7-8

302612 5/05 7-1

Deck Assembly

2

4

1

3

3

9

12

5

7

6

12

2

4

13

16

17

8

15

13

15

15

2

16

13

14

18

15

4

13

2

14

16

13

8

1

12

4

15

14

13

10

11

4

8

8

2

16

10

2

12A

2

16A

13A

14A

44" DECK

15A

1A

5

7-2 302612 5/05

12

Deck Assembly

INDEX

NO.

5

1A 546382 367946 1 44" MINI-Z DECK

10 015495 015495 2 STRAIGHT GREASE FITTING
11 036244 036244 6 CS .375-16 X1.00 HX G5 ZNYC
12 781708 N/A 4 CS .500-13 X 4.25 HX G5 ZNYC

12A 781708 N/A 3 CS .500-13 X 4.25 HX G5 ZNYC

13 767962 N/A 8 FW .531 X 1.063 X.090 SAE HD ZN

13A 767962 N/A 6 FW .531 X 1.063 X.090 SAE HD ZN

14 053199 N/A 4 NT .500-13 HX JAM ZNYC

14A 053199 N/A 3 NT .500-13 HX JAM ZNYC

15 781567 781567 4 NT .50-13 HX LK NY

15A 781567 781567 3 NT .50-13 HX LK NY

16 031997 N/A 4 ANTI-SCALP WHEEL

16A 031997 N/A 3 ANTI-SCALP WHEEL

17 781880 781880 1 BUMPER
18 055822 055822 2 CS .375-16 X .750 HX G5 ZNYC

4

SERVICE

PART NO.

1 546408 367730 1 52" MINI-Z DECK

2 3 57111 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 .312-18 HX NL ZNYC
8 N/A 808485 4 5/16-18 THREAD RIVET NUT
9 389189 389189 1 PUSHER

788166 788166 4 ANTI-SCALP WHEEL ASSEMBLY

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Do not torque, Item 2 (357111 Discharge Chute) must pivot freely.

2. Factory assembled in top hole for shipping purposes.

3. Item 9 (389189 Pusher) installed as shown with zerks pointing upward,
apply grease to zerks.

4. Includes items 12(A), 13(A), 14(A), and 16(A).

5. Service part deck includes decals, see “52" Deck Decals” on page 9-4
and “44" Deck Decals” on page 9-5.

302612 5/05 7-3

Deck Pulley Assembly

2

10

11

1

2

3

4

5

6

7

22

21

13

12

7

22

18

23

25

14

22
24

13

8

9

7

1

15

14

16

17

18

22

19

26

21

27

29

20

18

1

17

7-4 302612 5/05

Deck Pulley Assembly

INDEX

NO.

10 259812 259812 1 SPRING CHAIN
11 781302 781302 1 IDLER SPRING
12 016972 016972 2 NT .625-11 HX G5 ZNYC
13 781385 781385 2 IDLER PULLEY
14 786335 786335 1 UHMW (.03 THICK)
15 781872 781872 6 CS .625-11 X 1.25 HX G5 ZNYC
16 782474 782474 8 CW .631 2.25 X .187 PNT
17 786889 786889 3 DECK DRIVE PULLEY (52" DECKS)

5

18 054502 054502 12 NT .375-16 HX GRD 5 ZNYC
19 767954 767954 24 FW .406 X .812 X .060 SAE HD ZN
20 368993 368993 1 L.S. PULLEY COVER (52" DECKS)

21 368985 368985 1 R.S. PULLEY COVER (52" DECKS)

22 792002 792002 4 5/16-18 X 3/4"MALE KNOB

3

23 794875 794875 2 CS .625-11 X 3.50 FULL HX G5 ZN
24 768523 768523 6 FW .343 X .687 X .051/.080 HD ZNYC
25 058776 058776 6 NT .312-18 HX NL ZNYC
26 783506 783506 3 BLADE SPINDLE ASSEMBLY
27 005116 005116 12 CS .375-16 X 1.375 HX G5 ZNYC
28 795526 795526 3 BLADE, F17.86"-H-F-CW

4

29 796300 796300 3 BLADE, F15.66"-H-F-CW

4

30 079186 079186 5 CS .312-18 X1.25 HX G5 ZNYC
31 712927 712927 5 FW .344 X 1.00 X .12 HRD ZNYC
32 378745 N/A 1 DECK IDLER
33 364315 N/A 1 SPRING CHAIN

SERVICE

PART NO.

1 789388 789388 1 52" DECK BELT

791335 791335 1 44" DECK BELT
2 784199 784199 1 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 5.00" PULLEY
9 102970 102970 1 MINI Z DECK IDLER

792689 792689 3 5.00" OD PULLEY (44" DECKS)

368977 368977 1 L.S. PULLEY COVER (44" DECKS)

368944 368944 1 R.S. PULLEY COVER (44" DECKS)

075291 N/A 4 CLAMP KNOB

783753 N/A 3 BLADE, 17.86"-L-F-CW

784256 N/A 3 BLADE,15.66"-L-F-CW

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Torque to 118 ft. lbs.

2. See “Deck Belt Routing and Tensioning” on page 8-3 for belt tensioning.

3. Used on mowers with serial number prior to 04032000.

302612 5/05 7-5

4. Used on mower with serial number prior to 05050800.

31

33

11

3

230

4

5

6

12

7

13

7

5. Used on mowers with serial number 05050800 and higher.

6. Optional blades:

785428 16" CW Gator Blade
785436 18" CW Gator Blade

8

32

7-6 302612 5/05

Blade Spindle Assembly Breakdown

1

3

2

4

2

5

INDEX

NO.

SERVICE

PART NO.

1 783548 783548 1 BLADE SPINDLE RETAINING RING
2 783555 783555 2 BLADE SPINDLE BEARING
3 783530 783530 1 BLADE SPINDLE SPACER
4 783514 783514 1 BLADE SPINDLE HOUSING
5 783522 783522 1 BLADE SPINDLE SHAFT

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

302612 5/05 7-7

7-8 302612 5/05

Chapter 8 Contents

Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Deck Belt Routing and Tensioning. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

302612 5/05 8-1

Deck Installation

TRACTOR
ASSEMBLY

1

1

2

3

4

5

5

INDEX

NO.

SERVICE

PART NO.

1 055749 055749 4 CS .437-14 X 1.750 HX G5 ZNYC
2 051169 051169 2 CS .750-10X3.000 HX G5 ZNYC
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

MFG. PART

NO.

QTY. DESCRIPTION

DECK
ASSEMBLY

NOTES:

1. 52" Deck installation shown, 44" Deck installation is similar.

8-2 302612 5/05

302612 5/05

8-3

Deck Belt Routing and Tensioning

1

NOTES:

1. Spring length after tensioning new belt, measured from outside of hook
to outside of hook.

2. Route belt as shown.

8-4 302612 5/05

Chapter 9 Contents

Tractor Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

52" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

44" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

302612 5/05 9-1

Tractor Decals

11

B

B

2

3

1

6

5

AA

7

8

4

12

10

16

9

13

BOTTOM OF
SEAT PAN

15

14

9-2 302612 5/05

Tractor Decals

INDEX

NO.

10 782136 782136 1 Z OPERATION DECAL
11 785154 785154 1 DECK HEIGHT DECAL
12 793588 793588 1 HUSTLER NAME PLATE
13 727016 727016 1 BATTERY DECAL
14 785188 785188 1 Z ARMREST WARNING DECAL
15 788968 788968 1 ENGINE COMPARTMENT DECAL
16 771436 771436 1 STABILIZER DECAL

SERVICE

PART NO.

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 786814 786814 1 HUSTLER MINI-Z ID DECAL
8 727172 727172 1 "MADE IN U.S.A." DECAL
9 N/A 083279 1 TURF PROD SERIAL NO PLATE

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

302612 5/05 9-3

52" Deck Decals

1

8

2

3

7

4

3

5

5

6

INDEX

NO.

SERVICE

PART NO.

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." DECAL
8 797845 797845 1 FUSION DECAL

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

9-4 302612 5/05

44" Deck Decals

1

8

2

3

4

7

3

5

5

6

INDEX

NO.

SERVICE

PART NO.

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 784801 784801 1 DECK 44" ID DECAL
7 727172 727172 1 "MADE IN U.S.A." DECAL
8 797845 797845 1 FUSION DECAL

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

302612 5/05 9-5

9-6 302612 5/05

Chapter 10 Contents

Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

302612 5/05 10-1

Seat Installation

19

18

6

5

3

3

4

2

9

8

15

9

7

1

1

11

10

12

13

16

14

16

17

2

10-2 302612 5/05

Seat Installation

INDEX

NO.

2

10 724716 724716 1 FIBER WASHER
11 350421 350421 1 SEAT PAN STOP
12 388983 388983 1 SEAT PAN
13 768523 768523 4 FW .343 X .687 X .051/.080 HD ZNYC
14 034272 034272 4 NT .312-18 HX G5 ZNYC
15 080358 080358 1 GM .50 X 1.00 X .75 X .12
16 781880 781880 2 .500 X 1.00X .312 X.188 BUMPER
17 052860 052860 2 CS .375-16 X 1.25 HX G5 ZNYC
18 768523 768523 2 FW .343 X .687 X .051/.080 HD ZNYC
19 055822 055822 2 CS .375-16 X .75 HX G5 ZNYC

SERVICE

PART NO.

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 793661 793661 1 MICHIGAN STANDARD SEAT

781104 781104 1 MILSCO STANDARD SEAT
8 000331 000331 3 SMALL/SHORT WIRE TIE
9 086660 086660 3 NT .375-16 HX LK NY

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Must pivot freely.

2. Used on mowers with serial number prior to 04032000.

3. Service parts available for Michigan seat;

PART NO. DESCRIPTION

793695 SLIDE KIT
797464 L.H. ARMREST ASSMBLY
797472 R.H. ARMREST ASSMBLY
793315 SEAT SWITCH
797480 MOLDED ARMREST KIT (INCLUDES BOTH ARMRESTS)
793273 ARMREST STOP ASSY

4. Service parts available for Milsco seats:

PART NO. DESCRIPTION

782144 ADJUSTER, STANDARD AND LOW PROFILE SUSPENSION SEAT
782151 ARMREST FOR STANDARD SEAT
782177 OPERATOR PRESENCE SWITCH
783472 Z ARMREST ONLY KIT

302612 5/05 10-3

Chapter 11 Contents

Maintenance & Adjustments Safety Precautions . . . . . . . . . . . . . . .11-3

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-7

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-15

302612_0606

11-1

302612_0606

11-2

302612_0606

11-3

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.
IMPORTANT calls attention to special mechanical information and
NOTE: emphasizes general information worthy of special attention.

All operators/mechanics should read this manual, or be instructed about
safe operating and maintenance procedures. This is the owner’s
responsibility.

Improper use or maintenance by the operator, mechanic, or owner
can result in injury. To reduce the potential for injury, comply with
these safety instructions and always pay attention to the safety alert ▲
symbol, which means DANGER or WARNING - “personal safety
instructions.” Failure to comply with the instructions may result in
personal injury or death.

Incorrect usage of this machine may result in severe injury.
Personnel operating and maintaining it should be trained in the proper
use and should read the manuals completely and thoroughly before
attempting to set-up, operate, adjust, or service this machine.

The Quick Reference Decals, located in front of and to the right of the
seat, are designed to give the operator/mechanic brief information needed
in the daily operation and service of the machine. These decals are not
intended to be used in place of this manual but instead is to be used as an
extension of this manual. These decals should not be removed or
obliterated. Replace these decals if they become unreadable.

It is the owner’s responsibility to make certain that the
operator/mechanic reads and understands this manual and all decals before
operating this machine. It is also the owner’s responsibility to make
certain that the operator/mechanic is a qualified and physically able
individual, properly trained in the operation of this equipment. Local
regulations may restrict the age of the operator/mechanic.

The owner should also ensure that the operator/mechanic know that they
are responsible for their own safety as well as the safety of other persons
within the vicinity. Remember, the operator/mechanic is responsible for
accidents or hazards occurring to other people or their property.

Safe Maintenance & Adjustment Practices

This product is capable of amputating hands and feet and throwing
objects. Always follow all safety instructions to avoid serious injury or
death.

▲

Unless specifically required, DO NOT have engine running when
servicing or making adjustments to tractor. Place control levers in
the park brake position, disengage deck clutch, remove ignition
switch key and disconnect the negative battery cable. Repairs or
maintenance requiring engine power should be performed by trained
personnel only. To prevent carbon monoxide poisoning, be sure
proper ventilation is available when engine must be operated in an
enclosed area.

▲

Follow daily and weekly checklists, making sure hoses are tightly
secured and bolts are tightened.

▲

Keep your machine clean and remove any deposits of trash and
clippings, which can cause engine fires and hydraulic overheating as

well as excessive belt wear. Clean up oil or fuel spillage. Allow
machine to cool before storing.

▲▲

Clean flammable material from machine. Prevent fires by
keeping engine compartment, battery, hydraulic lines, fuel line,
fuel tank and operator’s station clean of accumulated trash,
grass clippings, and other debris. Always clean up spilled fuel
and oil.

▲ Always wear adequate ear protection, such as earplugs, when

operating this equipment as prolonged exposure to uncomfortable or
loud noises can cause impairment or loss of hearing. Do not wear
radios or music headphones while operating the machinery. Safe
operation requires your full attention.

▲

Never put hands or feet under any part of the machine while it is
running.

▲

Except when changing or checking belt, always keep belt covers on
mower for safety as well as cleanliness.

▲

Stop the engine before removing the grass catcher or unclogging the
discharge chute. Never clear the discharge chute with the engine
running. Turn off the engine and be sure the blades have stopped
before cleaning. Use a stick to clear a plugged discharge area.

Never use your hand!

▲

Exercise caution when loading or unloading the machine onto a
trailer or truck.

▲

Always wear safety goggles or safety glasses with side shields when
operating the mower.

▲

Never leave machine unattended with ignition key in switch,
especially with children present.

▲

Be alert and turn the machine off if children enter the area.

▲

Always wear adequate eye protection when servicing the battery,
hydraulic system, cooling system or when grinding mower blades
and removing accumulated debris.

▲

Use extra caution when handling gasoline and other fuels. They are
flammable and vapors are explosive.

▲

Never refuel tractor while engine is running; never refuel near an
open flame or near devices which can create a spark. Refuel
outdoors preferably, or in well ventilated areas.

▲

Never attempt to start engine when there is a strong odor of gasoline
fumes present. Locate and correct cause.

▲

Never run the engine in an enclosed area unless exhaust is vented to
the outside. Exhaust gases contain carbon monoxide which is
odorless and deadly poison.

▲

Never attempt to make any adjustments or repairs to the tractor drive
system, mower deck or any attachment while the tractor engine is
running or deck clutch is engaged. Repairs or maintenance requiring
engine power should be performed by trained personnel only.

▲

Never work under the machine or attachment unless it is safely
supported with jack stands. Make certain machine is secure when it
is raised and placed on the jack stands. The jack stands should not
allow the machine to move when the engine is running and the drive
wheels are rotating. Use only certified jack stands. Use only
appropriate jack stands, with a minimum weight rating of 2000
pounds to block the unit up. Use in pairs only. Follow the
instructions supplied with the vehicle stands.

▲

Before working on or under the deck, make certain engine cannot be
accidentally started. Shut engine off and remove ignition switch key
for maximum safety. Repairs or maintenance requiring engine
power should be performed by trained personnel only.

▲

Use a stick or similar instrument to clean under the mower making
sure that no part of the body, especially arms and hands are under
mower.

▲

Exercise caution when working under the deck as the mower blades
are extremely sharp. Wearing gloves or wrapping the blade(s) is
advisable when working around or with the blades.

▲

Do not touch hot parts of machine.

▲

Keep nuts and bolts tight, especially the blade attachment bolts.
Keep equipment in good condition.

▲

Never tamper with safety devices. Check their proper operation
regularly.

SAFETY PRECAUTIONS

▲

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

Using a ramp

▲

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. Having a full width ramp provides a surface
for the tractor frame to contact if the unit starts to tip backwards. It
also reduces the risk of a wheel going off and the machine tipping
over.

▲

Do not exceed a 15 degree angle between the ramp and the ground
or between the ramp and the trailer or truck.

▲

When on a ramp avoid sudden acceleration

302612_0606

11-4

302612_0606

11-5

Read Owner’s Manual and Quick

Reference Decal before attempting to

operate this machine.

Do not smoke while refueling.
Do not fill tank with engine running, or
while the engine is hot.
Allow engine to cool before storing
machine inside a building.
Store away from open flame or spark if
there is fuel in tank.
Clean up any gasoline spills.
Do not refuel while in enclosed trailer or
other enclosed areas

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.

Avoid skin contact with battery acid.
Always wear eye protection when
checking the battery, acid can cause
serious injury to skin and eyes. If contact
occurs, flush area with clean water and
call physician immediately. Acid will also
damage clothing.
Do not allow open flame near the battery
when charging.
Hydrogen gas forms inside the battery.
This gas is both toxic and flammable and
may cause an explosion if exposed to
flame. Always remove the negative
ground first and replace it last.
Do not overfill battery.
Electrolyte may overflow and damage
paint, wiring or structure. When cleaning
the battery, use soap and water. Be
careful not to get soap and water into the
battery. Use soda mixed in water to clean
corrosion off the terminals.

Hydraulic fluid escaping under pressure
can penetrate skin.
Hydraulic fluid may also cause infection in
a minor cut or opening in the skin; if
exposed to hydraulic fluid, see a doctor at
once.
Before applying pressure to hydraulic
system, make sure all connections are
tight and all hoses and lines are in good
condition.
Relieve all pressure in the system before
disconnecting or working on hydraulic
lines.
To find a leak under pressure, use a
piece of cardboard or wood – never use
your hands.
To relieve all pressure in system, turn
engine off and lower attachment.

Do not remove or modify stabilizer
wheels or rear engine guard or injury can
result.
Never stop suddenly while backing down
slopes. This action may result in a
reaction of the tractor that can cause
serious physical injury.

Never operate the mower deck with side
deflector removed or in raised position,
except when the grass catcher
attachment is being used.

Hot surface!

Keep shields or covers in place while
machine is in operation.
Keep hands away from rotating pulleys
and belts.

Whirling blades! Keep hands and feet
away.
Beware of thrown objects.

If you loose steering control while

operating the machine, place the steering
control levers in the park brake position
immediately. Inspect the machine and
involve your Hustler dealer to resolve the
problem before continuing to operate.

If pump belt fails, steering control will
be lost. Refer to owner’s manual for

inspection and replacement intervals and
refer to above paragraph for emergency
procedures.

Part Number

600899

Part Number

727016

Part Number

727420

Part Number

727438

Part Number

727453

Part Number

771436

Part Number

727008

Part Number

779280

Keep engine and pump compart­ment(s) clean (especially in exhaust
area) to prevent fire and provide
maximum engine and hydraulic
cooling.

Part Number

788968

If you lose steering control while operating the machine, place the steering
control levers in the park brake position immediately. Inspect the machine and

involve your Hustler dealer to resolve the problem before continuing to operate.

If pump belt fails, steering control will be lost. Refer to owner’s manual for
inspection and replacement intervals and refer to above paragraph for
emergency procedures.

600899

302612_0606

11-6

11-7

302612_0606

MAINTENANCE

MAINTENANCE LOCATOR

CHART

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. Deck Height Pivot Zerks (4)

13. Park Brake Switch

14. Drive Tire

15. Pump Idler Zerk (1)

16. Deck Belt

17. Pump Belt

18. Blades

6

11

2A

4

3

12

16

10

12

10

5

13

7

1A

6

13

12

12

Figure 11-1

18

18

8

8

16

2B

14

9

14

17

15

Viewed from bottom of tractor

1B

2C

NOTES:

1. Initial oil change is after 5 hours of operation. Thereafter, change oil after every 40

hours operation. Change more often under dusty or dirty conditions and during hot weather
periods.

2. Torque initially and after first 2 hours of operation.

3. Perform initial hydraulic filter change after 50 hours (one week) of operation.

4. Change engine oil filter per the engine manufacturer’s recommendations. Refer to

Engine Owner’s Manual for recommendations and other maintenance items.

5. Service more often under dusty or dirty conditions. Use caution when servicing to prevent
dust contamination in the engine. Do not clean filter element. Replace with a new one.

6. Pump drive belt only - Inspect every 100 hours and replace if worn or cracking is
noticed. Otherwise, replace every 400 hours or 2 years whichever comes first.

7. Check fuel line hoses, fuel valve and grommet for any cracks or leaks.
REFERENCES:
a — Refer to Engine Owner’s Manual

NOTE: After completing maintenance cycle (500 hours), repeat cycle.

Introduction

Regular maintenance is the best prevention for costly downtime or
expensive, premature repair. The following pages contain suggested
maintenance information and schedules which the operator should follow
on a routine basis.

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. Correcting the problem as quickly as possible is the
best insurance.

Clear away heavy build-up of grease, oil and dirt, especially in the
engine and hydraulic reservoir area; minute dust particle 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, especially when grass is wet or has high moisture content. This
build-up will harden, restricting blade and air movement and will probably
show a poorer quality of cutting. Therefore it should be removed routinely.

To do this it will be necessary to raise and block the deck in the full up
position and scrape the build-up from underneath.

Some repairs require the assistance of a trained service mechanic and
should not be attempted by unskilled personnel. Consult your Hustler
service center when assistance is needed.

Torque values

WARNING: Particular attention must be given to tightening the

drive wheel lug nuts, wheel motor nuts, and blade spindle bolts.
Failure to correctly torque these items may result in the loss of a
wheel or blade, which can cause serious damage or personal
injury.

Torque values given below:

Ft-lbs. Nm

Wheel (lug) nuts..................................................65-75 ............88.14-101.7

Wheel motor nut ............................................290-310 ...........393.2-420.4

Blade spindle bolt top . . . . . . . . . . . . . . . . . . .118 ..................160.01

Blade spindle bolt bottom . . . . . . . . . . . . . . . .118 ..................160.01

It is recommended that these be checked after the first 2 hours of
operation, initially and every 50 hours following removal for repair or
replacement.

For all other torques refer to the tractor parts manual for standard torque
chart.

For engine torque values, see engine owner’s manual.

Tires

It is important for level mowing that the tires have the same amount of
air pressure. The recommended pressure are:

Drive wheels...................................................................8-10 psi

Gauge wheels .................................................................8-10 psi

Solid fill tires are not recommended for Hustler turf equipment. On
any machine, with solid filled tires, the warranty claim will be denied.

WARNING: Explosive separation of a tire and rim can cause
serious injury or death.
Do not attempt to mount a tire without the proper equipment and
experience to perform the task.
Always maintain the correct tire pressure and never over inflate.
Never weld or heat a wheel and tire assembly as an explosion
may occur. Welding can weaken or deform a wheel.
When inflating tires stand to one side and not in front of or over
the tire assembly.
Check tires for low pressure, blemishes, damaged rims or missing
lug bolts and nuts.

Hour meter

To recognize when your machine needs servicing, check the hour
meter and the maintenance schedule. The hour meter shows the number of
hours the engine has run and the maintenance schedule lists the service
intervals. Fig. 11-2

Lubrication

1. Grease the front gauge wheel bearings per the Maintenance
Schedule. Use SAE multi-purpose grease.

2. Grease the four deck lift pivots, located to the side of the
operator’s footrest per the Maintenance Schedule. Use SAE

11-8

302612_0606

Figure 11-2

Hour

meter

WEEKLY MONTHLY ANNUALLY OR

SERVICE AT OR 50 OR 100 500

INTERVALS INDICATED HOURS HOURS HOURS

Verify safety start interlock system Daily

Visually inspect unit for loose

hardware and/or damaged parts Daily

Visually inspect tires Daily

Check oil level, engine (1) Daily or every 4 hrs.

Clean air intake screen (5) Daily or every 4 hrs.

Check fuel level Daily

Blades - sharpen & securely fastened Daily

Discharge chute - securely in place &

in lowest position Daily

Clean engine and pump compartments Daily

Replace air cleaner paper element (5) As needed

Grease deck pusher arms x

Grease pump idler x

Grease deck height pivots x

Grease gauge wheel bearings x

Change engine oil & filter (1) (4) x

Clean cylinder and head fins (a) x

Check battery connections x

Check tire pressure with a gauge x

Check hydraulic oil level x

Clean engine exterior (a) x

Clean and regap spark plugs (a) x

Check pump and deck belt tension

& condition (6) x

Check fuel and hydraulic lines (7) x

Check fuel valve and grommet (7) x

Tighten lug nuts on wheels (2) x

Change fuel filter x

Clean or replace hydraulic fill cap x

Change hydraulic filter and oil (3) x

Replace spark plugs x

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.

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. Otherwise,
follow battery manufacturer’s maintenance, safety, storing and charging
specifications.

The battery is located under the seat. Fig. 11-3

WARNING: Battery posts, terminals, and related accessories
contain lead and lead compounds, chemicals known to cause
cancer and reproductive harm. Wash hands after handling.

WARNING: Avoid skin contact with battery acid.
Always wear eye protection when checking the battery, acid can
cause serious injury to skin and eyes. If contact occurs, flush area
with clean water and call physician immediately. Acid will also
damage clothing.
Do not allow open flame near the battery when charging.
Hydrogen gas forms inside the battery. This gas is both toxic and
flammable and may cause an explosion if exposed to flame.
Always remove the negative ground first and replace it last.
Do not overfill battery.
Electrolyte may overflow and damage paint, wiring or structure.
When cleaning the battery, use soap and water. Be careful not to
get soap and water into the battery. Use soda mixed in water to
clean corrosion off the terminals.

WARNING: Shorts caused by battery terminals or metal tools
touching metal tractor components can cause sparks. Sparks can
cause a battery gas explosion which will result in personal injury.
Prevent the battery terminals from touching any metal tractor
parts when removing or installing the battery.
Do not allow metal tools to short between the battery terminals
and metal tractor parts.

WARNING: Incorrect battery cable routing could cause damage
to the tractor and battery cables. This can cause sparks which can
cause a battery gas explosion which will result in personal injury.
Always disconnect the negative (black) battery cable before
disconnecting the positive (red) cable.

Common circuit failures are usually caused by shorting, corroded or
dirty terminals; loose connections, defective wire insulation or broken
wires. Switches, solenoids and ignition components may also fail, causing
a shorted or open circuit.

Before attempting any failure diagnosis of the electrical system, use a
test light or voltmeter to check the battery voltage. If the battery voltage is
satisfactory, check the cleanliness and tightness of the terminals and ground
connections. A general understanding of electrical servicing and use of
basic test equipment is necessary for troubleshooting and repair.

Major overhaul or repair of the starting motor or alternator should be
performed by trained technicians only.

Burnishing the electric clutch

WARNING: To insure maximum performance and life, it is

necessary to burnish the clutch.

Mini Z units built with serial number 03120228 and later were built

with Warner clutches. It is not necessary to burnish these clutches.

Mini Z units built prior to serial number 03120228 were built with

Ogura clutches. Occassionally it may be necessary to burnish the clutch.

Burnishing the Ogura clutch (Fig. 11-4) will develop better contact
between the armature and rotor, helping to develop higher torque
capabilities without slipping. The warranty on the new clutch will be
voided if it is not burnished properly.

Use the following procedure to burnish the clutch:

1. Check the air gap between armature and rotor. Gap should be .012”
to .024”.

2. Cycle the clutch on and off 10 times (15 seconds on and 15 seconds
off) with the engine operating at half throttles, approximately 1500
rpm.

Access to engine and hydraulic pumps

The hydraulic pumps are accessed by lifting the seat platform. The seat
platform is hinged at the front. To raise it, release seat latch and tilt seat
platform up and forward. The seat platform catch (Fig. 11-5) will prevent
the seat from going all the way over. However, if more access is desired
under the seat platform, the seat platform catch can be raised allowing the
seat to pivot more. Make certain to place the control levers in the park

brake position and pivot the arm rests upward before placing the seat
platform in the full forward position to prevent arm rest damage.

WARNING: Always wear adequate eye protection when
servicing the hydraulic system and battery.

302612_0606

11-9

Electric clutch

Figure 11-4

Figure 11-3

Battery

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. If exposed to hydraulic fluid, see a doctor at once.
Before applying pressure to hydraulic system, make sure all
connections are tight and all hoses and lines are in good
condition. To find a leak under pressure, use a piece of cardboard
or wood — never use your hands. Relieve all pressure in the
system before disconnecting or working on hydraulic lines. To
relieve pressure, lower all attachments and shut off engine.

The 1.0 U.S. gallon (3.79 liter) hydraulic reservoir is located in front of

the engine and under the operator’s platform. Fig. 11-6

Check oil level in hydraulic system after every 50 hours of operation or
weekly, whichever occurs first. Check more often if system appears to be
leaking or otherwise malfunctioning.

Fluid level should be 1” from top of reservoir. Use only SAE 10W40
SG, SF/CC, CD service motor oil.

Change hydraulic system filter element (Fig. 11-6) after first 50 hours
of tractor operation, then replace filter and oil in reservoir every 500 hours
thereafter. When changing hydraulic oil use 1/2 unit (approximately 3.5
oz.) of Lubrizol additive (Hustler P/N 027912). This additive, available
from your Hustler dealer, will increase the performance life of the hydraulic
system components.

The system filter is located to the right of the hydraulic reservoir. A
standard oil filter wrench is used to change filter, threads are right handed.
Use a Hustler approved filter element only.

IMPORTANT: Prefill the filter element with clean oil, before
installing, to prevent drawing air into the system pump.

1. Fill the filter element with clean system oil. Smear a light coating of
oil on upper surface of rubber seal.

2. Install the filter element on base. Tighten the oil filter by hand until
the filter seal makes contact with the filter head, then tighten an
additional 3/4 turn with a an oil filter wrench. — DO NOT
OVERTIGHTEN.

3. Start tractor engine and let run at approximately 2/3 throttle for a few
minutes to work any trapped air out of the system before engaging
the steering control lever.

4. Stop the engine and check the filter and connections for leaks.

5. Check the hydraulic reservoir for specified oil level. Add clean oil

as necessary.

Clean or replace hydraulic reservoir cap annually. Cap may be cleaned
by dipping in or flushing with cleaning solvent. Follow manufacturer’s
instructions and warnings for application of solvent type selected.

Fuel system

DANGER: Observe usual fuel handling precautions:

Do not smoke while refueling.
Do not fill tank with engine running or while engine is hot. Clean
up any gasoline spills.
Allow engine to cool before storing machine inside a building.
Keep fuel away from open flame or spark and store machine
away from open flame or spark if there is fuel in the tank.
Use extra caution when handling gasoline and other fuels. They
are flammable and vapors are explosive. A fire or explosion from
gasoline can burn you and others and can damage property.
Refuel outdoors preferably, or in well ventilated areas.
Never attempt to start engine when there is a strong odor of
gasoline fumes present. Locate and correct 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.
Always place gasoline containers on the ground away from your
vehicle before filling.
Do not fill gasoline containers inside a vehicle or on a truck or
trailer as interior carpets or plastic truck bed liners may insulate
the container and slow the loss of any static charge.
When practical, remove equipment from the truck or trailer and
refuel the equipment with its wheels on the ground. If this is not
possible, then refuel the equipment on the truck or trailer using a
portable container and not a gasoline dispenser nozzle. If a
gasoline dispenser nozzle must be used, keep the nozzle in
contact with the rim of the fuel tank or container opening at all
times until fueling is complete.

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.

Figure 11-6

Hydraulic

reservoir

Hydraulic filter

Figure 11-5

Seat platform catch

Control lever

Seat platform

11-10

302612_0606

Figure 11-7

Fuel tank

The fuel tanks are located in the tractor’s fenders. (Fig. 11-7) Total

capacity for the fuel tanks is 12 U.S. gallon (45.4 liter)

Use regular unleaded gasoline with an octane rating of 87 or higher.

The fuel filter (Fig. 11-8A, 11-8B & 11-8C) is installed in the fuel line
between fuel tanks and engine fuel pump. Replace filter annually or after
every 500 hours of operation, whichever occurs first.

When replacing the fuel filter, check the fuel line hoses and fuel shut­off valve grommet for any cracks or leaks.

On early units a fuel shut-off valve is located on the outlet port of each
fuel tank. (Fig. 11-9A) Close these valves (turn clockwise) to prevent fuel
flow to the engine.

Current production units have a fuel shut-off valve attached to the
crossmember next to the hour meter. (Fig. 11-9B) Close this valve (center
position) to prevent fuel flow to the engine. Fig 11-9B shows the valve’s
two other positions.

Engine oil and filter

Check engine oil daily and after every 4 hours of operation. Crankcase

dipstick and oil filler tube are located at the rear of the machine (Fig. 11­10A & 11-10B). Tractor must be setting level when checking oil. Refer to
engine manual and maintenance schedule for oil recommendation and
capacities.

Change the engine oil and filter after the first 5 hours of operation, per
the engine manufacturer’s recommendations after that. If tractor is being
operated in extremely dirty conditions, then it is recommended oil be
changed more frequently.

The oil drain and oil filter are located at the rear of the engine. Fig. 11­10A & 11-10B

Engine air filter

Perform engine air filter maintenance per the Service Interval chart on
page 11-8.

A specially designed dry filter is standard equipment on the Mini Z
tractors and supplies clean combustion air to the engine. Fig. 11-11

Recommended service procedure

Many engine failures can be attributed to improper air cleaner
servicing. Ingested dust and dirt will cause cylinder, piston and bearing
damage in a few hours. “Dusted” engines will result from:

1. Overservicing the air filter element.

2. Improper installation.

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.

Overservicing

Overservicing occurs when an air filter element is removed for cleaning
or replacement before it is necessary. Each time the filter is removed a
small amount of dirt and dust could fall in the intake system. This
accumulated dirt can cause a dusted engine. It only takes a few grams of
ingested dirt over the normal service life of an engine to cause a dusted
engine.

Do not clean element, replace with a new element only. Cleaning
used air filter elements, through improper cleaning procedures, can get dust
on the inside of the filter causing dirt ingestion and engine failure.

Figure 11-9B

Fuel valve (shown in closed position)

Left fuel tank

Right fuel tank

Figure 11-9A

Fuel shut-off valve

Valve grommet

Figure 11-8B

Fuel filter

Honda engine

11-11

302612_0606

Figure 11-8C

Fuel filter

Figure 11-8A

Fuel filter

Kawasaki engine

Kohler engine

It is important to note that whenever an air filter element is cleaned by
any method, the person or company performing the cleaning assumes
responsibility for the integrity of the filter from then on. The Donaldson

warranty for air filters expires upon cleaning or servicing in any
manner because the condition of the filter after servicing is completely
out of their control. Therefore, on a dust ingested engine failure, there
will be no 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. When dirty air passes through the filter, the dirt plugs some of
the holes in the media and actually acts as part of the filter media. When
the next round of dirt enters, the first dirt helps filter out even smaller
particles making the filter more efficient at stopping dirt from entering the
engine. This is referred to as barrier filtration.

Of course, at some point the filter media becomes too clogged to allow
air to pass.

The mowing conditions will determine the frequency of air filter
element changing.

Improper installation of an air filter element

Dust must not leak past the seals on each end of the air filter element.
The filter must be aligned within the canister and properly seated for an
effective seal so that no dirt can enter the engine.

Damaged filter, seals or canister

Never bang or bump the filter element against the tire or any solid
object, as dust and dirt particles will be forced through the media causing
continual passing of dirt into the engine. Visually inspect the outside of the
air cleaner canister periodically for external damage and replace if
necessary.

Incorrect air cleaner element

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. Always use genuine Hustler filters.
Many aftermarket filters have been found to be incompatible with Hustler’s
canisters and engines.

The air filter must remain intact to block passage of dirt and foreign
particles from entering the engine. Being inclined to disbelieve the need for
more expensive air filter elements used on gasoline engines may cause
some individuals to opt for a less expensive part.

The filter element must be sufficient size and construction to withstand
stresses, caused by rapid cycling of the air volume demanded by the engine,
without cracking or tearing under fatigue and pressure (especially diesel
engines). Therefore, Hustler Turf Equipment and the engine manufacturers
have carefully selected a reliable filter designed to fit the needs of the
engines. The filter specified is a Donaldson filter, Hustler part number

785261.

Owners should be reminded that failure to use original equipment
replacement parts is an “alteration” and will not be considered for warranty
in the event of engine damage.

Recommended service procedure

1. Release clamps and remove element. Clean the canister with a damp
cloth.

2. Before installing a new element, inspect it by placing a bright light
inside and rotate the element slowly, looking for any holes 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. Reinstall the dust cup. Make sure it seals all the way around the air
cleaner body, then tighten the clamps.

4. Check all fittings and clamps periodically for tightness and inspect
hoses for holes or cracks.

5. Periodically check the intake hose for signs of ingested dust. Locate
and repair the source of ingested dirt.

6. Never operate a machine without an air filter installed.

Air restriction indicator

Any unit with a Kawasaki engine will have an air restriction indicator

installed in the air cleaner. Fig. 11-12

Replace the element whenever the restriction indicator shows reaches the
change filter red line. Check the indicator daily and replace element as
needed or annually whichever occurs first.

Reset the indicator by pushing in on the yellow button after each element
change. Fig, 11-12

A restriction indicator takes the guesswork out of air cleaner servicing
and allows you to safely benefit from the filter’s optimum performance.

General engine maintenance

Detailed instructions and recommendations for break-in and regular

302612_0606

11-12

Figure 11-10C

Engine oil
drain plug

Engine oil filter

Kohler engine

Figure 11-10A

Engine oil
drain plug

Engine oil filter

Engine oil filler tube

Kawasaki Engine

Figure 11-10B

Engine oil
drain plug

Engine

oil filter

Engine oil filler tube Honda Engine

maintenance are specified in the Engine Owner’s manual. Please refer to
this manual for engine servicing, lubricating oil levels with quality and
viscosity recommendations, bolt torques, etc. The engine warranty is
backed by the manufacturer. Special attention should be paid to applicable
data which will not be duplicated here.

Belt replacement

Figures 11-13 and 11-14 show diagrams and descriptions of the unit’s

belt drive systems.

Inspect these belts frequently for wear and serviceability. Replace a belt
that shows signs of severe cuts, tears, separation, weather checking and
cracking, or burns caused by slipping. Slight raveling of belt covering does
not indicate failure, trim ravelings with a sharp knife.

WARNING: If the pump belt fails, loss of control will occur
especially when operating on a slope. If you lose steering

control while operating the machine, place the steering
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.

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.

Mower blade maintenance

Check the mower blades daily, they are the key to power efficiency and
well groomed turf. Keep them sharp, a dull blade will tear rather than cut
the grass, leaving a brown ragged top on the grass within a few hours. A
dull blade also requires more power from the engine.

Replace any blade which is bent, cracked or broken.

WARNING: Never attempt to straighten a bent blade by heating,
or weld a cracked or broken blade as the blade may break and
cause serious injury.

DANGER: Never work with blades while engine is running or
deck clutch is engaged. Always place deck clutch in the
disengaged position, engage parking brake and neutral lock
levers and turn engine off. Block up mower when you must
work under it. Wear gloves when handling blades. Always
check for blade damage if mower strikes rock, branch or other
foreign object during mowing!

Figure 11-12

Indicator

Reset

button

Figure 11-13

1

2, 6

4

5

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

7

Viewed from

bottom for unit

5

3

Figure 11-14

1

Deck Belt Drive Layout

1. Spindle drive belt

2. Deck blade spindle pulley

3. Spindle belt tension idler

4. Spindle belt tension idler spring

(7.75" at operation)

5. Deck belt idler

6. Idler arm

2

2

2

6

4

5

3

5

Figure11-11

Pre-cleaner

Canister

302612_0606

11-13

Mower blade removal

Use a 15/16" wrench to remove the 5/8" cap screw holding the blade to

the spindle shaft from underneath.

Sharpen the blades on a grinder following pattern as shown (Fig. 11-

15). Touch-up sharpening can be done with a file.
Check the blades for balance following grinding. A commercial

balancing tool is available through most hardware supply stores, or
balancing can be done by placing the blade on an inverted line punch or
5/8" bolt. Blade should not lean or tilt. Spin the blade slowly, blade should
not wobble. If blade is out of balance, true it up before reinstalling.

Lay the blade on a flat surface and check for distortion (Fig. 11-16 and

11-17). Replace any distorted blade.

Do not re-use spindle bolts which have stripped, worn or undercut

threads. Torque bolts to 118 foot-pounds when reinstalling blades.

WARNING: When mounting blades, rotate them after
installation to ensure blade tips do not touch each other or sides
of the mower.

WARNING: Failure to correctly torque the bolt may result in the
loss of the blade which can cause serious injury.

WARNING: Mower blades are sharp and can cut. Wrap the
blade(s) or wear gloves and use extra caution when servicing
them.

302612_0606

11-14

Figure 11-17

Twisted Blade Edge

(Replace)

Cutting Edge

Straight Blade Edge

End view of blades, comparing
twisted and straighten blades.

Cutting Plane

Cutting Edge

Figure 11-15

Resharpening Pattern

Do not sharpen to original pattern (below).
It is easier to get a straight cutting edge following
the resharpening pattern shown above.

Original Edge

Warped Blade (Replace)

Straight Blade

Comparison of Warped and Straight Blades

Cutting

Plane

Figure 11-16

ADJUSTMENTS

Introduction

Your 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. Correcting the problem as quickly as possible is the
best insurance.

Clear away heavy build-up of grease, oil and dirt, especially in the area
of reservoir and oil and engine combustion air; minute dust particle are
abrasive to close-tolerance engine and hydraulic assemblies.

Some repairs require the assistance of a trained service mechanic and
should not be attempted by unskilled personnel. Consult your Hustler
service center when assistance is needed.

Steering linkage

The 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 in the neutral position (Fig. 11-18). However,
should the tractor begin to creep, the control lever linkage can be adjusted
as follows:

Control Lever Neutral Adjustment

Before considering any adjustment, check the tire air pressure and make
certain hydraulic system oil is at operating temperature. Unequal tire
pressure will cause the tractor to drift to one side. Refer to tire pressure
information in the Maintenance section of this manual.

Fine adjustment to the unit’s steering is made with the adjustable pump
linkage rods located between the control lever and pump arms. Fig. 11-19

Neutral is properly adjusted when the control levers are in the neutral
position and the drive wheels are not turning.

If the tractor creeps in the neutral position the control linkage may be
adjusted as follows:

1. Raise and block the tractor up so the drive wheels are off of the
floor.

WARNING: Never work under the machine or attachment
unless it is safely supported with jack stands. Make certain
machine is secure when it is raised and placed on the jack stands.
The jack stands should not allow the machine to move when the
engine is running and the drive wheels are rotating. Use only
certified jack stands. Use only appropriate jack stands, with a
minimum weight rating of 2000 pounds to block the unit up. Use
in pairs only. Follow the instructions supplied with the vehicle
stands

2. Position the control lever in the neutral position. Disengage the
deck clutch.

3. Start the engine and observe which way the wheels are rotating.

4. If wheel(s) are rotating forward, loosen the jam nuts on the pump

linkage rods and rotate the rod to lengthen the steering control
linkage until the wheel(s) come to a stop. Fig. 11-19
NOTE: The left linkage controls the left hydraulic pump and the
right linkage controls the right hydraulic pump.
Repeat for the opposite side if necessary.

5. If wheel(s) are rotating in reverse then loosen the jam nuts on the
pump linkage rods and rotate the rod to shorten the steering control
linkage until the wheel(s) come to a stop. Fig. 11-19
NOTE: The left linkage controls the left hydraulic pump and the
right linkage controls the right hydraulic pump.
Repeat for the opposite side if necessary.

6. When both wheels remain in neutral, tighten the jam nuts to lock the
turnbuckle in place.

7. Test again by moving the control levers forward and backward
before returning them to the neutral position. If the tires are in
neutral, the unit is now ready for operation.

8. After adjusting for neutral it may be necessary to re-adjust the
steering dampener and/or the control lever stop. Fig. 5-3 or Fig. 5-4

11-15

302612_0606

Figure 11-18

Park brake slot

Control lever

in the neutral

position

Control

lever

Figure 11-19

Pump

linkage

rod

Jam nut

Figure 11-20

Control

lever

Stop

Jam

nut

Control lever stops

The control lever stops (Fig. 11-20) 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. To make the first adjustment the tractor engine must NOT be
running.

2. Check to make sure the control levers are against the stops before the
pumps are bottomed out internally.
To do this, gently and slowly move the control levers forward and
feel if there is some resistance on the pump lever before the control
levers hit the stops. Check one side at a time. If you sense that the
pump arms are stopping the forward motion of the control arms,
loosen the jam nut on the adjustable stop of the corresponding side
and turn the stop (set screw) inward to stop the control levers slightly
before the pump bottoms out. Lock in place when the adjustment is
correct by re-tightening the jam nut.

3. Do this for each side.

To adjust the stops for driving straight when control levers are against

the stops during operation:

1. Determine which drive tire is rotating too fast when both control
levers are against the stops. Then stop the tractor and loosen the
lock nut on the side which is rotating too fast and turn the stop (set
screw) inward to stop the control lever sooner. Tighten the lock nut
on the stop and test again. Repeat this procedure until unit drives
straight.

NOTE: Since this is a hydrostatic drive, variables such as temperature of

oil, efficiency of pumps and motors, tire pressure etc. may effect the
consistency of the ability to rely on the stops to drive straight without the
operator making minor steering adjustments with the control arms.

Steering dampener

This steering dampener (Fig. 11-21) is spring loaded to return the control
levers to the neutral position from the reverse position. This gives the
operator a sense of neutral during operation.

To set the steering dampeners in the correct operating position follow
these steps:

1. Place the control lever in the neutral position.

2. Loosen the steering dampener’s front ball stud.

3. Pull the dampener spring housing pass the point that the internal

spring is engaged.

4. Release the dampener spring housing and allow the internal spring to
bring the housing back to the neutral position.

5. Tighten the nut on the steering dampener’s front ball stud.

Control lever adjustment

The control levers can be adjusted for operator comfort. By loosening
the cap screws that attaches the upper control lever to the lower lever (Fig.
11-22), the upper control lever can be pivoted to fit the operator’s personal
preference.

The control levers should be adjusted so that they align with each other
when in the neutral position.

Park brake adjustment

Occasionally check the park brakes and adjustment using the following
method:

1. Position the control levers in the neutral position. Disengage the
deck clutch.

WARNING: Never work under the machine or attachment
unless it is safely supported with jack stands. Make certain
machine is secure when it is raised and placed on the jack stands.
The jack stands should not allow the machine to move when the
engine is running and the drive wheels are rotating. Use only
certified jack stands. Use only appropriate jack stands, with a
minimum weight rating of 2000 pounds to block the unit up. Use
in pairs only. Follow the instructions supplied with the vehicle
stands

302612_0606

11-16

Figure 11-22

Cap screw

Upper

control

lever

Lower control

lever

Figure 11-21

Spring

housing

Front ball

stud

Figure 11-23

Front brake link

(right side)

Steering dampener

with spring

NOTE: The front brake link is not adjustable. Fig. 11-23

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. 11-24), 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. Remember hydraulic oil
resistance will prevent the tire from rotating freely even with the
bypass valves open. There should be no resistance from the brakes
at this point.

5. Move the control lever to where it is just inside (1/8”) the park brake
slot. Fig. 11-25
NOTE: When the control lever is against the outside edge of the the
slot, the brakes should not be engaged. Fig. 11-26

6. Rotate the tire. If the brake is adjusted properly the tire will still
rotate but friction will start to become noticeable here. However, if
no brake resistance is noticed, the brake needs adjusted as follows:

7. Loosen the brake linkage jam nuts. Fig. 11-27

8. Rotate the tire and at the same time rotate the turnbuckle to shorten

the length of the brake linkage to increase the brake pressure. When
you feel the brake begin to engage, stop adjusting the turnbuckle.
Re-tighten the jam nuts on the turnbuckle.

9. Place the control lever in the park brake slot (Fig. 11-28). The tire
should not rotate when the control lever is in the park brake position.

10. Place the control lever in the neutral position. The tire should rotate
freely.

11. Close the hydraulic pump’s bypass valve.

12. Repeat steps 3 thru 11 for the other side.

13. Remove the jack stands and lower the unit. It is now ready to

operate.

Hydraulic pump belt adjustment

The pump drive belt tension remains constant by means of a tension idler

and spring (Fig. 11-29). There is no tension adjustment of this belt.

NOTE: Replace the belt every 400 hours or every two (2) years
whichever comes first.

WARNING: If the pump belt fails, loss of control will occur
especially when operating on a slope. If you lose steering

control while operating the machine, place the steering
control levers in the park brake position immediately.
Inspect the machine and involve your Hustler dealer to
resolve the problem before continuing to operate.

Deck drive belt adjustment

The spindle belt tension remains constant by means of a tension idler and
spring (Fig. 11-30). The spring tension should be such that the belt does
not slip under normal operating load conditions, assuming the belt is not

302612_0606

11-17

Figure 11-25

1/8”

Outside edge

Control lever

Park brake

slot

Figure 11-24

Bypass valve

Figure 11-28

Figure 11-26

Travel slot

Outside edge

Control lever

Park brake slot

Figure 11-27

Turnbuckle

Brake linkage

Jam nut

Jam nut

Control lever in park brake position

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. 11-30). Installed spring
length should be 7.75" ± .3" (19.7 cm ± .76 cm) originally with adjustments
of .60" (15.2mm) per chain link. (Fig. 11-31)

IMPORTANT: Do not over tension the spring to compensate for a

badly worn belt or pulley.

Engine RPM setting

The Mini Z is designed so that the engine will run at 3600 rpm static
pump load only. At this speed the hydraulic pumps are running at their
maximum rated speed.

Deck leveling and height adjustment

The mower deck has three areas that may need to be checked and
adjusted periodically. Before considering any mower deck leveling
adjustments, check that the tire air pressure is within the specified range.

Deck level adjustments

Leveling the deck must be done in the following manner and order:

1. Check tire pressures to make certain they are properly inflated before

starting to level deck. The recommended pressures are as follows:

Drive wheels tire pressure ........................................8 - 10 psi

Gauge wheels tire pressure.......................................8 - 10 psi

WARNING: Stop engine. Make sure deck clutch switch is in
the down (OFF) position. 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 deck

(Fig. 11-32). This will set the cutting height at 3 ¼ ". NOTE: Back

of deck will automatically be set ¼" higher.

4. Set cutting height at 3 ¼" in the height indicator by placing the
height adjusting stop in the 3" hole, and turning the height stop so
that the flat side is against the stop handle. Fig. 11-33

Figure 11-34

Deck lift threaded rod

Nut

Nut

Chains

Figure 11-33

Height

adjusting

stop

Stop

handle

302612_0606

11-18

Figure 11-31

1.75”

Spring Extension

7.75”

6.0”

Normal Spring Length

Figure 11-29

Spring

Tension

idler

Pump drive

belt

Figure 11-30

Spring

Tension idler

Chain

Figure 11-32

Blocks

5. Clamp the height adjusting stop against the stop handle (5-16). This
will assure that the height will not move during the setting process.
Otherwise, spring pressure from the deck lift springs will tend to pull
the stop away from the handle.

6. Loosen all nuts on the deck lift threaded rods, and the hardware on
the adjuster (on the right front), until all the deck lift chains are
loose, and the deck is sitting tightly on all four blocks. Fig. 11-34,
11-35, 11-36

7. Loosen the two nuts on the front of height indicator so that the foot
pedal is free. Fig. 11-37

8. Start the leveling process on the left front of the tractor.

9. Set the amount of threads protruding on the deck lift rod from the lift

block at approximately 1". Fig. 11-38

10. Jam both nuts against the block.

11. Push or pull on the deck lift foot pedal until the chain on the left

front just becomes tight, making sure that the deck stays tight against
the 3" block.

12. While keeping the chain tight, tighten the nuts against the deck lift
block on the height indicator rod. Fig. 11-37

13. Go to the right front of the tractor.

14. Loosen the 5/16" jam nut on the adjuster lift chain (11-36), and back

the adjuster bolt out to allow the adjuster to move up and down
freely.

15. Be sure that adjuster is free to move up and down.

16. Tighten the adjuster bolt until the chain just becomes tight, making

sure that the deck stays tight against the 3" block.

17. Tighten the adjuster bolt jam nut to prevent the adjuster bolt from
moving. Fig. 11-36

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. 11-35

21. Tighten the appropriate nut until the chain just becomes tight,
making sure that the deck stays tight against the 3" block.

22. Tighten the other nut on the opposite side of the block, and jam them
tightly together against the block.

23. Go to the left rear of the tractor.

24. 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. 11-34

25. Tighten the appropriate nut until the chain just becomes tight.

26. Tighten the other nut on the opposite side of the block, and jam them

tightly together against the block.

27. Compress the deck lift assist springs so that there is 1” of space
between the front nut and on the spring and the rear nut on the deck
lift block (Fig. 11-38). Typical both sides.

28. When completed, all chains will be tight, and deck cutting height
will be set to the deck height indicator.

11-19

302612_0606

Figure 11-37

Foot

pedal

Nuts

Figure 11-38

Lift block

1”

Deck lift rod

1”

Deck lift

assist springs

Figure 11-36

5/16” bolt

Adjuster

Hardware

Jam nut

Figure 11-35

Deck lift

threaded

rod

Nut

Nut

Chains

302612_0606

11-20

302612_0606

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.............................................................................11-5

Deck drive belt adjustment...........................................11-17

Deck leveling and height adjustment ...........................11-18

Electrical system ............................................................11-9

Engine air filter ............................................................11-11

Engine oil and filter......................................................11-11

Engine rpm setting .......................................................11-18

Fuel system...................................................................11-10

General engine maintenance ........................................11-12

PAGE

Hour meter .....................................................................11-8

Hydraulic pump belt adjustment ..................................11-17

Hydraulic system..........................................................11-10

Lubrication .....................................................................11-8

Maintenance introduction...............................................11-8

Mower blade maintenance ...........................................11-13

Mower blade removal ..................................................11-14

Park brake adjustment ..................................................11-16

Safety precautions ..........................................................11-3

Steering dampener........................................................11-16

Steering linkage............................................................11-15

Tires................................................................................11-8

Torque values .................................................................11-8

Wheel motor information.................................................8-1

11-21

302612_0606

11-22

10-4 302612 5/05