Hustler Super Mini Z Parts Manual ······· Hustler Turf Equipment ····· P.O. Box 7000 ··· Hesston, Kansas · 67062-2097 302620 Rev. 8/06 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering and Brake Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Belt and Pulley Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 5 Contents Kawasaki Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Honda Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kohler Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Panel Installation/Assembly . . . . . . . . . . . . . . . . . . . . . Electrical Schematic - Kawasaki Engines (783894) . . . . . . . . . . . . Electrical Schematic - Honda Engines (787200). . . . . . . . . . . . . . . Electrical Schematic--Kohler (788000) . . . . . . . . . . . . . . . . . . . . . Chapter 6 Contents Front Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Wheel Breakdown - 786061 . . . . . . . . . . . . . . . . . . . . . . . . . Drive Wheel Assembly/Installation . . . . . . . . . . . . . . . . . . . . . . . . . Anti-Rollover Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4-4 4-6 4-10 5-2 5-6 5-10 5-13 5-15 5-17 5-19 5-21 6-2 6-4 6-5 6-6 Chapter 7 Contents Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Deck Pulley Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Blade Spindle Assembly Breakdown . . . . . . . . . . . . . . . . . . . . . . . 7-7 Chapter 8 Contents Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Deck Belt Routing and Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Chapter 9 Contents Tractor Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 52" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 44" Deck Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Chapter 10 Contents Seat Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 302620 8/06 Chapter 11 Contents Maintenance & Adjustments Safety Precautions . . . . . . . . . . . . . . 11-2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-15 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1 302620 8/06 Chapter 1 General Information This Manual covers Hustler Super Mini Z 23/44 model 927269, Super Mini Z 25/52 model 927277, Super Mini Z 24/52 model 927285, and Super Mini Z 27/52 model 927533. Frequently Ordered Parts PART NO. 027912 027920 783936 786533 791335 789388 785626 068478 785261 785279 785634 772079 747303 784256 783753 DESCRIPTION Lubrizol 7 oz. Bottle Lubrizol 10 oz. Bottle Hydraulic Oil Filter Pump Drive Belt 44" Deck Belt 52" Deck Belt Honda Fuel Filter Kawasaki Fuel Filter Main Air Filter Safety Air Filter Element Honda Engine Oil Filter Kawasaki Engine Oil Filter Kohler Engine Oil Filter 16" X 2.5" X 0.204 .631 Dia. Hole Blade 18" X 2.5" X 0.204 .631 Dia. Hole Blade Service Literature PART NO. 302638 778423 785642 742684 DESCRIPTION Hustler Mini Z Owner's Manual Kawasaki 19/23HP Engine Manual Honda 18/20/24HP Engine Manual Kohler Engine Manual Note: When ordering parts, you must use the part number as shown for each part, not the index number. Always give the model and serial number to your parts and service representative. Note: Items sold in bulk such as seals and hoses are sold by the foot. Using this manual Illustrations used were current at the time of printing, but subsequent production changes may cause your machine to vary slightly in detail. Excel Industries, Inc. reserves the right to redesign and change the machine as deemed neces302620 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 CB CE CP CS CW FDRW FW HX LW MB MS NT SC SH SB SS OD ID DESCRIPTION Carriage Bolt Clevis Pin Cotter Pin Cap Screw Cup Washer Fender Washer Flat Washer Hex Head Lock Washer Machine Bushing Machine Screw Nut Self Tapping Cap Screw Socket Head Shoulder Bolt Set Screw Outside Diameter Inside Diameter Standard Torques The following chart lists the standard torque values for the threaded fasteners found in this manual. Torque all cap screws, nuts and set screws to these values unless a different torque is shown in the Notes section next to the fastener SIZE .250 .312 .375 .438 .500 .562 .625 .750 .875 1.00 FT-LBS 8.2 17 30 48 73 105 145 260 420 625 NM 11.1 23 40 65 99 143 200 350 565 850 NOTE: SIZE M3 M4 M5 M6 M8 M10 M12 M16 M20 M24 FT-LBS 1 2.2 4.5 7.7 18.5 37 64 160 320 555 NM 1.3 3 6.1 10.4 25 50 87 215 435 750 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 2 3 1 4 5 6 5 7 1 INDEX NO. 1 2 3 4 5 6 7 SERVICE PART NO. 388884 785485 785493 086660 767954 781880 052860 MFG. PART NO. 388884 785485 785493 086660 767954 781880 052860 QTY. 1 2 1 2 4 2 2 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 4 5 11 7 8 9 10 2 3 1 18 13 15 21 16 26 27 17 20 19 2 23 28 29 30 22 33 31 12 19 24 22 6 14 21 25 26 27 32 34 35 28 27 29 31 30 36 39 44 43 3-2 27 37 38 41 42 40 302620 8/06 Hydraulic System Installation INDEX NO. 1 2 3 4 5 6 7 8 9 SERVICE PART NO. 068551 768515 055939 713198 713198 787192 032763 032771 368803 783985 787564 787572 781658 700484 034272 768523 055947 787580 784108 787598 784082 781559 781542 786368 786350 041707 704742 791152 008573 767962 781526 787440 791061 795278 791103 791087 705186 787622 787457 791814 787606 788174 783936 783928 MFG. PART NO. 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 N/A 786368 786350 041707 704742 791152 008573 767962 N/A N/A N/A N/A N/A N/A 705186 N/A N/A N/A N/A N/A 783936 783928 QTY. 2 8 4 2 2 1 1 1 1 1 1 1 1 1 3 3 2 1 2 1 2 3 1 1 1 4 8 2 8 8 3 1 1 1 1 1 4 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 3 3 3 3 10 11 12 13 14 15 16 17 3 3 3 3 3 18 19 20 21 22 23 24 25 26 27 28 29 30 3 3 3 3 3 3 3 3 3 3 3 31 32 33 34 35 36 37 38 39 40 41 42 43 44 302620 8/06 3-3 NOTES: 1. Add 3.5 oz. Lubrizol® (027912) to new system or when hydraulic oil is changed (see Owner's Manual). 2. Hydraulic system capacity is 5 US quarts. Fill reservoir to within 1" of top of Item 8 (032771 Strainer). 3. Included in Hydro Kit (791160). Note: Seal Kit for hydraulic pump; 788133 (BDP16 Overhaul Seal Kit) 3-4 302620 8/06 Chapter 4 Contents Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Deck Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Steering and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Pump Belt and Pulley Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 302620 8/06 4-1 Battery Installation 1 2 3 5 6 4 7 6 8 7 9 7 8 10 1 11 2 12 13 14 4-2 302620 8/06 Battery Installation INDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 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. 2 3 1 1 1 2 4 2 1 2 1 1 1 2 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 4 6 4 6 10 7 6 4 6 8 1 5 14 1 4 4 13 14 4 12 15 11 14 1 7 6 8 1 6 5 7 8 6 9 8 14 4-4 302620 8/06 Deck Lift Assembly INDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 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. 1 1 1 7 2 8 3 4 1 1 1 1 1 4 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 ...