advertisement
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 forest-covered, brush-covered, or grass-covered unimproved land. Other states or federal areas may have similar laws.
This spark ignition system complies with Canadian ICES-002.
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 per the information found in the Product Information section of the
owner’s manual.
Table of Contents
Chapter 1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Chapter 2 Contents
Rivet-nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Chapter 3 Contents
Hydraulic System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Chapter 4 Contents
Battery Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
302620 8/06
Maintenance & Adjustments Safety Precautions . . . . . . . . . . . . . . 11-2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
LW
MB
MS
NT
SC
SH
SB
SS
OD
ID
CB
CE
CP
CS
CW
FDRW
FW
HX
Standard Torques
Carriage Bolt
Clevis Pin
Cotter Pin
Cap Screw
Cup Washer
Fender Washer
Flat Washer
Hex Head
Lock Washer
Machine Bushing
Machine Screw
Nut
Self Tapping Cap Screw
Socket Head
Shoulder Bolt
Set Screw
Outside Diameter
Inside Diameter
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
.312
.375
.438
.500
.562
.625
.750
.875
1.00
8.2
17
30
48
73
105
145
260
420
625
11.1
23
40
65
99
143
200
350
565
850
M3
M4
M5
M6
M8
M10
M12
M16
M20
M24
1
2.2
4.5
7.7
18.5
37
64
160
320
555
1.3
3
6.1
10.4
25
50
87
215
435
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
1
2
INDEX
NO.
1
2
SERVICE
PART NO.
546630
546648
N/A
MFG. PART
NO.
387936
392449
808493
QTY.
1
2
DESCRIPTION
52" MINI Z FRAME
44" MINI Z FRAME
3/8-16 THREAD NUTSERT
NOTES:
2-2 302620 8/06
Footrest Assembly
3
1
2
4
5
6
5
7
1
INDEX
NO.
6
7
4
5
1
2
3
SERVICE
PART NO.
388884
785485
785493
086660
767954
781880
052860
MFG. PART
NO.
388884
785485
785493
086660
767954
781880
052860
QTY.
2
2
2
4
1
2
1
DESCRIPTION
MINI Z FLOOR PLATE
UPPER STEP TREAD
LOWER STEP TREAD
NT .375-16 HX LK NY
FW .406 X .812 X .060 SAE HD ZN
RUBBER BUMPER
CS .375-16 X 1.25 HX G5 ZNYC
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
21
25
26
27
20
19
22
9
13
7
8
4
5
11
6
14
10
17
2
2
1
15
21
16
26
27
18
3
12
19
24
22
23
33
34
28
29
30
32
31
35
29
28
30
31
27
36
39
44
43
3-2
37
27
38
41
42
40
302620 8/06
Hydraulic System Installation
SERVICE
PART NO.
787598
784082
781559
781542
786368
786350
041707
704742
791152
008573
767962
781526
787440
791061
068551
768515
055939
713198
713198
787192
032763
032771
368803
783985
787564
787572
781658
700484
034272
768523
055947
787580
784108
795278
791103
791087
705186
787622
787457
791814
787606
788174
783936
783928
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
INDEX
NO.
29
30
31
32
33
26
27
28
20
21
22
23
24
25
12
13
14
15
16
17
18
19
10
11
8
9
6
7
4
5
1
2
3
37
38
39
40
34
35
36
41
42
43
44
MFG. PART
NO.
N/A
N/A
N/A
N/A
786368
786350
041707
704742
791152
008573
767962
N/A
N/A
N/A
068551
768515
055939
713198
713198
787192
032763
032771
368803
N/A
N/A
N/A
N/A
700484
034272
768523
055947
N/A
N/A
N/A
N/A
N/A
705186
N/A
N/A
N/A
N/A
N/A
783936
783928
QTY.
3
1
1
8
8
4
8
2
1
2
3
1
1
1
1
3
1
1
3
2
1
2
1
1
1
1
1
1
2
2
2
8
4
1
1
4
1
1
1
1
1
1
1
1
DESCRIPTION
NT .250-20 HX NL ZNYC
FW .281 X .625 X .051/.080 HD ZNYC
CS .250-20 X .750 HX G5 ZNYC
SEAL 3/8 X 3/4 X 7¾" LONG
SEAL 3/8 X 3/4 X 1½" LONG
HYDRAULIC OIL COOLER
BREATHER CAP
STRAINER
HYDRAULIC OIL RESERVOIR
FITTING, STR ORB-BEADED TUBE
MINI-Z CASE DRAIN HOSE ASSEMBLY
MINI-Z CASE DRAIN HOSE ASSEMBLY
FITTING, STR-8MORB/HEX PLUG
HOSE CLAMP
NT .312-18 HX G5 ZNYC
FW .343 X .687 X .051/.080 HD ZNYC
CS .250-20 X .500 HX G5 ZNYC
HOSE ASSEMBLY, PUMP TO COOLER SMZ
FITTING, 6 BEADED TUBE-ORB 45
HOSE ASSEMBLY, PUMP TO COOLER SMZ
FITTING, 8 BEADED TUBE-ORB 90
FITTING, 45-8MORB/-8MSL
FITTING, 90-8MORB/-8MSL
PUMP, HYDRO-GEAR BDP16A-306
PUMP, HYDRO-GEAR BDP16A-409
NT .437-14 HX G5 ZNYC
FW .453 X .812 X .060 ZNYC
WHITE MOTOR CE14
CS .500-13 X 2.500 HX G5 ZNYC
FW .531 X 1.063 X .090 SAE HD ZN
FITTING, 90-10MORB/-8MSL
FITTING, 45-10MORB/-8MSL
HYDRO TUBE, SMZ-RH SIDE-RP/BM
HYDRO TUBE, SMZ RH SIDE LP/TM
HYDRO TUBE SMZ LH SIDE- LP/TM
HYDRO TUBE SMZ LH SIDE-RP/BM
CS .437-14 X 1.375 HX G5 ZNYC
HOSE ASSEMBLY, RESERVOIR TO FILTER SMZ
FITTING, 90-12MORB/-12MJIC
HOSE ASSY FILTR TO RH PUMP SMZ
HOSE ASSEMBLY, FILTER TO PUMP SMZ
FITTING, T -8MJIC/8MJIC/12MORB
FILTER ELEMENT
FILTER HEAD ZAF SERIES
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
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
1
12
2
11
13
8
7
9
3
1
2
5
6
7
6
4
8
7
10
4-2
14
302620 8/06
Battery Installation
INDEX
NO.
12
13
14
10
11
8
9
6
7
4
5
1
2
3
SERVICE
PART NO.
058776
768523
348417
785063
771428
055939
029868
024927
740696
034272
768820
034280
029876
779850
MFG. PART
NO.
058776
768523
348417
785063
771428
055939
029868
024927
740696
034272
768820
034280
029876
779850
QTY.
1
1
2
2
1
2
1
2
4
1
1
2
3
1
DESCRIPTION
NT .312-18 HX NL ZNYC
FW .343 X .687 X .051/.080 HD ZNYC
BATTERY CLAMP STRAP
POSITIVE BATTERY CABLE
RED BATTERY CABLE BOOT
CS .250-20 X .750 HX G5 ZNYC
LW .250 INT-EXT TOOTH ZNYC
NT .250-20 HX GR.5 ZNYC
BATTERY
NT .312-18 HX G5 ZNYC
BATTERY GROUND CABLE
CS .312-18 X .750 HX G5 ZNYC
LW .312 INT-EXT TOOTH ZNYC
CB .312-18 X 3.00 FUL ZN
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
1
2
3
5 7
8
4
6
6
4
6
13
1
14
4
12
11
15
10
6
7
8
4
4
14
1
6
6
5
4
8
7
11
14
6
9
8
14
1
4-4 302620 8/06
Deck Lift Assembly
INDEX
NO.
12
13
14
15
8
9
10
11
6
7
4
5
1
2
3
SERVICE
PART NO.
348318
348284
784488
781294
782995
704643
055749
348391
781831
756270
034272
348458
781229
015495
784686
MFG. PART
NO.
348318
348284
784488
781294
782995
704643
055749
348391
781831
756270
034272
348458
781229
015495
784686
QTY.
4
1
1
1
1
1
4
1
8
3
7
2
1
1
1
DESCRIPTION
STOP HANDLE
HEIGHT ADJUSTMENT STOP
DECK LIFT INDICATOR
CLIP E, 1.00 X.625X .050
DECK LIFT SPRING
NT .437-14 HX FLG ZN
CS .437-14 X 1.750 HX G5 ZNYC
DECK LIFT CHAIN
CS .437-14 X 1.750 FULTH G5 ZNYC
CS .312-18 X 1.50 FLTHR GR5 ZNYC
NT .312-18 HX G5 ZNYC
DECK LEVELER YOKE
CE .750X2.25 X1.75 HEADLESS
STRAIGHT GREASE FITTING
FW .812 X 1.469 X .134 THK ZNYC
NOTES:
1. Apply grease at zerks (see owner’s manual).
302620 8/06 4-5
Steering and Brake Assembly
1
2
5
6
4
7
8
6
9
10
12
13
11
3
6
28
14 12
13
15
17
27
6
7
16
26
30
24
12
25
24
12
18
20
19
12
13
21
12
23
12
20
22
31
29
15
5
6
37
40
1
45
44
43 42
2
41
47
12
46
21
26
32
12 13
26
36 35
33
34
26
6
12
21
38
33
39
4-6 302620 8/06
Steering and Brake Assembly
SERVICE
PART NO.
768515
034272
369660
068551
781922
600221
783696
086660
367573
367565
063198
782979
781211
059832
781260
368704
367128
368670
055822
767954
781716
053199
036244
781583
705178
768523
041152
348862
781153
784439
368910
781286
704163
060541
765339
302943
302935
367169
783852
791327
017004
048876
783118
783126
782953
783845
064014
712927
3
4
5
INDEX
NO.
12
13
14
15
16
17
18
19
10
11
8
9
6
7
4
5
1
2
3
20
21
22
23
24
25
6
44
45
46
47
40
41
42
43
36
37
38
39
33
34
35
26
27
28
29
30
31
32
MFG. PART
NO.
768515
034272
369660
068551
781922
600221
783696
086660
367573
367565
063198
782979
781211
059832
781260
N/A
367128
368670
055822
767954
781716
053199
036244
781583
705178
768523
041152
348862
781153
784439
368910
781286
704163
060541
765339
302943
302935
367169
N/A
791327
017004
048876
783118
783126
782953
N/A
064014
712927
QTY.
2
2
4
1
4
2
12
1
4
8
2
2
4
2
34
8
4
4
2
1
2
2
2
6
2
4
26
4
2
6
2
2
1
4
8
2
2
1
1
4
8
2
2
1
2
4
4
1
DESCRIPTION
STEERING BAR GRIP
STEERING BAR
CONTROL PANEL
STEERING ARM MOUNT
CS .375-16 X .750 HX G5 ZNYC
FW .406 X .812 X .060 SAE HD ZN
SS .500-13 X 1.75 SH ZN
NT .500-13 HX JAM ZNYC
CS .375-16 X 1.00 HX G5 ZNYC
BRAKE ROD ASSEMBLY
CS .375-16 X1.75 HX G5 ZNYC
FW .343 X .687 X .051/.080 HD ZNYC
NT .312-24 HX ZNYC
STEERLEVER BUSHING
.750 X 1.00 X .50 PLASTIC BUSHING
LOCK COLLAR
STEERING CENTER PIVOT TUBE
PUMP ROD ADJUSTER ASSEMBLY
CS .250-20 X 2.00 HX G5 ZNYC
FW .281X.625X.051/.080HD ZNYC
NT .312-18 HX G5 ZNYC
PUMP ARM
NT .250-20 HX NL ZNYC
DAMPER BALL STUD
CENTERING DAMPENER
CENTERING DAMPENER
NT .375-16 HX LK NY
LH STEERLEVER SUPPORT
RH STEERLEVER SUPPORT (NOT SHOWN)
CS 10-24 X .750 HXFLK ZNYC
CS .375-16 X 4.75 HX G5 ZNYC
PUSH BUTTON SWITCH
NT #10-24 HX NL ZN
SB .500 X .625 SH .375-16 ZN
INGUS#MFI-0608_05 BUSHING
LEFT BRAKE PIVOT ARM
RIGHT BRAKE PIVOT ARM (NOT SHOWN)
BRAKE LEVER EXTENSION
KEY
BRAKE LINKAGE ASSEMBLYY
LW .312 MED SPRING ZNYC
CS .312-18 X .750 HX G8 ZNYC
BRAKE ASSEMBLY
BRAKE ASSEMBLY (NOT SHOWN)
HUB ASSEMBLY
NUT
CS .312-18 X .875 HX G5 ZNYC
FW .344 X 1.00 X .12 HRD ZN
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
14
LOCATION FOR
RUBBER BUMPER
1
2
25
2
5
26
28
29
27
28
30
31
32
33
34
35
13
1
12
8
2
3
2
9
8
2
4
10
5
9
6
1
7
23
20
21
22
16
4
15
14
13
11
17
18
19
3
24
4-10 302620 8/06
Pump Belt and Pulley Installation
MFG.
PART NO.
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
786848
028118
781872
781302
786533
N/A
783761
212076
797654
791251
787366
783829
785659
083196
782466
768127
366765
016527
767962
008193
784918
015495
368860
025296
061101
SERVICE
PART NO.
786848
028118
781872
781302
786533
787408
778217
036244
767954
054502
055939
362392
778738
768515
024927
748681
783761
212076
797654
791251
787366
783829
785659
083196
782466
768127
366765
016527
767962
008193
784918
015495
368860
025296
061101
INDEX
NO.
29
30
31
32
33
34
26
27
28
20
21
22
23
24
25
12
13
14
15
16
17
18
19
10
11
8
9
6
7
4
5
1
2
3
QTY
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
2
4
1
1
1
1
2
1
4
2
1
1
1
1
1
1
1
DESCRIPTION
SUPER Z SINGLE PULLEY
KEY 1/4 SQ X 1.50 LONG
FW 1.156 X 1.750 X .250 ZY
CLUTCH PIGTAIL HARNESS (DIODE)
WARNER Z CLUTCH
FW .460X 1.750X .250 ZNYC
CS .437-20 X 2.50 HX G5 ZNYC
SS .312-18 X .750 SQ-HD ZN
PULLEY & FAN BDP-21
KEY 5MM X 30MM RADIUS ENDS
CLUTCH ANCHOR ANGLE
CS .500-13 X 1.00 HX G5 ZNYC
FW .531 X 1.063 X .090 SAE HD ZN
NT .500-13 HX G5 ZNYC
RUBBER BUMPER
STRAIGHT GREASE FITTING
PUMP IDLER ARM
FW .760 X 1.625 X .08 ZN
NT .750-10 HX NL ZN
IDLER PULLEY
FW .62 X 1.00 X.134 ZN
CS .625-11 X 1.25 HX G5 ZN
IDLER SPRING
A-SEC PUMP IDLER BELT
CLUTCH
CS .437-20 X 2.25 G5 ZNYC
CS .375-16 X 1.000 HX G5 ZN
FW .406 X .812 X .060 SAE HD ZN
NT .375-16 HX GRD 5 ZN
CS .250-20 X .750 HX G5 ZN
CLUTCH ANCHOR BRACKET
.312 WIRING CLAMP
FW .281 X .625 X .051/.080 HD ZN/YL
NT .250-20 HX GR.5 ZN
GM .75 X 1.35 X 1.06 X .18 GROMMET
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
2
1
4
3
13
10
11
12
18
19
20
1
21 25
26
24
22
23
37
39
38
40
7
5
2
8
7
9
11
10
14
6
7
16
6
7
3
17
3
36
7
15
TO SPADE
TERMINAL
PUR
3
6
YEL
3
P/O ENGINE
11
27
28
29
28
3
TO BULLET
TERMINALS
(MALE-BRN)
(FEMALE-ORG)
30
11
33
11
31
11
3
34
35
RED/BLK
41
32
POSITIVE
BATTERY
CABLE
3
PUR
42
43
44
45
46
47
7
47
5-2 302620 8/06
Kawasaki Engine Installation
INDEX
NO.
13
14
15
16
9
10
11
12
17
18
7
8
5
6
3
4
1
2
SERVICE
PART NO.
360693
017004
782664
796524
024927
768820
783894
044255
786038
777656
782318
786863
720177
786566
780841
786871
036236
055939
768515
783837
047654
369470
044818
045088
786673
785741
057661
788943
782763
034272
768523
370270
034280
369132
300061
029876
052837
016527
767962
064006
771428
030817
055947
792192
769166
388892
055822
767954
7
39
40
41
42
35
36
37
38
43
44
45
46
47
31
32
33
34
27
28
29
30
23
24
25
26
19
20
21
22
MFG. PART
NO.
360693
017004
782664
796524
024927
768820
783894
044255
786038
777656
782318
786863
720177
786566
780841
786871
036236
055939
768515
783837
047654
369470
044818
045088
786673
785741
057661
788943
782763
034272
768523
370270
034280
369132
300061
029876
052837
016527
767962
064006
771428
030817
055947
792192
769166
388892
055822
767954
QTY.
1
1
3
1
4
1
1
4
2
1
2
1
1
1
1
1
4
1
2
1
11
1
2
6
1
10
18
1
2
1
1
1
6
2
4
6
1
4
4
1
8
8
1
1
2
1
1
1
DESCRIPTION
DONALDSON AIR CLEANER CAP
MOUNTING BAND
HOSE CLAMP
AIR FILTER INDICATOR
AIR CLEANER
NT .312-18 HX G5 ZNYC
FW .343 X .687 X .051/.080HD ZNYC
MINI Z DEFLECTOR SCOOP
CS .312-18 X 1.00 HX G5 ZNYC
CS .250-20 X .75 HX G5 ZNYC
FW .281 X .625 X .051/.080HD ZNYC
ELECTRIC COOLER FAN
CLIP
SUPER MINI Z HOOD
CN ZN TIN-C7343-1420
HOSE CLAMP 1"
REMOTE AIR FILTER HOSE
KAWASAKI 23 HP ENGINE (FH680V, 3600 RPM) (USED ON 927269)
KAWASAKI 25 HP ENGINE (FH601V, 3600 RPM) (USED ON 927277)
19/23/25 KAWASAKI MUFFLER
CS M 8-1.25 X 20 10.9 HXFLZNYC
1.375" MUFFLER CLAMP
KAW (23) MUFFLER GASKET
KAWASAKI MUFFLER MANIFOLD
HEAT SHIELD
LW .312 MED SPRING ZNYC
NT M8-1.25 HX STAINLESS STEEL
M20 X 2.5 OIL DRAIN VALVE
NT .250-20 HX GR.5 ZNYC
BATTERY CABLE
TRACTOR WIRE HARNESS
NT #10-32 HX ZN
RED BATTERY CABLE BOOT
STARTER SOLENOID
CS .250-20 X .50 HX G5 ZNYC
STARTER RELAY GROUND WIRE
HOUR METER
SEAT SUPPORT CROSSMEMBER
CS .375-16 X .750 HX G5 ZNYC
FW .406 X .812 X .060 SAE HD ZN
CS .312-18 X .75 HX G5 ZNYC
MUFFLER GUARD
ENGINE GUARD
LW .312 INT-EXT TOOTH ZNYC
CS .312-18 X1.50 HX G5 ZNYC
CS .500-13 X1.00 HX G5 ZNYC
FW .531 X 1.063 X.090 SAE HD ZN
CS .312-18 X .625 HX G5 ZNYC
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
763318
MAIN AIR FILTER ELEMENT
VACUATOR VALVE
5-4 302620 8/06
This page intentionally left blank.
302620 8/06 5-5
Honda Engine Installation
39
42
1
10
38
33
32
1
37
43
10
34
35
36
BRN
ORG
3
3
41
GRA/PUR
3
POSITIVE
BATTERY
CABLE
36
3
RED/BLK
40
PUR
3
42
20
9
5
10
3
12
2
2
4
6
7
6
7
3
15
14
16
45
8
11
7
9
10
13
6
7
YEL
3
PART OF
ENGINE
17
18
19
22
21
23
7
ANTI-ROLLOVER
WHEEL BRACKET
27
29
30
24
25
5-6
26
28
7
31
302620 8/06
Honda Engine Installation
SERVICE
PART NO.
052837
369132
377994
300061
767962
016527
064006
047654
787689
787713
769166
388892
767954
055822
034280
029876
055939
768515
036236
783837
369470
044818
045088
785675
785014
775353
057661
785741
782763
034272
768523
370270
784843
785543
784959
017004
782664
785378
720177
077545
787200
056077
785477
024927
797670
INDEX
NO.
29
30
31
32
25
26
27
28
21
22
23
24
17
18
19
20
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
37
38
39
40
33
34
35
36
41
42
43
44
45
MFG. PART
NO.
052837
369132
377994
300061
767962
016527
064006
047654
787689
787713
769166
388892
767954
055822
034280
029876
055939
768515
036236
783837
369470
044818
045088
785675
785014
775353
057661
785741
782763
034272
768523
370270
784843
N/A
784959
N/A
N/A
785378
720177
N/A
787200
056077
N/A
024927
797670
QTY.
2
2
6
6
1
1
4
1
4
4
8
8
1
1
1
1
1
1
1
4
6
10
2
1
1
10
18
1
2
1
1
1
2
1
4
1
1
5
1
2
1
2
1
2
1
DESCRIPTION
HONDA 24 HP ENGINE (USED ON 927285)
CENTRIFICAL AIR CLEANER CAP
HOSE CLAMP
MOUNTING BAND
AIR CLEANER
NT .312-18 HX G5 ZNYC
FW .343 X .687 X .051/.080HD ZNYC
MINI Z DEFLECTOR SCOOP
CS .250-20 X .750 HX G5 ZNYC
FW .281 X.625 X .051/.080 HD ZNYC
CS .312-18 X 1.00 HX G5 ZNYC
ELECTRIC COOLER FAN
SUPER MINI Z HOOD
CN ZN TIN-C7343-1420
HOSE CLAMP 1"
REMOTE AIR FILTER HOSE
HONDA OIL DRAIN VALVE
0.50" LOW PRESSURE HOSE, 3.00" LONG
HOUR METER
SEAT SUPPORT CROSSMEMBER
FW .406 X .812 X .060 SAE HD ZN
CS .375-16 X .75 HX G5 ZNYC
CS .312-18 X .75 HX G5 ZNYC
LW .312 INT-EXT TOOTH ZNYC
CS .312-18 X1.50 HX G5 ZNYC
MUFFLER GUARD
MMZ ROLLER HEAT SHIELD
REAR BUMPER ENGINE GUARD
FW .531 X 1.063 X.090 SAE HD ZN
CS .500-13 X1.00 HX G5 ZNYC
CS .312-18 X .625 HX G5 ZNYC
CLIP
HONDA MUFFLER
HONDA MUFFLER GASKET
MUFFLER MANIFOLD
LW .312 MED SPRING ZNYC
NT M8-1.25 HX STAINLESS STEEL
1.50" MUFFLER CLAMP
CS M 8-1.25 X 20 10.9 HXFLZNYC
NT M8-1.25 10 HX ZNYC
TRACTOR WIRE HARNESS
CS .250-20 X 1.00 HX G5 ZNYC
HONDA 20 AMP RECTIFIER
NT .250-20 HX GR.5 ZNYC
HONDA AIRCLEANER HOSE CLAMP
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
763318
MAIN AIR FILTER ELEMENT
VACUATOR VALVE
5-8 302620 8/06
This page intentionally left blank.
302620 8/06 5-9
Kohler Engine Installation
1
2
3
4
2
7
6
1
10
8
9
9
11
21
19
20
14
13
22
9
14
16
17
18
15
12
13
14
4
5
27
26
25
13
14
24
23
3
RED/BLK
2
39
POSITIVE
BATTERY
CABLE
PUR (P/O ENGINE)
29
28
30
14
ANTI-ROLLOVER
WHEEL BRACKET
35
36
37
31
32
5-10
33
34
14
38
302620 8/06
Kohler Engine Installation
4
7
INDEX
NO.
29
30
31
32
25
26
27
28
21
22
23
24
17
18
19
20
37
38
39
33
34
35
36
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
SERVICE
PART NO.
769166
388892
808493
767954
055822
034280
029876
052837
055939
768515
783837
044818
369470
795310
796672
787713
057661
788943
782763
785741
034272
768523
370270
036236
788216
788018
029751
705137
016899
785378
788026
786673
369132
300061
377994
767962
016527
064006
788000
MFG. PART
NO.
769166
388892
808493
767954
055822
034280
029876
052837
055939
768515
783837
044818
369470
795310
796672
787713
057661
788943
782763
785741
034272
768523
370270
036236
788216
788018
029751
705137
016899
785378
788026
786673
369132
300061
377994
767962
016527
064006
788000
QTY.
4
4
8
4
4
8
1
1
1
1
1
1
1
4
4
4
6
2
1
1
6
1
1
10
18
1
2
1
1
3
1
1
1
2
1
2
4
1
1
DESCRIPTION
KOHLER CV740 ENGINE (27 HP)
KOHLER MUFFLER
CS .375-16 X 1.00 HXFLK ZNYC
FW .391 X 1.250 X .060 ZNYC
NT .375-16 HXFLK ZNYC
MUFFLER 1.50" CLAMP
KOHLER 27-2 MANIFOLD
DONALDSON AIR CLEANER CAP
HOSE CLAMP
AIR FILTER INDICATOR
AIR CLEANER
MOUNTING BAND
NT .312-18 HX G5 ZNYC
FW .343 X .687 X .051/.080 HD ZNYC
MINI Z DEFLECTOR SCOOP
CS .312-18 X 1.00 HX G5
CS .250-20X .750 HX G5 ZNYC
FW .281X.625X.051/.080HD ZNYC
ELECTRIC COOLER FAN
CN ZN TIN-C7343-1420
SUPER MINI Z HOOD
REMOTE AIR FILTER HOSE
3/8-18 OIL DRAIN VALVE
0.50" LOW PRESSURE HOSE
HOUR METER
MINI Z CROSSMEMBER
RIVET NUT, 3/8-16 THREAD
FW .406 X .812 X .060 SAE ZN
CS .375-16 X .750 HX G5 ZNYC
CS .312-18 X .750 HX G5 ZNYC
LW .312 INT-EXT TOOTH ZNYC
CS .312-18X1.500 HX G5 ZNYC
MINI Z MUFFLER GUARD
ENGINE GUARD
MMZ ROLLER HEAT SHIELD
FW .531X 1.063X.090 SAE ZN
CS .500-13X1.00 HX G5 ZNYC
CS .312-18X .625 HX G5 ZNYC
WIRE HARNESS
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
1
2
1
2
4
7
9
8
6
10
6
12
6
6
5
SEAT SUPPORT
CROSSMEMBER
9
1
11
8
6
3
4
2
1
8
9
1
5-14 302620 8/06
Fuel System Installation
ITEM NO.
7
8
5
6
3
4
1
2
9
10
11
12
SERVICE
PART NO.
784181
796318
796326
791277
745059
000323
000331
767954
055822
015818
015818
015818
015818
MFG. PART
NO.
784181
796318
796326
791277
745059
000323
000331
767954
055822
015818
015818
015818
015818
QTY
1
6
3
12
1
2
2
1
12
1
1
1
1
DESCRIPTION
FUEL TANK CAP
RIGHT SIDE FUEL TANK
LEFT SIDE FUEL TANK
FITTING, FUEL TANK 90°
3-WAY FUEL VALVE
CLIP
BLACK CABLE TIE
FW .406 X .812 X .060 SAE HD ZN
CS .375-16 X .75 HX G5 ZNYC
FUEL LINE 12.5” TOTAL
FUEL LINE 29" TOTAL
FUEL LINE 7.5” TOTAL KAWASAKI
FUEL LINE 22” TOTAL HONDA
NOTES:
1. Torque to 20 ft.-lbs.
2. Supplied with new fuel tank.
302620 8/06 5-15
Instrument Panel Installation/Assembly
1
1
6
2
4
5
3
10
8
7
1
9
8
5
12
13
10
11
1
6
8
1
RIGHT SIDE
FUEL TANK
14
13
12
15a
FUSE SIZE AND LOCATIONS
5a KAWASAKI
10a HONDA
15a KOHLER
20a
5-16 302620 8/06
Instrument Panel Installation/Assembly
9
10
11
12
13
14
7
8
5
6
4
4
2
3
ITEM NO.
1
SERVICE
PART NO.
059832
026237
704932
762195
714998
778365
055947
768515
349308
785030
786657
786657
776476
712257
083022
785808
045898
MFG. PART
NO.
059832
N/A
704932
N/A
714998
778365
055947
768515
349308
785030
786657
786657
776476
712257
N/A
785808
045898
QTY
3
3
3
1
1
6
1
6
3
1
1
1
2
1
1
1
1
DESCRIPTION
Z CHOKE CABLE (KAWASAKI ENGINES)
Z CHOKE CABLE (HONDA ENGINES)
Z CHOKE CABLE (KOHLER ENGINES)
PTO SWITCH
RED INDICATOR LIGHT
IGNITION KEY
INDAK COATED KEY
KEY SWITCH
NT #10-24 HX NL ZN
RELAY
FW .219 X .500 X .048 ZN
DELAY MODULE
MS #10-24 X .625 HX ZN
THROTTLE/CHOKE CABLE
CS .250-20 X .500 HX G5 ZN
FW .281 X .625 X .051 /.080 HD ZN/YL
INSTRUMENT PANEL
NOTES:
1. Part of Tractor Wire Harness.
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
2
1
4
5
2
3
2
6
5
7
8
9
10
10
11
2
TRACTOR
FRAME
5
1
2
3
4
6
5
7
8
2
10
10
12
1
9
12
1
6-2 302620 8/06
Front Wheel Assembly
6
7
4
5
1
2
3
8
9
10
11
12
INDEX NO.
SERVICE
PART NO.
705954
344267
798603
263517
784223
784603
045765
366625
786731
025296
061101
786061
795245
MFG. PART
NO.
705954
344267
798603
263517
784223
784603
045765
366625
786731
025296
061101
786061
N/A
QTY
4
2
2
2
2
2
2
2
2
4
2
2
2
DESCRIPTION
CS .500-13 X 1.25 HX G5 ZN
FW .510 X 2.15 X .187 SPL ZN
FW .515 X 1.65 X .125 HD ZY
BEARING DISC
BEARING W/O COLLAR
SPACER
FW 1.030 X 1.500 X.134 ZN
FORK
CS .750-10 X 8.00 HX GR5 ZYNC
FW .760 X 1.625 X .08 ZN
NT .750-10 HX NL ZN
WHEEL & TIRE ASSY
OPTIONAL SEMI-PNEUMATIC TIRE/WHEEL ASSEMBLY
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
2
1
3
1
5
ITEM NO.
2
2
1
2
3
4
5
SERVICE
PART NO.
786103
747402
786079
019521
015511
MFG. PART
NO.
N/A
N/A
N/A
N/A
N/A
QTY
2
1
1
1
1
DESCRIPTION
WHEEL BEARING
TIRE 13 X 5.00
WHEEL
TIRE VALVE
GREASE FITTING 45 DEG 1/4
NOTES:
1. Inflate tire to 8-10 psi.
2. Service parts for 795245 (Optional Semi-Pneumatic Tire/Wheel
Assembly), also.
4
6-4 302620 8/06
Drive Wheel Assembly/Installation
1
6
4
5
1
3
INDEX NO.
1
2
3
4
5
6
SERVICE
PART NO.
782078
782284
782086
019521
061077
770859
MFG. PART
NO.
782078
N/A
N/A
N/A
061077
N/A
QTY
2
5
5
DESCRIPTION
WHEEL/TIRE ASSEMBLY 23 X 9.50
TIRE 23 X 9.50-12
WHEEL 10 X 7.5
TIRE VALVE
WHEEL NUT (QTY PER WHEEL)
1/2" WHEEL LUG STUD (QTY PER WHEEL)
NOTES:
1. Torque to 65-75 ft. lbs.
2. Inflate tire to 8-10 psi.
2
2
302620 8/06 6-5
Anti-Rollover Wheel Assembly
1
2
1
2
4
5
3
5
6
1
5
7
8
4
5
7
6
7
4
5
8
1
2
3
INDEX NO.
SERVICE
PART NO.
034272
768523
350835
068239
767962
781567
016253
031997
MFG. PART
NO.
034272
768523
350835
068239
767962
781567
016253
031997
QTY
2
6
2
4
2
6
6
2
DESCRIPTION
NT .312-18 HX G5 ZNYC
FW .343 X .687 X .051/.080 HD ZNYC
ANTI ROLLOVER WHEEL BRACKET
CS .500-13 X 4.500 HX G5 ZN
FW .531 X 1.063 X .090 SAE HD ZN
NT .50-13 HX LK NY
CB .312-18 X .750 FUL ZN
ANTI-SCALP WHEEL
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
4
2
3
1
5
2
15
16
6
7
17
4
17
1
9
3
8
4
10
9
11
12
13
11
2
12
15
4
18
14
12
13
14
13
2
12
15
12
11
4
2
15A
1A
5
14
13
12
17
11
17
15
2
11A
12A
13A
44" DECK
14A
7-2 302620 8/06
Deck Assembly
5
11
11A
12
12A
9
10
7
8
5
6
3
4
1
1A
2
13
13A
14
14A
15
15A
16
17
4
INDEX
NO.
18
SERVICE
PART NO.
546408
546382
357111
063297
767954
054502
357103
058776
389189
015495
036244
781708
781708
767962
767962
053199
053199
781567
781567
031997
031997
781880
808485
788166
055822
MFG. PART
NO.
367730
367946
357111
063297
767954
054502
357103
058776
389189
015495
036244
N/A
N/A
N/A
N/A
N/A
N/A
781567
781567
N/A
N/A
781880
808485
788166
055822
QTY.
8
6
4
3
2
6
2
1
2
20
8
1
1
1
1
3
4
3
1
4
4
2
4
3
4
DESCRIPTION
52" MINI-Z DECK
44" MINI-Z DECK
DISCHARGE CHUTE
SB .375 X .50 SH .312-18 TD ZN
FW .406 X .812 X .060 SAE HD ZN
NT .375-16 HX GRD 5 ZNYC
DISCHARGE CHUTE MOUNT BRACKET
NT .312-18 HX NL ZNYC
PUSHER
STRAIGHT GREASE FITTING
CS .375-16 X1.00 HX G5 ZNYC
CS .500-13 X 4.25 HX G5 ZNYC
CS .500-13 X 4.25 HX G5 ZNYC
FW .531 X 1.063 X.090 SAE HD ZN
FW .531 X 1.063 X.090 SAE HD ZN
NT .500-13 HX JAM ZNYC
NT .500-13 HX JAM ZNYC
NT .50-13 HX LK NY
NT .50-13 HX LK NY
ANTI-SCALP WHEEL
ANTI-SCALP WHEEL
BUMPER
5/16-18 THREAD RIVET NUT
ANTI-SCALP WHEEL ASSEMBLY
CS .375-16 X .750 HX G5 ZNYC
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
1
2
11
23
12
22
14
13
7
23
3
2
7
6
4
5
8
9
10
13
7
14 15
16
17
1
19
19
20
23
21
17
24
23
26
25
27
19
28
29
15
16
1
7-4 302620 8/06
Deck Pulley Assembly
5
3
4
4
30
31
32
33
34
24
25
26
27
28
29
13
14
15
16
9
10
11
12
17
18
7
8
5
6
2
3
4
INDEX
NO.
1
19
20
21
22
23
SERVICE
PART NO.
786335
781872
782474
786889
792689
054502
767954
368993
368977
368985
368944
792002
075291
794875
789388
791335
784199
017129
785832
787069
025007
028118
781856
600296
350884
259812
781302
016972
781385
768523
058776
783506
005116
795526
783753
796300
784256
079186
712927
378745
364315
MFG. PART
NO.
786335
781872
782474
786889
792689
054502
767954
368993
368977
368985
368944
792002
075291
794875
789388
791335
784199
017129
785832
787069
025007
028118
781856
600296
350884
259812
781302
016972
781385
768523
058776
783506
005116
795526
783753
796300
784256
079186
712927
378745
364315
QTY.
4
4
2
1
1
24
1
1
1
6
8
3
3
12
2
2
1
1
1
1
4
1
2
1
6
2
1
1
6
12
3
3
3
6
6
3
5
1
3
5
1
DESCRIPTION
52" DECK BELT
44" DECK BELT
CS .312-18 X 1.25 FLT SH ZNYC
FW .440 X 1.00 X .083 ZNYC
DECK IDLER UHMW CLAMP
DECK IDLER UHMW RISER
CS .625-11 X1.75 HX G5 ZNYC
FW .62 X 1.00 X.134 ZNYC
IDLER NHI 5.00" PULLEY
DECK IDLER SPACER
DECK IDLER
SPRING CHAIN
IDLER SPRING
NT .625-11 HX G5 ZNYC
IDLER PULLEY
UHMW (.03 THICK)
CS .625-11 X 1.25 HX G5 ZNYC
CW .631 2.25 X .187 PNT
DECK DRIVE PULLEY (52" DECKS)
5.00" OD PULLEY (44" DECKS)
NT .375-16 HX GRD 5 ZNYC
FW .406 X .812 X .060 SAE HD ZN
L.S. PULLEY COVER (52" DECKS)
L.S. PULLEY COVER (44" DECKS)
R.S. PULLEY COVER (52" DECKS)
R.S. PULLEY COVER (44" DECKS)
5/16-18 X 3/4" MALE KNOB
CLAMP KNOB
CS .625-11 X 3.50 FULL HX G5 ZN
FW .343 X .687 X .051/.080 HD ZNYC
NT .312-18 HX NL ZNYC
BLADE SPINDLE ASSEMBLY
CS .375-16 X 1.375 HX G5 ZNYC
BLADE, F17.86"-H-F-CW
BLADE, 17.86"-L-F-CW
BLADE, F15.66"-H-F-CW
BLADE,15.66"-L-F-CW
CS .312-18 X1.25 HX G5 ZNYC
FW .344 X 1.00 X .12 HRD ZNYC
DECK IDLER
SPRING CHAIN
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.
31
32
2
34
12
3
4
6
5
7
13
7
8
14
33
5. Used on mowers with serial number 05050800 and higher, mowers with serial number pior to 05050800, use 786889.
6. Optional blades:
785428
785436
16" CW Gator Blade
18" CW Gator Blade
7-6 302620 8/06
Blade Spindle Assembly Breakdown
1
2
3
4
5
2
302620 8/06
INDEX
NO.
1
2
3
4
5
SERVICE
PART NO.
783548
783555
783530
783514
783522
MFG. PART
NO.
783548
783555
783530
783514
783522
QTY.
1
2
1
1
1
DESCRIPTION
BLADE SPINDLE RETAINING RING
BLADE SPINDLE BEARING
BLADE SPINDLE SPACER
BLADE SPINDLE HOUSING
BLADE SPINDLE SHAFT
NOTES:
7-7
7-8 302620 8/06
Chapter 8 Contents
Deck Belt Routing and Tensioning. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
302620 8/06 8-1
Deck Installation
TRACTOR
ASSEMBLY
2
3
4
1
1
5
DECK
ASSEMBLY
5
INDEX
NO.
1
2
3
4
5
SERVICE
PART NO.
055749
051169
025296
061101
704643
MFG. PART
NO.
055749
051169
025296
061101
704643
QTY.
4
2
4
2
8
DESCRIPTION
CS .437-14 X 1.750 HX G5 ZNYC
CS .750-10X3.000 HX G5 ZNYC
FW .760 X 1.625 X.08 ZNYC
NT .750-10 HX NL ZN
NT .437-14 HX FLG ZN
NOTES:
1. 52" Deck installation shown, 44" Deck installation is similar.
8-2 302620 8/06
Deck Belt Routing and Tensioning
1
NOTES:
1. Spring length after tensioning new beltmeasured from outside of hook to outside of hook.
2. Route belt as shown.
302620 8/06 8-3
8-4 302620 8/06
Chapter 9 Contents
52" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
44" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
302620 8/06 9-1
Tractor Decals
2
3
SECTION A-A
11
12
SEE
DETAIL A
6
7
8
DETAIL A
9
5
TOP OF
SEAT PAN
10
14
13
4
SECTION B-B
17
15
BOTTOM OF
SEAT PAN
16
9-2 302620 8/06
Tractor Decals
INDEX
NO.
12
13
14
15
10
11
8
9
16
17
6
7
4
5
1
2
3
SERVICE
PART NO.
784702
782128
779280
727008
791848
782573
786822
727172
N/A
782136
785154
793588
600899
785188
727016
788968
771436
MFG. PART
NO.
784702
782128
779280
727008
791848
782573
786822
727172
083279
782136
785154
793588
600899
785188
727016
788968
771436
QTY.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
DESCRIPTION
INSTRUMENT PANEL DECAL
Z SERVICE DECAL
HOT & HYD OIL DECAL
HYD PRESSURE DECAL
FUEL INDICATOR DECAL
FIRST ZERO TURN DECAL
HUSTLER SUPER MINI-Z ID DECAL
"MADE IN U.S.A." DECAL
TURF PROD SERIAL NO PLATE
Z OPERATION DECAL
DECK HEIGHT DECAL
HUSTLER NAME PLATE
PUMP BELT WARNING DECAL
Z ARMREST WARNING DECAL
BATTERY DECAL
ENGINE COMPARTMENT DECAL
STABILIZER DECAL
NOTES:
302620 8/06 9-3
52" Deck Decals
1
3
7
8
2
5
6
INDEX
NO.
7
8
5
6
3
4
1
2
SERVICE
PART NO.
781419
760637
727438
727420
727453
785535
727172
797845
MFG. PART
NO.
781419
760637
727438
727420
727453
785535
727172
797845
QTY.
1
1
2
1
2
1
1
1
DESCRIPTION
BELT ROUTING DECAL
MOWER DECK QUICK REF DECAL
WHIRLING BLADES DECAL
DEFLECTOR SHIELD DECAL
BELT & PULLEY DECAL
DECK I.D. 52" DECAL
"MADE IN U.S.A." DECAL
FUSION DECAL
NOTES:
3
4
5
9-4 302620 8/06
44" Deck Decals
1
8
3
7
5
6
2
3
5
4
INDEX
NO.
6
7
4
5
8
1
2
3
SERVICE
PART NO.
781419
760637
727438
727420
727453
784801
727172
797845
MFG. PART
NO.
781419
760637
727438
727420
727453
784801
727172
797845
QTY.
1
1
1
2
1
1
1
2
DESCRIPTION
BELT ROUTING DECAL
MOWER DECK QUICK REF DECAL
WHIRLING BLADES DECAL
DEFLECTOR SHIELD DECAL
BELT & PULLEY DECAL
DECK 44" ID DECAL
"MADE IN U.S.A." DECAL
FUSION DECAL
NOTES:
302620 8/06 9-5
9-6 302620 8/06
Chapter 10 Contents
302620 8/06 10-1
Seat Installation
19
18
3
4
3
17
7
2
8
9
2
10
1
11
1
12
9
15
16
13
14
16
5
6
10-2 302620 8/06
Seat Installation
SERVICE
PART NO.
036244
767954
748756
389940
781617
722199
792051
000331
086660
724716
350421
388983
768523
034272
080358
781880
052860
768523
055822
INDEX
NO.
12
13
14
15
16
17
18
19
10
11
8
9
6
7
4
5
1
2
3
MFG. PART
NO.
036244
767954
748756
389940
781617
722199
792051
000331
086660
724716
350421
388983
768523
034272
080358
781880
052860
768523
055822
QTY.
4
1
1
4
2
2
2
2
1
1
3
3
1
1
1
3
1
5
1
DESCRIPTION
CS .375-16 X 1.00 HX G5 ZNYC
FW .406 X .812 X .060 SAE HD ZN
SPRING PLUNGER LATCH
SEAT LATCH BRACKET
RUBBER BUMPER
2" WIDE SCOTCH POLYURETHANE 6"
SEAT
SMALL/SHORT WIRE TIE
NT .375-16 HX LK NY
FIBER WASHER
SEAT PAN STOP
SEAT PAN
FW .343 X .687 X .051/.080 HD ZNYC
NT .312-18 HX G5 ZNYC
GM .50 X 1.00 X .75 X .12
.500 X 1.00X .312 X.188 BUMPER
CS .375-16 X 1.25 HX G5 ZNYC
FW .343 X .687 X .051/.080 HD ZNYC
CS .375-16 X .75 HX G5 ZNYC
NOTES:
1. Must pivot freely.
2. Service parts available for Michigan seats:
PART NO.
793307
793323
793281
793299
797571
793315
797480
793265
793273
DESCRIPTION
SLIDE KIT
KNOB KIT
BACK CUSHION KI
SEAT CUSHION KIT
SEAT BACK PANEL KIT
SEAT SWITCH
ONE ARMREST (ROUND STYLE W/O BRACKET))
ONE ARMREST (SQUARE STYLE W/O BRACKET)
ARMREST STOP ASSEMBLY
3. Service parts available for Milsco seats:
PART NO.
782144
782177
783472
DESCRIPTION
ADJUSTER, STANDARD AND LOW PROFILE SUSPENSION SEAT
OPERATOR PRESENCE SWITCH
Z ARMREST ONLY KIT
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
302620 8/06
11-1
11-2 302620
8/06
SAFETY PRECAUTIONS
This safety alert symbol is used to call attention to a message intended to provide a reasonable degree of PERSONAL SAFETY for operators and other persons during the normal operation and servicing of this equipment.
DANGER –
denotes immediate hazards which WILL result in severe personal injury or death.
WARNING -
denotes a hazard or unsafe practice which COULD result in severe personal injury or death.
This manual uses two other words to highlight information.
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
â–²
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.
â–² 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.
â–² Follow daily and weekly checklists, making sure hoses are tightly secured and bolts are tightened.
â–² Keep your machine clean and remove any deposits of trash and clippings, which can cause engine fires and hydraulic overheating as
302620
8/06 11-3 well as excessive belt wear. Clean up oil or fuel spillage. Allow machine to cool before storing.
â–² 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.
â–² 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.
â–² Never put hands or feet under any part of the machine while it is running.
â–² Except when changing or checking belt, always keep belt covers on mower for safety as well as cleanliness.
â–² 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!
â–² Exercise caution when loading or unloading the machine onto a trailer or truck.
â–² Always wear safety goggles or safety glasses with side shields when operating the mower.
â–² Never leave machine unattended with ignition key in switch, especially with children present.
â–² Be alert and turn the machine off if children enter the area.
â–² Always wear adequate eye protection when servicing the battery, hydraulic system, cooling system or when grinding mower blades and removing accumulated debris.
â–² Use extra caution when handling gasoline and other fuels. They are flammable and vapors are explosive.
â–² 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.
â–² Never attempt to start engine when there is a strong odor of gasoline fumes present. Locate and correct cause.
â–² 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.
â–² 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.
â–² 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.
â–² 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.
â–² 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.
â–² 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.
â–² Do not touch hot parts of machine.
â–² Keep nuts and bolts tight, especially the blade attachment bolts.
Keep equipment in good condition.
â–² Never tamper with safety devices. Check their proper operation regularly.
â–² 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.
â–² Use only genuine Hustler replacement parts to ensure that original standards are maintained
Using a ramp
â–² Use extreme caution when loading and unloading a unit with a ramp.
â–² 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.
â–² Do not exceed a 15 degree angle between the ramp and the ground or between the ramp and the trailer or truck.
â–² When on a ramp avoid sudden acceleration
11-4 302620
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Safety and Instruction Decals
â–²
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.
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
Part Number
727016
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.
Part Number
727008
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.
Part Number
771436
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.
Part Number
727420
Keep shields or covers in place while machine is in operation.
Keep hands away from rotating pulleys and belts.
Hot surface!
Part Number
727453
Part Number
779280
Part Number
788968
Keep engine and pump compartment(s) clean (especially in exhaust area) to prevent fire and provide maximum engine and hydraulic cooling.
Whirling blades! Keep hands and feet away.
Beware of thrown objects.
If you lose steering control while operating the machine, place the steering
control levers in the park brake position immediately. Inspect the machine and involve your Hustler dealer to resolve the problem before continuing to operate.
If pump belt fails, steering control will be lost. Refer to owner’s manual for inspection and replacement intervals and refer to above paragraph for emergency procedures.
600899
Part Number
600899
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
727438
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8/06
11-5
11-6 302620
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MAINTENANCE
19
16
8
18
8
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18
15
19. Hydraulic Oil Heat Exchanger
Figure 11-1
11-7
9
14
Viewed from bottom of tractor
SERVICE AT
INTERVALS INDICATED
Verify safety start interlock system
Visually inspect unit for loose hardware and/or damaged parts
Visually inspect tires
Check oil level, engine (1)
Clean air intake screen (5)
Clean oil heat exchanger (5)
Check fuel level
Blades - sharpen & securely fastened
Discharge chute - securely in place & in lowest position
Clean engine and pump compartments
Replace air cleaner paper element (5)
Grease deck pusher arms
Grease pump idler
Grease deck height pivots
Grease gauge wheel bearings
Change engine oil & filter (1) (4)
Clean cylinder and head fins (a)
Check battery connections
Check tire pressure with a gauge
Check hydraulic oil level
Clean engine exterior (a)
Clean and regap spark plugs (a)
Check pump and deck belt tension
& condition (6)
Check fuel and hydraulic lines (7)
Check fuel valve and grommet (7)
Tighten lug nuts on wheels (2)
Change fuel filter
Clean or replace hydraulic fill cap
Change hydraulic filter and oil (3)
Replace spark plugs
WEEKLY MONTHLY ANNUALLY OR
OR 50 OR 100 500
HOURS HOURS HOURS
Daily x x x x x x x x x x x x x x x
Daily
Daily
Daily or every 4 hrs.
Daily or every 4 hrs.
Daily or every 4 hrs.
Daily
Daily
Daily
Daily
As needed x x x 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
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
Figure 11-2
11-8 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.
Battery
Figure 11-3
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.
Electric clutch
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.
Figure 11-4
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.
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
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11-9
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.
Seat platform catch
Cooling fan
Heat exchanger
Engine
Seat platform
Control lever
Hydraulic reservoir
Figure 11-5
Hydraulic filter
Figure 11-7
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
Figure 11-6
Hydraulic system
IMPORTANT:
Never use hydraulic or automatic transmission fluid in this system; use only motor oil as specified. Remember, dirt is the primary enemy of any hydraulic system.
WARNING:
Hydraulic oil escaping under pressure can penetrate skin. Hydraulic oil may cause infection in a minor cut or opening in the skin. 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.
11-10
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.
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Fuel tank
Fuel filter
Honda engine
Figure 11-8
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. 11-
11A, 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. 11-
11A, 11-11B & 11-11C
Fuel filter
Figure 11-9B
Kohler engine
Figure 11-9C
Valve grommet
Fuel shut-off valve
Figure 11-10A
Fuel valve (shown in closed position)
Right fuel tank
Fuel filter
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Kawasaki engine
Figure 11-9A
11-11
Left fuel tank
Figure 11-10B
Engine oil filler tube
Kawasaki Engine
Pre-cleaner
Engine oil drain plug
Engine oil filter Canister
Figure 11-11A
Engine oil filler tube Honda Engine
Figure 11-12
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.
Engine oil filter
Kohler engine
Figure 11-11B
Engine oil filter
Engine oil drain plug
Engine oil drain plug
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.
Figure 11-11C
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
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.
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.
11-12
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.
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Reset button
Viewed from bottom for unit
1. Pump belt
2. Engine pulley
3. Pump idler pulley
4. Pump idler arm
5. Pump pulley
6. Electric deck clutch
7. Pump idler spring
1
5
Indicator
5
4
Figure 11-13
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.
2
5
7
2
3
Figure 11-14
2, 6
2
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.
3
6
1
5
4
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
Figure 11-15
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.
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
302620
8/06
11-13
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
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.
Do not sharpen to original pattern (below).
It is easier to get a straight cutting edge following the resharpening pattern shown above.
Resharpening Pattern
Figure 11-16
Warped Blade (Replace)
Figure 11-17
Cutting Edge
Original Edge
Straight Blade
Comparison of Warped and Straight Blades
Cutting Plane
Cutting Edge
Twisted Blade Edge
(Replace)
Straight Blade Edge
End view of blades, comparing twisted and straighten blades.
Figure 11-18
Cutting
Plane
11-14 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.
Remain alert for unusual noises, they could be signaling a problem.
Visually inspect the machine for any abnormal wear or damage. A good time to detect potential problems is while performing scheduled maintenance service. Correcting the problem as quickly as possible is the best insurance.
Clear away heavy build-up of grease, oil and dirt, especially in the area of reservoir and oil and engine combustion air; minute dust particle are abrasive to close-tolerance engine and hydraulic assemblies.
Some repairs require the assistance of a trained service mechanic and should not be attempted by unskilled personnel. Consult your Hustler service center when assistance is needed.
Steering linkage
The neutral adjustment for the control levers in the neutral position is discussed in this section.
The tractor steering has been factory adjusted to eliminate creeping when the control levers are in the neutral position (Fig. 11-19). 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
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
11-15
Control lever in the neutral position
Jam nut
Park brake slot
Figure 11-19
Jam nut
Figure 11-20
Stop
Pump linkage rod
Control
Figure 11-21 lever
Control lever
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
Front ball stud
Spring housing
Upper control lever
Cap screw
Steering dampener with spring
Figure 11-22
Control lever stops
The control lever stops (Fig. 11-21) are designed to do two things: First, and most important, they must keep the pumps from bottoming out internally. Secondly, the stops may be adjusted to help drive straight when the control levers are pushed forward against the stops.
To keep the pumps from bottoming out internally use the following procedure:
1. 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.
Lower control lever
Figure 11-23
Front brake link
(right side)
Figure 11-24
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.
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
11-16 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
Park brake slot
Figure 11-27
Jam nut
Brake linkage
Turnbuckle
Figure 11-28
Control lever in park brake position
Bypass valve
Figure 11-25
Control lever
Outside edge
302620
8/06
Figure 11-26
1/8”
Park brake slot
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.
11-17
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
Spring
Tension idler
Figure 11-30
Pump drive belt
Figure 11-33
Blocks
Stop handle
Spring
Height adjusting stop
Tension idler
Chain
Figure 11-31
Spring Extension
7.75”
Figure 11-34
Deck lift threaded rod
Normal Spring Length
6.0”
1.75”
Nut
Nut
Figure 11-32
excessively worn or damaged. As belt stretches and wears in, adjustment may become necessary. To increase belt tension, move the spring chain one (or more) link(s) at the anchor bracket (Fig. 11-31). Installed spring length should be 7.75" ± .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.
Chains
Figure 11-35
starting to level deck. The recommended pressures are as follows:
Drive wheels tire pressure ........................................8 - 10 psi
Gauge wheels tire pressure.......................................8 - 10 psi
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
11-18
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).
302620
8/06
Deck lift threaded rod
Nut
Chains
Figure 11-36
5/16” bolt
Nut
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.
Hardware
Jam nut
Adjuster
Figure 11-37
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
Foot pedal
Lift block
Figure 11-38
Deck lift assist springs
1”
1”
Figure 11-39
Nuts
Deck lift rod
302620
8/06
11-19
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
302620
8/06
11-21
034280
036236
036244
041152
041707
044255
044818
045088
045765
045898
047654
048876
051169
052837
052860
053199
054502
055749
Numerical Index
Part
No.
Page
No.
Index
Numerics
025007
025296
026237
027912
027920
028118
029751
029868
029876
030817
031997
032763
032771
034272
000323
000331
005116
008193
008573
015495
015511
015818
016253
016527
016899
016972
017004
017129
019521
024927
,
,
Part
No.
055822
055939
077545
079186
080358
083022
083196
083279
086660
212076
259812
263517
300061
302638
302935
302943
344267
348284
055947
056077
057661
058776
059832
060541
061077
061101
063198
063297
064006
064014
068239
068478
068551
075291
348318
348391
348417
348458
348862
349308
350421
350835
350884
357103
357111
360693
362392
364315
366625
366765
Page
No.
Part
No.
,
,
369470
369660
370270
377994
378745
387936
388884
388892
388983
389189
389940
392449
546382
546408
546630
546648
367128
367169
367565
367573
367730
367946
368670
368704
368803
368860
368910
368944
368977
368985
368993
369132
600221
600296
600899
700484
704163
704643
704742
704932
705137
705178
705186
705954
712257
712927
713198
714998
720177
722199
724716
727008
Page
No.
302620 8/06 i-1
767962
768127
768515
768523
781153
781211
781229
781260
781286
781294
781302
781385
781419
781526
781542
768820
769166
770859
771428
771436
772079
775353
776476
777656
778217
778365
778423
778738
779280
779850
780841
Part
No.
727016
727172
727420
727438
727453
740696
742684
745059
747303
747402
748681
748756
756270
762195
763318
765339
767954
Page
No.
,
,
Part
No.
783522
783530
783548
783555
783696
783753
783761
783829
783837
783845
783852
783894
783928
783936
783985
784066
784082
784108
784181
784199
784223
784256
782177
782284
782318
782466
782474
782573
782664
782763
782953
782979
782995
783118
783126
783472
783506
783514
781559
781567
781583
781617
781658
781708
781716
781831
781856
781872
781880
781922
782078
782128
782136
782144
Page
No.
i-2
Page
No.
Part
No.
786038
786061
786079
786103
786335
786350
786368
786533
786566
786657
786673
786731
786822
786848
786863
786871
786889
787069
787192
787200
787366
787408
785378
785428
785436
785477
785485
785493
785535
785543
785626
785634
785642
785659
785675
785741
785808
785832
784439
784488
784603
784686
784702
784801
784843
784918
784959
785014
785030
785063
785154
785188
785261
785279
302620 8/06
Part
No.
787440
787457
787564
787572
787580
787598
787606
787622
787689
787713
788000
788018
788026
788133
788166
788174
788216
788943
788968
789388
791061
791087
Page
No.
Part
No.
791103
791152
791160
791251
791277
791327
791335
791814
791848
792002
792051
792192
792689
793265
793273
793281
793299
793307
793315
793323
793588
794875
Page
No.
Part
No.
795245
795278
795310
795526
796300
796318
796326
796524
796672
797480
797571
797654
797670
797845
798603
808485
808493
927269
927277
927285
Page
No.
302620 8/06 i-3
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