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302620 Rev. 8/06
Hustler Super Mini Z
Parts Manual
•••••••
Hustler Turf Equipment
•••••
P.O. Box 7000
•••
Hesston, Kansas
67062-2097
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Summary of Contents

  • Page 1

    302620 Rev. 8/06 Hustler Super Mini Z Parts Manual ••••••• Hustler Turf Equipment ••••• P.O. Box 7000 ••• Hesston, Kansas • 67062-2097...

  • Page 2

    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.

  • Page 3: Table Of Contents

    Chapter 1 General Information ........1-1 Chapter 2 Contents Rivet-nut Installation .

  • Page 4

    Chapter 11 Contents Maintenance & Adjustments Safety Precautions ....11-2 Maintenance ......... . 11-7 Adjustments .

  • Page 5: General Information

    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 Lubrizol 7 oz. Bottle 027920 Lubrizol 10 oz.

  • Page 6

    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 FDRW Standard Torques...

  • Page 7: Rivet-nut Installation

    Chapter 2 Contents Rivet-nut Installation ........2-2 Footrest Assembly .

  • Page 8

    Rivet-nut Installation INDEX SERVICE PART NO. 546630 546648 MFG. PART QTY. 387936 52" MINI Z FRAME 392449 44" MINI Z FRAME 808493 3/8-16 THREAD NUTSERT NOTES: DESCRIPTION 302620 8/06...

  • Page 9

    Footrest Assembly INDEX SERVICE PART NO. 388884 785485 785493 086660 767954 781880 052860 1. Do not tighten, Item 1 ( 388884 Mini Z Floor Plate) must be able to pivot on these bolts. 302620 8/06 MFG. PART QTY. 388884 MINI Z FLOOR PLATE 785485 UPPER STEP TREAD 785493...

  • Page 10

    302620 8/06...

  • Page 11: Hydraulic System Installation

    Chapter 3 Contents Hydraulic System Installation....... 3-2 302620 8/06...

  • Page 12

    Hydraulic System Installation 302620 8/06...

  • Page 13

    Hydraulic System Installation INDEX 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...

  • Page 14

    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;...

  • Page 15

    Chapter 4 Contents Battery Installation ........4-2 Deck Lift Assembly .

  • Page 16: Battery Installation

    Battery Installation 302620 8/06...

  • Page 17

    Battery Installation INDEX SERVICE PART NO. 058776 768523 348417 785063 771428 055939 029868 024927 740696 034272 768820 034280 029876 779850 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).

  • Page 18: Deck Lift Assembly

    Deck Lift Assembly 302620 8/06...

  • Page 19

    Deck Lift Assembly INDEX SERVICE PART NO. 348318 348284 784488 781294 782995 704643 055749 348391 781831 756270 034272 348458 781229 015495 784686 1. Apply grease at zerks (see owner’s manual). 302620 8/06 MFG. PART QTY. DESCRIPTION 348318 STOP HANDLE 348284 HEIGHT ADJUSTMENT STOP 784488 DECK LIFT INDICATOR...

  • Page 20: Steering And Brake Assembly

    Steering and Brake Assembly 14 12 12 13 302620 8/06...

  • Page 21

    Steering and Brake Assembly INDEX SERVICE PART NO. 781260 368704 367128 368670 055822 767954 781716 053199 036244 781583 705178 768523 041152 348862 781153 784439 368910 781286 704163 768515 034272 369660 068551 781922 600221 783696 086660 367573 367565 063198 782979 781211 059832 060541 765339...

  • Page 22

    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. 302620 8/06...

  • Page 23

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  • Page 24: Pump Belt And Pulley Installation

    Pump Belt and Pulley Installation For mowers with serial numbers prior to 04040580 LOCATION FOR RUBBER BUMPER 4-10 302620 8/06...

  • Page 25

    Pump Belt and Pulley Installation INDEX SERVICE PART NO. 783761 212076 797654 791251 787366 783829 785659 083196 782466 768127 366765 016527 767962 008193 784918 015495 368860 025296 061101 786848 028118 781872 781302 786533 787408 778217 036244 767954 054502 055939 362392 778738 768515 024927...

  • Page 26

    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...

  • Page 27

    Chapter 5 Contents Kawasaki Engine Installation ....... 5-2 Honda Engine Installation ....... . . 5-6 Kohler Engine Installation .

  • Page 28

    Kawasaki Engine Installation TO BULLET TERMINALS (MALE-BRN) (FEMALE-ORG) TO SPADE TERMINAL P/O ENGINE RED/BLK POSITIVE BATTERY CABLE 302620 8/06...

  • Page 29: Kawasaki Engine Installation

    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)

  • Page 30

    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).

  • Page 31

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  • Page 32

    Honda Engine Installation GRA/PUR POSITIVE BATTERY CABLE RED/BLK ANTI-ROLLOVER WHEEL BRACKET PART OF ENGINE 302620 8/06...

  • Page 33: Honda Engine Installation

    CS .250-20 X .750 HX G5 ZNYC 768515 FW .281 X.625 X .051/.080 HD ZNYC 036236 CS .312-18 X 1.00 HX G5 ZNYC 783837 ELECTRIC COOLER FAN 369470 SUPER MINI Z HOOD 044818 CN ZN TIN-C7343-1420 045088 HOSE CLAMP 1" 785675 REMOTE AIR FILTER HOSE 787689...

  • Page 34

    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.

  • Page 35

    This page intentionally left blank. 302620 8/06...

  • Page 36

    Kohler Engine Installation POSITIVE BATTERY CABLE PUR (P/O ENGINE) RED/BLK ANTI-ROLLOVER WHEEL BRACKET 5-10 302620 8/06...

  • Page 37: Kohler Engine Installation

    CS .250-20X .750 HX G5 ZNYC 768515 FW .281X.625X.051/.080HD ZNYC 783837 ELECTRIC COOLER FAN 044818 CN ZN TIN-C7343-1420 369470 SUPER MINI Z HOOD 795310 REMOTE AIR FILTER HOSE 796672 3/8-18 OIL DRAIN VALVE 787713 0.50" LOW PRESSURE HOSE 769166 HOUR METER...

  • Page 38

    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...

  • Page 39

    This page intentionally left blank. 302620 8/06 5-13...

  • Page 40: Fuel System Installation

    Fuel System Installation SEAT SUPPORT CROSSMEMBER 5-14 302620 8/06...

  • Page 41

    Fuel System Installation SERVICE ITEM NO. PART NO. 784181 796318 796326 791277 745059 000323 000331 767954 055822 015818 015818 015818 015818 1. Torque to 20 ft.-lbs. 2. Supplied with new fuel tank. 302620 8/06 MFG. PART 784181 FUEL TANK CAP 796318 RIGHT SIDE FUEL TANK 796326...

  • Page 42: Instrument Panel Installation/assembly

    Instrument Panel Installation/Assembly FUSE SIZE AND LOCATIONS RIGHT SIDE FUEL TANK 5a KAWASAKI 10a HONDA 15a KOHLER 5-16 302620 8/06...

  • Page 43

    Instrument Panel Installation/Assembly SERVICE ITEM NO. PART NO. 785030 786657 786657 776476 712257 083022 785808 045898 059832 026237 704932 762195 714998 778365 055947 768515 349308 1. Part of Tractor Wire Harness. 302620 8/06 MFG. PART 785030 Z CHOKE CABLE (KAWASAKI ENGINES) 786657 Z CHOKE CABLE (HONDA ENGINES) 786657...

  • Page 44: Electrical Schematic - Kawasaki Engines (783894)

    Electrical Schematic - Kawasaki Engines (783894) 5-18 302620 8/06...

  • Page 45

    Electrical Schematic - Kawasaki Engines (783894) 302620 8/06 5-19...

  • Page 46: Electrical Schematic - Honda Engines (787200)

    Electrical Schematic - Honda Engines (787200) 5-20 302620 8/06...

  • Page 47

    Electrical Schematic - Honda Engines (787200) 302620 8/06 5-21...

  • Page 48

    Electrical Schematic—Kohler (788000) 5-22 302620 8/06...

  • Page 49

    Electrical Schematic—Kohler (788000) 302620 8/06 5-23...

  • Page 50

    5-24 302620 8/06...

  • Page 51

    Chapter 6 Contents Front Wheel Assembly........6-2 Front Wheel Breakdown .

  • Page 52: Front Wheel Assembly

    Front Wheel Assembly TRACTOR FRAME 302620 8/06...

  • Page 53

    Front Wheel Assembly SERVICE INDEX NO. PART NO. 705954 344267 798603 263517 784223 784603 045765 366625 786731 025296 061101 786061 795245 1. Apply grease to zerks (see owner’s manual). 2. Assemble with extended inner race down. 302620 8/06 MFG. PART 705954 CS .500-13 X 1.25 HX G5 ZN 344267...

  • Page 54

    Front Wheel Breakdown - 786061 SERVICE ITEM NO. PART NO. 786103 747402 786079 019521 015511 1. Inflate tire to 8-10 psi. 2. Service parts for 795245 (Optional Semi-Pneumatic Tire/Wheel Assembly), also. MFG. PART WHEEL BEARING TIRE 13 X 5.00 WHEEL TIRE VALVE GREASE FITTING 45 DEG 1/4 NOTES:...

  • Page 55: Drive Wheel Assembly/installation

    Drive Wheel Assembly/Installation SERVICE INDEX NO. PART NO. 782078 782284 782086 019521 061077 770859 1. Torque to 65-75 ft. lbs. 2. Inflate tire to 8-10 psi. 302620 8/06 MFG. PART 782078 WHEEL/TIRE ASSEMBLY 23 X 9.50 TIRE 23 X 9.50-12 WHEEL 10 X 7.5 TIRE VALVE 061077...

  • Page 56: Anti-rollover Wheel Assembly

    Anti-Rollover Wheel Assembly SERVICE INDEX NO. PART NO. 034272 768523 350835 068239 767962 781567 016253 031997 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. MFG.

  • Page 57

    Chapter 7 Contents Deck Assembly ......... 7-2 Deck Pulley Assembly .

  • Page 58: Deck Assembly

    Deck Assembly 44" DECK 302620 8/06...

  • Page 59

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

  • Page 60: Deck Pulley Assembly

    Deck Pulley Assembly 14 15 302620 8/06...

  • Page 61

    Deck Pulley Assembly INDEX SERVICE PART NO. 789388 791335 784199 017129 785832 787069 025007 028118 781856 600296 350884 259812 781302 016972 781385 786335 781872 782474 786889 792689 054502 767954 368993 368977 368985 368944 792002 075291 794875 768523 058776 783506 005116 795526 783753 796300...

  • Page 62

    4. Used on mower with serial number prior to 05050800. 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 302620 8/06...

  • Page 63: Blade Spindle Assembly Breakdown

    Blade Spindle Assembly Breakdown INDEX SERVICE PART NO. 783548 783555 783530 783514 783522 302620 8/06 MFG. PART QTY. 783548 BLADE SPINDLE RETAINING RING 783555 BLADE SPINDLE BEARING 783530 BLADE SPINDLE SPACER 783514 BLADE SPINDLE HOUSING 783522 BLADE SPINDLE SHAFT NOTES: DESCRIPTION...

  • Page 64

    302620 8/06...

  • Page 65: Deck Installation

    Chapter 8 Contents Deck Installation ........8-2 Deck Belt Routing and Tensioning.

  • Page 66

    Deck Installation INDEX SERVICE PART NO. 055749 051169 025296 061101 704643 1. 52" Deck installation shown, 44" Deck installation is similar. MFG. PART QTY. 055749 CS .437-14 X 1.750 HX G5 ZNYC 051169 CS .750-10X3.000 HX G5 ZNYC 025296 FW .760 X 1.625 X.08 ZNYC 061101 NT .750-10 HX NL ZN 704643...

  • Page 67

    Deck Belt Routing and Tensioning 1. Spring length after tensioning new beltmeasured from outside of hook to outside of hook. 2. Route belt as shown. 302620 8/06 NOTES:...

  • Page 68

    302620 8/06...

  • Page 69: Tractor Decals

    Chapter 9 Contents Tractor Decals ......... . 9-2 52"...

  • Page 70

    Tractor Decals DETAIL A DETAIL A TOP OF SEAT PAN BOTTOM OF SEAT PAN SECTION A-A SECTION B-B 302620 8/06...

  • Page 71

    Tractor Decals INDEX SERVICE PART NO. 784702 782128 779280 727008 791848 782573 786822 727172 782136 785154 793588 600899 785188 727016 788968 771436 302620 8/06 MFG. PART QTY. 784702 INSTRUMENT PANEL DECAL 782128 Z SERVICE DECAL 779280 HOT & HYD OIL DECAL 727008 HYD PRESSURE DECAL 791848...

  • Page 72: Deck Decals

    52" Deck Decals INDEX SERVICE PART NO. 781419 760637 727438 727420 727453 785535 727172 797845 MFG. PART QTY. 781419 BELT ROUTING DECAL 760637 MOWER DECK QUICK REF DECAL 727438 WHIRLING BLADES DECAL 727420 DEFLECTOR SHIELD DECAL 727453 BELT & PULLEY DECAL 785535 DECK I.D.

  • Page 73

    44" Deck Decals INDEX SERVICE PART NO. 781419 760637 727438 727420 727453 784801 727172 797845 302620 8/06 MFG. PART QTY. 781419 BELT ROUTING DECAL 760637 MOWER DECK QUICK REF DECAL 727438 WHIRLING BLADES DECAL 727420 DEFLECTOR SHIELD DECAL 727453 BELT & PULLEY DECAL 784801 DECK 44"...

  • Page 74

    302620 8/06...

  • Page 75: Seat Installation, Seat Installation

    Chapter 10 Contents Seat Installation ........10-2 302620 8/06 10-1...

  • Page 76

    Seat Installation 10-2 302620 8/06...

  • Page 77

    Seat Installation INDEX SERVICE PART NO. 036244 767954 748756 389940 781617 722199 792051 000331 086660 724716 350421 388983 768523 034272 080358 781880 052860 768523 055822 1. Must pivot freely. 2. Service parts available for Michigan seats: PART NO. 793307 793323 793281 793299 797571...

  • Page 78

    10-4 302620 8/06...

  • Page 79

    Chapter 11 Contents Maintenance & Adjustments Safety Precautions ....11-3 Maintenance ......... . .11-7 Adjustments .

  • Page 80

    302620 8/06 11-2...

  • Page 81

    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.

  • Page 82

    ▲ Grass collection system components are subject to wear, damage and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check components and replace with manufacturer’s recommended parts, when necessary. ▲ Use only genuine Hustler replacement parts to ensure that original standards are maintained Using a ramp ▲...

  • Page 83

    Safety and Instruction Decals ▲ ▲ Specific safety warning decals are located on the equipment near the immediate areas of potential hazards. These decals should not be removed or obliterated. Replace them if they become non-readable. The following illustrations show the various safety decals that are located on the machine. A brief explanation is shown to help the operator understand the meanings of these decals.

  • Page 84

    302620 8/06 11-6...

  • Page 85

    MAINTENANCE LOCATOR MAINTENANCE LOCATOR CHART CHART 302620 8/06 MAINTENANCE Figure 11-1 11-7 1A. Engine Oil Fill & Dipstick 1A. Engine Oil Fill & Dipstick (Kawasaki & Honda) (Kawasaki & Honda) 1B. Engine Oil Fill & Dipstick 1B. Engine Oil Fill & Dipstick (Kohler) (Kohler) 2A.

  • Page 86

    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.

  • Page 87

    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.

  • Page 88

    Hydraulic filter 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.

  • Page 89

    Fuel tank 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.

  • Page 90

    Kawasaki Engine Engine oil filler tube Engine oil drain plug Engine oil filter Figure 11-11A Engine oil filler tube Engine oil filter Figure 11-11B Kohler engine Engine oil filter Figure 11-11C Engine air filter Perform engine air filter maintenance per the Service Interval chart on page 11-8.

  • Page 91

    (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.

  • Page 92

    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.

  • Page 93

    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.

  • Page 94

    Spring housing Front ball stud 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.

  • Page 95

    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.

  • Page 96

    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.

  • Page 97

    Deck lift threaded Chains Figure 11-36 Hardware 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.

  • Page 98

    302620 8/06 11-20...

  • Page 99

    INDEX 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...

  • Page 100

    Numerical Index Part Page Index Numerics 000323 5-14 000331 5-14 10-3 005116 008193 4-11 008573 015495 4-11 015511 015818 5-14 016253 016527 4-11 5-11 016899 5-11 016972 017004 017129 019521 024927 4-11 025007 025296 4-11 026237 5-16 027912 027920 028118 4-11 029751 5-11...

  • Page 101

    Part Page 727016 727172 727420 727438 727453 740696 742684 745059 5-14 747303 747402 748681 4-11 748756 10-3 756270 762195 5-16 763318 765339 767954 4-11 5-11 5-14 10-3 767962 4-11 5-11 768127 4-11 768515 4-11 5-11 5-16 768523 5-11 10-3 768820 769166 5-11 770859...

  • Page 102

    Part Page 787440 787457 787564 787572 787580 787598 787606 787622 787689 787713 5-11 788000 5-11 5-21 788018 5-11 788026 5-11 788133 788166 788174 788216 5-11 788943 5-11 788968 789388 791061 791087 302620 8/06 Part Page 791103 791152 791160 791251 4-11 791277 5-14 791327...

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