Hustler Turf Super Mini Z User Manual

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Hustler Super Mini Z

Parts Manual

302620 Rev. 8/06

•••••••

Hustler Turf Equipment

•••••

P.O. Box 7000

•••

Hesston, Kansas

•

67062-2097

WARNING:

The engine exhaust from this product

contains chemicals known to the State

of California to cause cancer, birth

defects or other reproductive harm.

IMPORTANT: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate this engine on any fores t-covered, brush-covered, or grass-covered unimproved land. Other states or federal areas may have similar laws.

This spark ignition system complies with Canadian ICES-002.

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

Keep Engine Owner’s Manual with your unit. Should the Engine Owner’s Manual become damaged or illegible, replace immediately. Replacements may be ordered pe r the information found in the Produc t Information sec tion of the

owner’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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Instrument Panel Installation/Assembly . . . . . . . . . . . . . . . . . . . . . 5-15

Electrical Schematic - Kawasaki Engines (783894) . . . . . . . . . . . . 5-17

Electrical Schematic - Honda Engines (787200). . . . . . . . . . . . . . . 5-19

Electrical Schematic—Kohler (788000) . . . . . . . . . . . . . . . . . . . . . 5-21

Chapter 6 Contents

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

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

Drive Wheel Assembly/Installation . . . . . . . . . . . . . . . . . . . . . . . . . 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

302620 8/06

Chapter 11 Contents

Maintenance & Adjustments Safety Precautions . . . . . . . . . . . . . . 11-2

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

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

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

302620 8/06

Chapter 1

General Information

This Manual covers Hustler Super Mini Z 23/44 model 927269, Super Mini Z 25/52 model 927277, Super Mini Z 24/52 model 927285, and Super Mini Z 27/52 model 927533.

Frequently Ordered Parts

PART NO. DESCRIPTION

027912 Lubrizol 7 oz. Bottle 027920 Lubrizol 10 oz. Bottle 783936 Hydraulic Oil Filter 786533 Pump Drive Belt 791335 44" Deck Belt 789388 52" Deck Belt 785626 Honda Fuel Filter 068478 Kawasaki Fuel Filter 785261 Main Air Filter 785279 Safety Air Filter Element 785634 Honda Engine Oil Filter 772079 Kawasaki Engine Oil Filter 747303 Kohler Engine Oil Filter 784256 16" X 2.5" X 0.204 .631 Dia. Hole Blade 783753 18" X 2.5" X 0.204 .631 Dia. Hole Blade

Service Literature

PART NO. DESCRIPTION

302638 Hustler Mini Z Owner’s Manual 778423 Kawasaki 19/23HP Engine Manual 785642 Honda 18/20/24HP Engine Manual 742684 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-

302620 8/06 1-1

sary, without notification. If a change has been made to your machine which is not reflected in this parts manual, see your Hustler dealer for current information and parts.

Hardware Description Codes & Abbreviations

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

ABBREVIATION DESCRIPTION

CB Carriage Bolt CE Clevis Pin CP Cotter Pin CS Cap Screw

CW Cup Washer

FDRW Fender Washer

FW Flat Washer

HX Hex Head LW Lock Washer MB Machine Bushing MS Machine Screw NT Nut SC Self Tapping Cap Screw SH Socket Head SB Shoulder Bolt SS Set Screw OD Outside Diameter

ID 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 302620 8/06

Chapter 2 Contents

Rivet-nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

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

302620 8/06 2-1

Rivet-nut Installation

INDEX

NO.

SERVICE

PAR T NO.

1 546630 387936 1 52" MINI Z FRAME

546648 392449 44" MINI Z FRAME

2 N/A 808493 2 3/8-16 THREAD NUTSERT

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

2-2 302620 8/06

Footrest Assembly

INDEX

NO.

SERVICE

PAR T 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.

302620 8/06 2-3

2-4 302620 8/06

Chapter 3 Contents

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

302620 8/06 3-1

Hydraulic System Installation

3-2 302620 8/06

Hydraulic System Installation

INDEX

NO.

10 783985 N/A 1 FITTING, STR ORB-BEADED TUBE

11 787564 N/A 1 MINI-Z CASE DRAIN HOSE ASSEMBLY

12 787572 N/A 1 MINI-Z CASE DRAIN HOSE ASSEMBLY

13 781658 N/A 1 FITTING, STR-8MORB/HEX PLUG

14 700484 700484 1 HOSE CLAMP

15 034272 034272 3 NT .312-18 HX G5 ZNYC

16 768523 768523 3 FW .343 X .687 X .051/.080 HD ZNYC

17 055947 055947 2 CS .250-20 X .500 HX G5 ZNYC

18 787580 N/A 1 HOSE ASSEMBLY, PUMP TO COOLER SMZ

19 784108 N/A 2 FITTING, 6 BEADED TUBE-ORB 45

20 787598 N/A 1 HOSE ASSEMBLY, PUMP TO COOLER SMZ

21 784082 N/A 2 FITTING, 8 BEADED TUBE-ORB 90

22 781559 N/A 3 FITTING, 45-8MORB/-8MSL

23 781542 N/A 1 FITTING, 90-8MORB/-8MSL

24 786368 786368 1 PUMP, HYDRO-GEAR BDP16A-306

25 786350 786350 1 PUMP, HYDRO-GEAR BDP16A-409

26 041707 041707 4 NT .437-14 HX G5 ZNYC

27 704742 704742 8 FW .453 X .812 X .060 ZNYC

28 791152 791152 2 WHITE MOTOR CE14

29 008573 008573 8 CS .500-13 X 2.500 HX G5 ZNYC

30 767962 767962 8 FW .531 X 1.063 X .090 SAE HD ZN

31 781526 N/A 3 FITTING, 90-10MORB/-8MSL

32 787440 N/A 1 FITTING, 45-10MORB/-8MSL

33 791061 N/A 1 HYDRO TUBE, SMZ-RH SIDE-RP/BM

34 795278 N/A 1 HYDRO TUBE, SMZ RH SIDE LP/TM

35 791103 N/A 1 HYDRO TUBE SMZ LH SIDE- LP/TM

36 791087 N/A 1 HYDRO TUBE SMZ LH SIDE-RP/BM

37 705186 705186 4 CS .437-14 X 1.375 HX G5 ZNYC

38 787622 N/A 1 HOSE ASSEMBLY, RESERVOIR TO FILTER SMZ

39 787457 N/A 1 FITTING, 90-12MORB/-12MJIC

40 791814 N/A 1 HOSE ASSY FILTR TO RH PUMP SMZ

41 787606 N/A 1 HOSE ASSEMBLY, FILTER TO PUMP SMZ

42 788174 N/A 1 FITTING, T -8MJIC/8MJIC/12MORB

43 783936 783936 1 FILTER ELEMENT

44 783928 783928 1 FILTER HEAD ZAF SERIES

SERVICE

PAR T NO.

1 068551 068551 2 NT .250-20 HX NL ZNYC

2 768515 768515 8 FW .281 X .625 X .051/.080 HD ZNYC

3 055939 055939 4 CS .250-20 X .750 HX G5 ZNYC

4 713198 713198 2 SEAL 3/8 X 3/4 X 7¾" LONG

5 713198 713198 2 SEAL 3/8 X 3/4 X 1½" LONG

6 787192 787192 1 HYDRAULIC OIL COOLER

7 032763 032763 1 BREATHER CAP

8 032771 032771 1 STRAINER

9 368803 368803 1 HYDRAULIC OIL RESERVOIR

MFG. PART

NO.

QTY. DESCRIPTION

302620 8/06 3-3

NOTES:

1. Add 3.5 oz. Lubrizol® (027912) to new system or when hydraulic oil is changed (see Owner’s Manual).

2. Hydraulic system capacity is 5 US quarts. Fill reservoir to within 1" of top of Item 8 (032771 Strainer).

3. Included in Hydro Kit (791160).

Note:

Seal Kit for hydraulic pump; 788133 (BDP16 Overhaul Seal Kit)

3-4 302620 8/06

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

302620 8/06 4-1

Battery Installation

4-2 302620 8/06

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

PAR T 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 performing maintenance, disconnect battery ground cable and black wire of harness and do not reconnect to battery until engine is ready to be started (See owners manual).

302620 8/06 4-3

Deck Lift Assembly

4-4 302620 8/06

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

PAR T NO.

1 348318 348318 1 STOP HANDLE

2 348284 348284 1 HEIGHT ADJUSTMENT STOP

3 784488 784488 1 DECK LIFT INDICATOR

4 781294 781294 7 CLIP E, 1.00 X.625X .050

5 782995 782995 2 DECK LIFT SPRING

6 704643 704643 8 NT .437-14 HX FLG ZN

7 055749 055749 3 CS .437-14 X 1.750 HX G5 ZNYC

8 348391 348391 4 DECK LIFT CHAIN

9 781831 781831 1 CS .437-14 X 1.750 FULTH G5 ZNYC

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

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

302620 8/06 4-5

Steering and Brake Assembly

2728

3536

4-6 302620 8/06

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 34 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 369660 369660 2 PUMP ARM

23 068551 068551 2 NT .250-20 HX NL ZNYC

24 781922 781922 4 DAMPER BALL STUD

25 600221 600221 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 .750 HX G8 ZNYC

42 783118 783118 1 BRAKE ASSEMBLY

43 783126 783126 1 BRAKE ASSEMBLY (NOT SHOWN)

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 ZN

SERVICE

PAR T NO.

1 781260 781260 2 STEERING BAR GRIP

2 368704 N/A 2 STEERING BAR

3 367128 367128 1 CONTROL PANEL

4 368670 368670 2 STEERING ARM MOUNT

5 055822 055822 6 CS .375-16 X .750 HX G5 ZNYC

6 767954 767954 26 FW .406 X .812 X .060 SAE HD ZN

7 781716 781716 4 SS .500-13 X 1.75 SH ZN

8 053199 053199 2 NT .500-13 HX JAM ZNYC

9 036244 036244 4 CS .375-16 X 1.00 HX G5 ZNYC

783696 783696 2 CENTERING DAMPENER

MFG. PART

NO.

QTY. DESCRIPTION

302620 8/06 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.

5. Includes Item 1 (781260 Steering Bar Grip).

6. Used on mowers with serial numbers prior to 06071186.

4-8 302620 8/06

This page intentionally left blank.

302620 8/06 4-9

Pump Belt and Pulley Installation

For mowers with serial numbers prior to 04040580

LOCATION FOR RUBBER BUMPER

4-10 302620 8/06

Pump Belt and Pulley Installation

INDEX

NO.

1 783761 783761 1 SUPER Z 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

4 791251 791251 1 CLUTCH PIGTAIL HARNESS (DIODE)

5 787366 787366 1 WARNER Z CLUTCH

6 783829 783829 1 FW .460X 1.750X .250 ZNYC

7 785659 785659 1 CS .437-20 X 2.50 HX G5 ZNYC

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

9 782466 782466 2 PULLEY & FAN BDP-21

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.

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 16 (368860 Pump Idler Arm) should pivot freely.

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

5. 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.

302620 8/06 4-11

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 302620 8/06

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 (787200). . . . . . . . . . . . . . . . . . . . . . 5-20

Electrical Schematic—Kohler (788000) . . . . . . . . . . . . . . . . . . . . . . 5-22

302620 8/06 5-1

Kawasaki Engine Installation

TO SPADE TERMINAL PUR

YEL

P/O ENGINE

TO BULLET TERMINALS

(MALE-BRN) (FEMALE-ORG)

RED/BLK

5-2 302620 8/06

POSITIVE

BATTERY CABLE

PUR

Kawasaki Engine Installation

INDEX

NO.

10 055939 055939 6 CS .250-20 X .75 HX G5 ZNYC

11 768515 768515 11 FW .281 X .625 X .051/.080HD ZNYC

12 783837 783837 1 ELECTRIC COOLER FAN

13 047654 047654 2 CLIP

14 369470 369470 1 SUPER MINI Z HOOD

15 044818 044818 4 CN ZN TIN-C7343-1420

16 045088 045088 1 HOSE CLAMP 1"

17 786038 786038 1 REMOTE AIR FILTER HOSE

18 777656 777656 1 KAWASAKI 23 HP ENGINE (FH680V, 3600 RPM) (USED ON 927269)

19 786863 786863 1 19/23/25 KAWASAKI MUFFLER

20 720177 720177 2 CS M 8-1.25 X 20 10.9 HXFLZNYC

21 786566 786566 1 1.375" MUFFLER CLAMP

22 780841 780841 2 KAW (23) MUFFLER GASKET

23 786871 786871 1 KAWASAKI MUFFLER MANIFOLD

24 360693 360693 1 HEAT SHIELD

25 017004 017004 4 LW .312 MED SPRING ZNYC

26 782664 782664 4 NT M8-1.25 HX STAINLESS STEEL

27 796524 796524 1 M20 X 2.5 OIL DRAIN VALVE

28 024927 024927 3 NT .250-20 HX GR.5 ZNYC

29 768820 768820 1 BATTERY CABLE

30 783894 783894 1 TRACTOR WIRE HARNESS

31 044255 044255 1 NT #10-32 HX ZN

32 771428 771428 1 RED BATTERY CABLE BOOT

33 030817 030817 1 STARTER SOLENOID

34 055947 055947 2 CS .250-20 X .50 HX G5 ZNYC

35 792192 792192 1 STARTER RELAY GROUND WIRE

36 769166 769166 1 HOUR METER

37 388892 388892 1 SEAT SUPPORT CROSSMEMBER

38 055822 055822 8 CS .375-16 X .750 HX G5 ZNYC

39 767954 767954 8 FW .406 X .812 X .060 SAE HD ZN

40 034280 034280 4 CS .312-18 X .75 HX G5 ZNYC

41 369132 369132 1 MUFFLER GUARD

42 300061 300061 1 ENGINE GUARD

43 029876 029876 4 LW .312 INT-EXT TOOTH ZNYC

44 052837 052837 4 CS .312-18 X1.50 HX G5 ZNYC

45 016527 016527 6 CS .500-13 X1.00 HX G5 ZNYC

46 767962 767962 6 FW .531 X 1.063 X.090 SAE HD ZN

47 064006 064006 2 CS .312-18 X .625 HX G5 ZNYC

SERVICE

PAR T 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 370270 370270 1 MINI Z DEFLECTOR SCOOP

9 036236 036236 2 CS .312-18 X 1.00 HX G5 ZNYC

782318 782318 1 KAWASAKI 25 HP ENGINE (FH601V, 3600 RPM) (USED ON 927277)

MFG. PART

NO.

QTY. DESCRIPTION

302620 8/06 5-3

NOTES:

1. Includes mounting hardware.

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

3. Part of Item 30 (783894 Tractor Wire Harness).

4. Engine oil capacity; 2 US quarts.

5. Engine RPM to be set at 3600±50.

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

7. Used on mowers with serial numbers 05031839 and higher. This part replaces “O” ring , drain extension, and drain plug, on mowers with serial numbers prior to 05031839,

8. Air filter service parts:

785261 MAIN AIR FILTER ELEMENT

763318 VACUATOR VALVE

5-4 302620 8/06

This page intentionally left blank.

302620 8/06 5-5

Honda Engine Installation

POSITIVE BATTERY CABLE

RED/BLK

BRN

ORG

GRA/PUR

PUR

6 7

YEL

PART OF ENGINE

ANTI-ROLLOVER WHEEL BRACKET

5-6 302620 8/06

Honda Engine Installation

INDEX

NO.

10 768515 768515 10 FW .281 X.625 X .051/.080 HD ZNYC

11 036236 036236 2 CS .312-18 X 1.00 HX G5 ZNYC

12 783837 783837 1 ELECTRIC COOLER FAN

13 369470 369470 1 SUPER MINI Z HOOD

14 044818 044818 4 CN ZN TIN-C7343-1420

15 045088 045088 1 HOSE CLAMP 1"

16 785675 785675 1 REMOTE AIR FILTER HOSE

17 787689 787689 1 HONDA OIL DRAIN VALVE

18 787713 787713 1 0.50" LOW PRESSURE HOSE, 3.00" LONG

19 769166 769166 1 HOUR METER

20 388892 388892 1 SEAT SUPPORT CROSSMEMBER

21 767954 767954 8 FW .406 X .812 X .060 SAE HD ZN

22 055822 055822 8 CS .375-16 X .75 HX G5 ZNYC

23 034280 034280 4 CS .312-18 X .75 HX G5 ZNYC

24 029876 029876 4 LW .312 INT-EXT TOOTH ZNYC

25 052837 052837 4 CS .312-18 X1.50 HX G5 ZNYC

26 369132 369132 1 MUFFLER GUARD

27 377994 377994 1 MMZ ROLLER HEAT SHIELD

28 300061 300061 1 REAR BUMPER ENGINE GUARD

29 767962 767962 6 FW .531 X 1.063 X.090 SAE HD ZN

30 016527 016527 6 CS .500-13 X1.00 HX G5 ZNYC

31 064006 064006 2 CS .312-18 X .625 HX G5 ZNYC

32 047654 047654 2 CLIP

33 784843 784843 1 HONDA MUFFLER

34 785543 N/A 2 HONDA MUFFLER GASKET

35 784959 784959 1 MUFFLER MANIFOLD

36 017004 N/A 5 LW .312 MED SPRING ZNYC

37 782664 N/A 4 NT M8-1.25 HX STAINLESS STEEL

38 785378 785378 1 1.50" MUFFLER CLAMP

39 720177 720177 2 CS M 8-1.25 X 20 10.9 HXFLZNYC

40 077545 N/A 1 NT M8-1.25 10 HX ZNYC

41 787200 787200 1 TRACTOR WIRE HARNESS

42 056077 056077 2 CS .250-20 X 1.00 HX G5 ZNYC

43 785477 N/A 1 HONDA 20 AMP RECTIFIER

44 024927 024927 2 NT .250-20 HX GR.5 ZNYC

45 797670 797670 1 HONDA AIRCLEANER HOSE CLAMP

SERVICE

PAR T NO.

1 785014 785014 1 HONDA 24 HP ENGINE (USED ON 927285)

2 775353 775353 1 CENTRIFICAL AIR CLEANER CAP

3 057661 057661 2 HOSE CLAMP

4 785741 785741 1 MOUNTING BAND

5 782763 782763 1 AIR CLEANER

6 034272 034272 10 NT .312-18 HX G5 ZNYC

7 768523 768523 18 FW .343 X .687 X .051/.080HD ZNYC

8 370270 370270 1 MINI Z DEFLECTOR SCOOP

9 055939 055939 6 CS .250-20 X .750 HX G5 ZNYC

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Includes mounting hardware.

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

302620 8/06 5-7

3. Part of Item 41 (787200 Tractor Wire Harness).

4. Engine oil capacity; 2 US quarts.

5. Engine RPM to be set at 3600±50.

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

7. Air filter service parts:

785261 MAIN AIR FILTER ELEMENT

763318 VACUATOR VALVE

5-8 302620 8/06

This page intentionally left blank.

302620 8/06 5-9

Kohler Engine Installation

RED/BLK

PUR (P/O ENGINE)

POSITIVE BATTERY CABLE

ANTI-ROLLOVER WHEEL BRACKET

5-10 302620 8/06

Kohler Engine Installation

INDEX

NO.

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 370270 370270 1 MINI Z DEFLECTOR SCOOP

16 036236 036236 2 CS .312-18 X 1.00 HX G5

17 055939 055939 4 CS .250-20X .750 HX G5 ZNYC

18 768515 768515 4 FW .281X.625X.051/.080HD ZNYC

19 783837 783837 1 ELECTRIC COOLER FAN

20 044818 044818 4 CN ZN TIN-C7343-1420

21 369470 369470 1 SUPER MINI Z HOOD

22 795310 795310 1 REMOTE AIR FILTER HOSE

23 796672 796672 1 3/8-18 OIL DRAIN VALVE

24 787713 787713 1 0.50" LOW PRESSURE HOSE

25 769166 769166 1 HOUR METER

26 388892 388892 1 MINI Z CROSSMEMBER

27 808493 808493 4 RIVET NUT, 3/8-16 THREAD

28 767954 767954 8 FW .406 X .812 X .060 SAE ZN

29 055822 055822 8 CS .375-16 X .750 HX G5 ZNYC

30 034280 034280 4 CS .312-18 X .750 HX G5 ZNYC

31 029876 029876 4 LW .312 INT-EXT TOOTH ZNYC

32 052837 052837 4 CS .312-18X1.500 HX G5 ZNYC

33 369132 369132 1 MINI Z MUFFLER GUARD

34 300061 300061 1 ENGINE GUARD

35 377994 377994 1 MMZ ROLLER HEAT SHIELD

36 767962 767962 6 FW .531X 1.063X.090 SAE ZN

37 016527 016527 6 CS .500-13X1.00 HX G5 ZNYC

38 064006 064006 2 CS .312-18X .625 HX G5 ZNYC

39 788000 788000 1 WIRE HARNESS

SERVICE

PAR T NO.

1 788216 788216 1 KOHLER CV740 ENGINE (27 HP)

2 788018 788018 1 KOHLER MUFFLER

3 029751 029751 2 CS .375-16 X 1.00 HXFLK ZNYC

4 705137 705137 4 FW .391 X 1.250 X .060 ZNYC

5 016899 016899 2 NT .375-16 HXFLK ZNYC

6 785378 785378 1 MUFFLER 1.50" CLAMP

7 788026 788026 1 KOHLER 27-2 MANIFOLD

8 786673 786673 1 DONALDSON AIR CLEANER CAP

9 057661 057661 3 HOSE CLAMP

MFG. PART

NO.

QTY. DESCRIPTION

NOTES:

1. Includes mounting hardware.

2. Supplied with engine.

3. Part of Item 39 (788000 Wire Harness).

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

5. Engine oil capacity: 2 US quarts.

6. Engine RPM to be set at 3600±50.

302620 8/06 5-11

7. Used on mowers with serial number 05031280 and higher. These parts replace drain hose, 90° fitting, and drain plug, on mowers with serial numbers prior to 05031280

5-12 302620 8/06

This page intentionally left blank.

302620 8/06 5-13

Fuel System Installation

SEAT SUPPORT CROSSMEMBER

5-14 302620 8/06

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 791277 2 FITTING, FUEL TANK 90°

5 745059 745059 1 3-WAY FUEL VALVE

6 000323 000323 6 CLIP

7 000331 000331 3 BLACK CABLE TIE

8 767954 767954 12 FW .406 X .812 X .060 SAE HD ZN

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

SERVICE

PART NO.

015818 015818 1 FUEL LINE 22” TOTAL HONDA

MFG. PART

NO.

1. Torque to 20 ft.-lbs.

2. Supplied with new fuel tank.

QTY DESCRIPTION

NOTES:

302620 8/06 5-15

Instrument Panel Installation/Assembly

RIGHT SIDE FUEL TANK

15a

FUSE SIZE AND LOCATIONS

5a KAWASAKI 10a HONDA 15a KOHLER

20a

5-16 302620 8/06

Instrument Panel Installation/Assembly

ITEM NO.

1 785030 785030 1 Z CHOKE CABLE (KAWASAKI ENGINES)

2 776476 776476 1 PTO SWITCH

3 712257 712257 1 RED INDICATOR LIGHT

4 083022 N/A 2 IGNITION KEY

4 785808 785808 1 INDAK COATED 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.

786657 786657 1 Z CHOKE CABLE (HONDA ENGINES)

786657 786657 1 Z CHOKE CABLE (KOHLER ENGINES)

MFG. PART

NO.

1. Part of Tractor Wire Harness.

QTY DESCRIPTION

NOTES:

302620 8/06 5-17

Electrical Schematic - Kawasaki Engines (783894)

5-18 302620 8/06

Electrical Schematic - Kawasaki Engines (783894)

302620 8/06 5-19

Electrical Schematic - Honda Engines (787200)

5-20 302620 8/06

Electrical Schematic - Honda Engines (787200)

302620 8/06 5-21

Electrical Schematic—Kohler (788000)

5-22 302620 8/06

Electrical Schematic—Kohler (788000)

302620 8/06 5-23

5-24 302620 8/06

Chapter 6 Contents

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

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

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

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

302620 8/06 6-1

Front Wheel Assembly

TRACTOR FRAME

6-2 302620 8/06

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 798603 798603 2 FW .515 X 1.65 X .125 HD ZY

4 263517 263517 2 BEARING DISC

5 784223 784223 4 BEARING W/O COLLAR

6 784603 784603 2 SPACER

7 045765 045765 2 FW 1.030 X 1.500 X.134 ZN

8 366625 366625 2 FORK

9 786731 786731 2 CS .750-10 X 8.00 HX GR5 ZYNC

10 025296 025296 4 FW .760 X 1.625 X .08 ZN

11 061101 061101 2 NT .750-10 HX NL ZN

12 786061 786061 2 WHEEL & TIRE ASSY

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.

302620 8/06 6-3

Front Wheel Breakdown - 786061

ITEM NO.

1 786103 N/A 2 WHEEL BEARING

2 747402 N/A 1 TIRE 13 X 5.00

3 786079 N/A 1 WHEEL

4 019521 N/A 1 TIRE VALVE

5 015511 N/A 1 GREASE FITTING 45 DEG 1/4

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.

6-4 302620 8/06

Drive Wheel Assembly/Installation

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)

1. Torque to 65-75 ft. lbs.

2. Inflate tire to 8-10 psi.

SERVICE

PART NO.

MFG. PART

NO.

QTY DESCRIPTION

NOTES:

302620 8/06 6-5

Anti-Rollover Wheel Assembly

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

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 302620 8/06

Chapter 7 Contents

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

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

Blade Spindle Assembly Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

302620 8/06 7-1

Deck Assembly

15A

11A

12A

13A

44" DECK

14A

7-2 302620 8/06

Deck Assembly

INDEX

NO.

1A 546382 367946 1 44" MINI-Z DECK

10 036244 036244 6 CS .375-16 X1.00 HX G5 ZNYC

11 781708 N/A 4 CS .500-13 X 4.25 HX G5 ZNYC

11A 781708 N/A 3 CS .500-13 X 4.25 HX G5 ZNYC

12 767962 N/A 8 FW .531 X 1.063 X.090 SAE HD ZN

12A 767962 N/A 6 FW .531 X 1.063 X.090 SAE HD ZN

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

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

14 781567 781567 4 NT .50-13 HX LK NY

14A 781567 781567 3 NT .50-13 HX LK NY

15 031997 N/A 4 ANTI-SCALP WHEEL

15A 031997 N/A 3 ANTI-SCALP WHEEL

16 781880 781880 1 BUMPER

17 808485 808485 4 5/16-18 THREAD RIVET NUT

18 055822 055822 2 CS .375-16 X .750 HX G5 ZNYC

SERVICE

PAR T NO.

1 546408 367730 1 52" MINI-Z DECK

2 357111 357111 1 DISCHARGE CHUTE

3 063297 063297 2 SB .375 X .50 SH .312-18 TD ZN

4 767954 767954 20 FW .406 X .812 X .060 SAE HD ZN

5 054502 054502 8 NT .375-16 HX GRD 5 ZNYC

6 357103 357103 1 DISCHARGE CHUTE MOUNT BRACKET

7 058776 058776 2 NT .312-18 HX NL ZNYC

8 389189 389189 1 PUSHER

9 015495 015495 2 STRAIGHT GREASE FITTING

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 8 (389189 Pusher) installed as shown with zerks pointing upward, apply grease to zerks.

4. Includes items 11(A), 12(A), 13(A), and 15(A).

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

302620 8/06 7-3

Deck Pulley Assembly

7-4 302620 8/06

Deck Pulley Assembly

INDEX

NO.

10 350884 350884 1 DECK IDLER

11 259812 259812 1 SPRING CHAIN

12 781302 781302 1 IDLER SPRING

13 016972 016972 2 NT .625-11 HX G5 ZNYC

14 781385 781385 2 IDLER PULLEY

15 786335 786335 1 UHMW (.03 THICK)

16 781872 781872 6 CS .625-11 X 1.25 HX G5 ZNYC

17 782474 782474 8 CW .631 2.25 X .187 PNT

18 786889 786889 3 DECK DRIVE PULLEY (52" DECKS)

19 054502 054502 12 NT .375-16 HX GRD 5 ZNYC

20 767954 767954 24 FW .406 X .812 X .060 SAE HD ZN

21 368993 368993 1 L.S. PULLEY COVER (52" DECKS)

22 368985 368985 1 R.S. PULLEY COVER (52" DECKS)

23 792002 792002 4 5/16-18 X 3/4" MALE KNOB

24 794875 794875 2 CS .625-11 X 3.50 FULL HX G5 ZN

25 768523 768523 6 FW .343 X .687 X .051/.080 HD ZNYC

26 058776 058776 6 NT .312-18 HX NL ZNYC

27 783506 783506 3 BLADE SPINDLE ASSEMBLY

28 005116 005116 12 CS .375-16 X 1.375 HX G5 ZNYC

29 795526 795526 3 BLADE, F17.86"-H-F-CW

30 784256 784256 3 BLADE,15.66"-L-F-CW

31 079186 079186 5 CS .312-18 X1.25 HX G5 ZNYC

32 712927 712927 5 FW .344 X 1.00 X .12 HRD ZNYC

33 378745 378745 1 DECK IDLER

34 364315 364315 1 SPRING CHAIN

SERVICE

PAR T NO.

1 789388 789388 1 52" DECK BELT

791335 791335 1 44" DECK BELT

2 784199 784199 6 CS .312-18 X 1.25 FLT SH ZNYC

3 017129 017129 6 FW .440 X 1.00 X .083 ZNYC

4 785832 785832 2 DECK IDLER UHMW CLAMP

5 787069 787069 2 DECK IDLER UHMW RISER

6 025007 025007 1 CS .625-11 X1.75 HX G5 ZNYC

7 028118 028118 4 FW .62 X 1.00 X.134 ZNYC

8 781856 781856 1 IDLER NHI 5.00" PULLEY

9 600296 600296 1 DECK IDLER SPACER

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 075291 4 CLAMP KNOB

783753 783753 3 BLADE, 17.86"-L-F-CW

796300 796300 3 BLADE, F15.66"-H-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

302620 8/06 7-5

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

231

5. Used on mowers with serial number 05050800 and higher, mowers with serial number pior to 05050800, use 786889.

6. Optional blades:

785428 16" CW Gator Blade

785436 18" CW Gator Blade

7-6 302620 8/06

Blade Spindle Assembly Breakdown

INDEX

NO.

SERVICE

PAR T 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:

302620 8/06 7-7

7-8 302620 8/06

Chapter 8 Contents

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

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

302620 8/06 8-1

Deck Installation

TRACTOR ASSEMBLY

INDEX

NO.

SERVICE

PAR T 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 302620 8/06

Deck Belt Routing and Tensioning

NOTES:

1. Spring length after tensioning new beltmeasured from outside of hook to outside of hook.

2. Route belt as shown.

302620 8/06 8-3

8-4 302620 8/06

Chapter 9 Contents

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

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

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

302620 8/06 9-1

Tractor Decals

SECTION A-A

SEE DETAIL A

DETAIL A

TOP OF SEAT PAN

SECTION B-B

BOTTOM OF SEAT PAN

9-2 302620 8/06

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 600899 600899 1 PUMP BELT WARNING DECAL

14 785188 785188 1 Z ARMREST WARNING DECAL

15 727016 727016 1 BATTERY DECAL

16 788968 788968 1 ENGINE COMPARTMENT DECAL

17 771436 771436 1 STABILIZER DECAL

SERVICE

PAR T 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 786822 786822 1 HUSTLER SUPER 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:

302620 8/06 9-3

52" Deck Decals

INDEX

NO.

SERVICE

PAR T 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 302620 8/06

44" Deck Decals

INDEX

NO.

SERVICE

PAR T 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:

302620 8/06 9-5

9-6 302620 8/06

Chapter 10 Contents

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

302620 8/06 10-1

Seat Installation

10-2 302620 8/06

Seat Installation

INDEX

NO.

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

PAR T 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 792051 792051 1 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. Service parts available for Michigan seats:

PART NO.

793307 SLIDE KIT

793323 KNOB KIT

793281 BACK CUSHION KI

793299 SEAT CUSHION KIT

797571 SEAT BACK PANEL KIT

793315 SEAT SWITCH

797480 ONE ARMREST (ROUND STYLE W/O BRACKET))

793265 ONE ARMREST (SQUARE STYLE W/O BRACKET)

793273 ARMREST STOP ASSEMBLY

DESCRIPTION

3. Service parts available for Milsco seats:

PART NO.

782144 ADJUSTER, STANDARD AND LOW PROFILE SUSPENSION SEAT

782177 OPERATOR PRESENCE SWITCH

783472 Z ARMREST ONLY KIT

DESCRIPTION

302620 8/06 10-3

10-4 302620 8/06

Chapter 11 Contents

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

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

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

11-1

302620 8/06

11-2

302620 8/06

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

302620 8/06

11-3

▲

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

11-4

302620 8/06

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

302620 8/06

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.

11-5

600899

11-6

302620 8/06

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

19. Hydraulic Oil Heat Exchanger

11-7

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

Figure 11-1

Viewed from bottom of tractor

302620 8/06

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.

Clean oil heat exchanger (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

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

WEEKLY MONTHLY ANNUALLY OR

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

Hour

meter

11-8

Figure 11-2

302620 8/06

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.

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

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

Super 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.

11-9

Electric clutch

Figure 11-4

Figure 11-3

Battery

302620 8/06

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.

A hydraulic oil heat exchanger is installed on the Super Mini Z. This heat exchanger is designed to keep hydraulic system oil temperature lower in hot operating conditions or heavy continuous operating conditions.

This hydraulic heat exchanger is located above the engine. Air is drawn across the cooling fins by an electric fan located above the heat exchanger. Fig. 11-7

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.

Figure 11-6

Hydraulic

reservoir

Hydraulic filter

Figure 11-5

Seat platform catch

Control lever

Seat platform

Figure 11-7

Cooling fan

Heat

exchanger

Engine

11-10

302620 8/06

WARNING: Gasoline is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness. Avoid prolonged breathing of vapors. Keep face away from nozzle and gas tank or conditioner opening. Keep gas away from eyes and skin.

The fuel tanks are located in the tractor’s fenders. (Fig. 11-8) Total

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

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

The fuel filter (Fig. 11-9A, 11-9B & 11-9C) 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. 11-10A) 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. 11-10B) Close this valve (center position) to prevent fuel flow to the engine. Fig 11-10B 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. 1111A, 11-11B & 11-11C). 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. 1111A, 11-11B & 11-11C

Figure 11-10B

Fuel valve (shown in closed position)

Left fuel tank

Right fuel tank

Figure 11-10A

Fuel shut-off valve

Valve grommet

Figure 11-9B

Fuel filter

Honda engine

Figure 11-8

Fuel tank

Figure 11-9C

Fuel filter

Figure 11-9A

Fuel filter

Kawasaki engine

Kohler engine

11-11

302620 8/06

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 Super Mini

Z tractors and supplies clean combustion air to the engine. Fig. 11-12

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.

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.

Figure 11-11B

Engine oil drain plug

Engine

oil filter

Engine oil filler tube Honda Engine

Figure 11-11A

Engine oil drain plug

Engine oil filter

Engine oil filler tube

Kawasaki Engine

11-12

Figure 11-12

Pre-cleaner

Canister

Figure 11-11C

Engine oil

drain plug

Engine oil filter

Kohler engine

302620 8/06

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. 11-13

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, 11-13

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

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 11-14 and 11-15 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

Figure 11-14

2, 6

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

Viewed from

bottom for unit

Figure 11-15

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

11-13

Figure 11-13

Indicator

Reset

button

302620 8/06

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!

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-

16). 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. 11-17 and 11-18). 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.

11-14

Figure 11-18

Twisted Blade Edge

(Replace)

Cutting Edge

Straight Blade Edge

End view of blades, comparing twisted and straighten blades.

Cutting Plane

Cutting Edge

Figure 11-16

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 11-17

302620 8/06

ADJUSTMENTS

Introduction

Your Super Mini Z was adjusted before it left the factory and was checked during predelivery setup. However, after start-up and continued use, a certain amount of break-in wear will cause some adjustments to change.

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.

Control lever in the neutral

position

Control

lever

Park brake slot

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. 11-19). 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. 11-20

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

Figure 11-19

Jam nut

Pump

linkage

rod

Figure 11-20

Jam

nut

Stop

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. 11-20 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. 11-20 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

302620 8/06

Control

lever

Figure 11-21

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. 11-23 or Fig. 11-24

11-15

Control lever stops

The control lever stops (Fig. 11-21) are designed to do two things: First, and most important, they must keep the pumps from bottoming out internally. Secondly, the stops may be adjusted to help drive straight when the control levers are pushed forward against the stops.

To keep the pumps from bottoming out internally use the following procedure:

1. 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. 11-22) 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. 11-23), 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.

11-16

Figure 11-23

Cap screw

Upper

control

lever

Lower control

lever

Figure 11-22

Spring

housing

Front ball

stud

Figure 11-24

Front brake link

(right side)

Steering dampener

with spring

302620 8/06

NOTE: The front brake link is not adjustable. Fig. 11-24

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

3. Open the hydraulic pump’s bypass valve (Fig. 11-25), on the side that is being adjusted, by turning bypass valve counter clockwise one-half to one revolution. The valve stems on each hydraulic pump are located near the top and are identified as a hex stud.

4. Rotate the tire. The tire should rotate. 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. 11-26 NOTE: When the control lever is against the outside edge of the the slot, the brakes should not be engaged. Fig. 11-27

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. 11-28

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. 11-29). 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.

Control lever

Travel slot

Outside edge

Jam nut

Turnbuckle

Park brake slot

Figure 11-27

Jam nut

Brake linkage

Control lever

Outside edge

Bypass valve

Figure 11-25

Park brake

1/8”

slot

Figure 11-28

Control lever in park brake position

Figure 11-29

Hydraulic pump belt adjustment

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

and spring (Fig. 11-30). 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.

302620 8/06

Figure 11-26

Deck drive belt adjustment

The spindle belt tension remains constant by means of a tension idler and spring (Fig. 11-31). The spring tension should be such that the belt does not slip under normal operating load conditions, assuming the belt is not

11-17

excessively worn or damaged. As belt stretches and wears in, adjustment may become necessary. To increase belt tension, move the spring chain one (or more) link(s) at the anchor bracket (Fig. 11-31). Installed spring length should be 7.75" ± .3" (19.7 cm ± .76 cm) originally with adjustments of .60" (15.2mm) per chain link. (Fig. 11-32)

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

badly worn belt or pulley.

Engine RPM setting

The Super 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. 11-33). 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. 11-34

5. Clamp the height adjusting stop against the stop handle (11-34).

Figure 11-35

Deck lift threaded rod

Nut

Chains

Figure 11-34

Height

adjusting

stop

Stop

handle

11-18

Figure 11-32

1.75”

Spring Extension

7.75”

6.0”

Normal Spring Length

Figure 11-30

Spring

Tension

idler

Pump drive

belt

Figure 11-31

Spring

Tension idler

Chain

Figure 11-33

Blocks

302620 8/06

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. 11-35, 11-36, 11-37

7. Loosen the two nuts on the front of height indicator so that the foot pedal is free. Fig. 11-38

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. 11-39

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. 11-38

13. Go to the right front of the tractor.

14. Loosen the 5/16" jam nut on the adjuster lift chain (11-37), 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. 11-37

18. Tighten the hardware holding the chain and adjuster onto the deck lift arm.

19. Go to the right rear of the tractor.

20. Make sure that there is still slack in the chain. If not, loosen the two

nuts on the block holding the threaded rod until there is slack in the deck lift chain. Fig. 11-36

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

22. 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. 11-35

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. 11-39). Typical both sides.

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

Figure 11-38

Foot

pedal

Nuts

Figure 11-37

5/16” bolt

Adjuster

Hardware

Jam nut

Figure 11-39

Lift block

1”

Deck lift rod

1”

Deck lift

assist springs

Figure 11-36

Deck lift

threaded

rod

Nut

Chains

11-19

302620 8/06

11-20

302620 8/06

INDEX

PAGE

Access to engine and hydraulic pump............................11-9

Adjustment introduction...............................................11-15

Belt replacement...........................................................11-13

Burnishing the electric clutch.........................................11-9

Control lever adjustment ..............................................11-16

Control lever stops .......................................................11-16

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

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

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

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

Engine air filter ............................................................11-12

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

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

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

General engine maintenance ........................................11-13

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 ...........................................11-14

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

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

Safety precautions ........................................................11-13

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

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

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

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

11-21

302620 8/06

Numerical Index

Part Page No. No.

Index

Numerics

000323 5-14 000331 5-14 005116 7-5 008193 4-11 008573 3-3 015495 4-5 015511 6-4 015818 5-14 016253 6-6 016527 4-11 016899 5-11 016972 7-5 017004 4-7 017129 7-5 019521 6-4 024927 4-3 025007 7-5 025296 4-11 026237 5-16 027912 1-1 027920 1-1 028118 4-11 029751 5-11 029868 4-3 029876 4-3 030817 5-3 031997 6-6 032763 3-3 032771 3-3 034272 3-3

034280 4-3 036236 5-3 036244 4-7 041152 4-7 041707 3-3 044255 5-3 044818 5-3 045088 5-3 045765 6-3 045898 5-16 047654 5-3 048876 4-7 051169 8-2 052837 5-3 052860 2-3 053199 4-7 054502 4-11 055749 4-5

, 10-3

, 4-11, 7-3

, 5-3, 5-7, 5-11

, 5-3, 5-7

, 6-5 , 4-11, 5-3, 5-7

, 6-3, 8-2

, 3-4

, 7-5

, 5-3, 5-7, 5-11

, 7-3

, 4-3, 4-5, 4-7,

5-3, 5-7, 5-11, 6-6, 10-3

, 5-3, 5-7, 5-11 , 5-7, 5-11 , 4-11, 7-3, 10-3

, 5-7, 5-11 , 5-7

, 5-7

, 5-7, 5-11 , 10-3 , 7-3

, 7-3, 7-5

, 8-2

Part Page No. No.

055822 4-7

055939 3-3

055947 3-3 056077 5-7 057661 5-3 058776 4-3 059832 4-7 060541 4-7 061077 6-5 061101 4-11 063198 4-7 063297 7-3 064006 5-3 064014 4-7 068239 6-6 068478 1-1 068551 3-3 075291 7-5 077545 5-7 079186 7-5 080358 10-3 083022 5-16 083196 4-11 083279 9-3 086660 2-3 212076 4-11 259812 7-5 263517 6-3 300061 5-3 302638 1-1 302935 4-7 302943 4-7 344267 6-3 348284 4-5 348318 4-5 348391 4-5 348417 4-3 348458 4-5 348862 4-7 349308 5-16 350421 10-3 350835 6-6 350884 7-5 357103 7-3 357111 7-3 360693 5-3 362392 4-11 364315 7-5 366625 6-3 366765 4-11

, 5-3, 5-7, 5-11,

5-14, 7-3, 10-3

, 4-3, 4-11, 5-3,

5-7, 5-11

, 5-3, 5-16

, 5-7, 5-11 , 7-3, 7-5 , 5-16

, 5-7, 5-11

, 4-7

, 4-7, 10-3

, 5-7, 5-11

, 6-3, 8-2

Part Page No. No.

367128 4-7 367169 4-7 367565 4-7 367573 4-7 367730 7-3 367946 7-3 368670 4-7 368704 4-7 368803 3-3 368860 4-11 368910 4-7 368944 7-5 368977 7-5 368985 7-5 368993 7-5 369132 5-3 369470 5-3 369660 4-7 370270 5-3 377994 5-7 378745 7-5 387936 2-2 388884 2-3 388892 5-3 388983 10-3 389189 7-3 389940 10-3 392449 2-2 546382 7-3 546408 7-3 546630 2-2 546648 2-2 600221 4-7 600296 7-5 600899 9-3 700484 3-3 704163 4-7 704643 4-5 704742 3-3 704932 5-16 705137 5-11 705178 4-7 705186 3-3 705954 6-3 712257 5-16 712927 4-7 713198 3-3 714998 5-16 720177 5-3 722199 10-3 724716 10-3 727008 9-3

, 5-7, 5-11 , 5-7, 5-11

, 5-7, 5-11 , 5-11

, 5-7, 5-11

, 8-2

, 7-5

, 5-7

302620 8/06 i-1

Hustler Turf Super Mini Z User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

Chapter 1

General Information

Chapter 2 Contents

Rivet-nut Installation

Footrest Assembly

Chapter 3 Contents

Hydraulic System Installation

Chapter 4 Contents

Battery Installation

Deck Lift Assembly

Steering and Brake Assembly

Pump Belt and Pulley Installation

Chapter 5 Contents

Kawasaki Engine Installation

Honda Engine Installation

Kohler Engine Installation

Fuel System Installation

Instrument Panel Installation/Assembly

Electrical Schematic - Kawasaki Engines (783894)

Electrical Schematic - Honda Engines (787200)

Chapter 6 Contents

Front Wheel Assembly

Front Wheel Breakdown - 786061

Drive Wheel Assembly/Installation

Anti-Rollover Wheel Assembly

Chapter 7 Contents

Deck Assembly

Deck Pulley Assembly

Blade Spindle Assembly Breakdown

Chapter 8 Contents

Deck Installation

Deck Belt Routing and Tensioning

Chapter 9 Contents

Tractor Decals

52" Deck Decals

44" Deck Decals

Chapter 10 Contents

Seat Installation

Chapter 11 Contents

MAINTENANCE

ADJUSTMENTS

INDEX