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HUSTLER Super 104 Operator'S Manual Download Page 3

606835

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REV B

Table of Contents

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-1

To the New Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-1
Using this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-1
Warranty Registration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-1
Model and Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-1
Parts and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-1

Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-1

Safe Operating Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-1
Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-4
Safety and Instructions Decals. . . . . . . . . . . . . . . . . . . . . . . . . .  2-6

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-1

Safe Operating Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-1
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-1
Controls  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-2
Safety Start Interlock System . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-2
Engine Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-3
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-3
Moving the Mower with Stalled Engine  . . . . . . . . . . . . . . . . . . .  3-3
ROPS (Roll Over Protective Structure)  . . . . . . . . . . . . . . . . . . .  3-4
Mower Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-6
Mower Deck Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-9
Deck Cutting Height Adjustment  . . . . . . . . . . . . . . . . . . . . . . .  3-10
Anti-scalp Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-11

Maintenance & Adjustments  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-1

Safe Servicing Practices  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-1
Service Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-1
Torque Values  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-1
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-1
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-1
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-1
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-2
Fuel and Evaporative Emissions Control System  . . . . . . . . . . .  4-2
Fuel Evaporation System Filter  . . . . . . . . . . . . . . . . . . . . . . . . .  4-4

Summary of Contents for Super 104

Page 1: ...606835 REV B Hustler Super 104 Operator s Manual 200 South Ridge Road Hesston Kansas 67062...

Page 2: ...t may create sparks that can start fires around dry vegetation California Public Resources Code Section 4442 6 provides that it is unlawful to use or operate an internal combustion engine on any fores...

Page 3: ...Panel 3 1 Controls 3 2 Safety Start Interlock System 3 2 Engine Starting 3 3 Stopping the Engine 3 3 Moving the Mower with Stalled Engine 3 3 ROPS Roll Over Protective Structure 3 4 Mower Operation 3...

Page 4: ...Filter 4 5 General Engine Maintenance 4 6 Belts 4 6 Mower Blade 4 7 Seat Adjustment 4 9 Steering Control Lever Adjustment 4 9 Maintenance Locator Chart 4 12 Maintenance Record 4 15 Troubleshooting 5 1...

Page 5: ...Directions used in this manual for example RIGHT or LEFT refer to directions when in the operator position and facing forward unless otherwise stated Though current at the time of printing photograph...

Page 6: ...REV B 1 2 606835...

Page 7: ...ct is capable of amputating hands and feet and throwing objects Always follow all safety instructions to avoid serious injury or death Never allow persons to operate this mower without proper instruct...

Page 8: ...e 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 Follow daily and wee...

Page 9: ...s retaining walls drainage ditches embankments and water to avoid mower rollover and serious injury or death Do not mow on wet grass Slippery conditions reduce traction which could cause sliding and l...

Page 10: ...o operate the mower Never allow children or others in or on towed equipment Use care when approaching blind corners shrubs trees the end of a fence or other objects that may obscure vision Service Pre...

Page 11: ...ng the battery Acid can cause serious injury to skin and eyes If contact occurs flush area with clean water and call a physician immediately Acid will also damage clothing Do not drink the battery ele...

Page 12: ...cause serious injury and illness Keep gasoline away from eyes and skin Keep face away from nozzle and fuel tank or fuel container opening If gasoline is spilled on clothing change clothing immediatel...

Page 13: ...r mulching system is being used DANGER Rotating blades pulleys belts Keep shields and covers in place while machine is in operation Keep hands feet and clothing away from rotating pulleys and belts Pa...

Page 14: ...perator s Manual and decals before attempting to operate this machine WARNING This structure s protective capability may be impaired by structural damage overturn or alteration If any of these conditi...

Page 15: ...ne if someone enters the area WARNING Roll over Slow down before turning Do not operate on slopes greater than 15 degrees Keep all movement on slopes slow and gradual Never make sudden changes in spee...

Page 16: ...e F Wear ear protection eye protection and safety shoes when operating this equipment G Before starting the engine Read Operator s Manual Disengage mower blades Place control levers in park brake posi...

Page 17: ...E A Mower blade engage disengage switch B Raise side decks C Lower side decks D If warning light comes on check engine oil E Ignition switch insert key F OFF G ON H Engine start position I Read Engin...

Page 18: ...REV B 2 12 606835...

Page 19: ...ch as pole tree or building 3 Fold the paper along the slope guide lines C D or E 4 Align the closest slope guide line with the ground slope This will give you a close estimation of the ground slope t...

Page 20: ...REV B 2 14 606835...

Page 21: ...manually operate the engine choke When the lever is in the down position the choke is in the OFF RUN position When the knob is pulled up the choke is in the ON START position Do not operate the machin...

Page 22: ...g control levers Figure 3 4 Figure 3 5 these levers control the mower s speed direction stopping and park brake Safety Start Interlock System The mower s safety start interlock system consists of the...

Page 23: ...a time At least two minutes between such cranking periods to protect the starter from overheating and burning out 5 As soon as the engine begins to run check to make certain all engine warning lights...

Page 24: ...en the seat belt during mower operation mower equipped with a ROPS in the raised up position A Bypass valve Figure 3 6 Do not operate the mower with the ROPS folded down lowered position as a standard...

Page 25: ...ld or straighten the ROPS ROPS Inspection Inspect the ROPS after the first 20 hours of operation Following the initial inspection check the ROPS after every 500 hours of operation or every six months...

Page 26: ...levers until they pass neutral and the machine starts to go rearward Figure 3 10 3 Pull the right steering control lever farther rearward from neutral than the left steering control lever until the re...

Page 27: ...AVEL N NEUTRAL POSITION Direction of arrows indicate direction of mower movement N N N N N N N N N N Figure 3 10 Step 1 THREE POINT TURN Step 2 Step 3 R i g h t c o n t r o l l e v e r L e f t c o n t...

Page 28: ...the mower if the grass is slightly taller than normal or if it contains a high degree of moisture Then mow it again with the cutting height set lower IMPORTANT If the machine s forward motion must be...

Page 29: ...shut off if one or both of the side decks raise beyond 15 degrees during operation To restart the blades with the decks in the mowing position it will be necessary to cycle the deck clutch switch fro...

Page 30: ...eck until the transport lever is engaged Figure 3 13 2 Move the pin to the desired cutting height in the center deck s height adjusting plate Figure 3 13 3 Using the center deck lift switch raise the...

Page 31: ...2 50 8mm below the mower blades This setting is preferred when mowing at cutting heights of 2 1 2 63 5mm or higher When the wheel is mounted in the top hole it is located 1 25 4mm below the mower bla...

Page 32: ...REV B 3 12 606835...

Page 33: ...Place the steering control levers in the park brake position and pivot the arm rests upward before lifting the seat platform to prevent arm rest damage Some repairs require the assistance of a traine...

Page 34: ...before adding system oil The Super 104 system filter is located inside the hydraulic reservoir on the underneath side of the tank Use a Hustler approved filter element only When changing the filter u...

Page 35: ...ith fuel temperature changes Use regular unleaded gasoline with an octane rating of 87 or higher Maximum of 10 ethanol E10 in fuel Fuels with greater than 10 ethanol such as E15 E20 and E85 voids warr...

Page 36: ...ine exhaust system and muffler guard Draining the engine oil 1 Locate the oil drain valve on the engine Figure 4 8 Figure 4 9 2 Position a suitable oil drain container under the machine below the oil...

Page 37: ...ster then tighten the clamps Figure 4 12 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 dus...

Page 38: ...ier 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 Air restriction indic...

Page 39: ...2 years whichever comes first Mower Blade Mower Blade Maintenance IMPORTANT Refer to the Safety section of this manual for blade handling safety information Refer to the Mower Blade Replacement secti...

Page 40: ...not re use spindle bolts which have stripped worn or undercut threads Torque bolts on spindles to 118 ft lbs 160 0 N m when reinstalling blades Properly compressed cup washers maintain the correct co...

Page 41: ...s forward or rearward loosen the cap screws that attach the upper control lever to the lower lever Then pivot the upper control lever Tighten the cap screws Figure 4 20 B To lower and raise the steeri...

Page 42: ...on wheels 2 Change fuel filter 7 Clean or replace hydraulic fill cap Change hydraulic filter oil 3 Grease deck spindle housings Replace spark plugs Check ROPS mounting hardware 9 Replace fuel evaporat...

Page 43: ...tension after 50 hours of use as outlined in the Hydraulic Pump Belt Adjustment section of the Super 104 General Service Manual p n 123942 7 Check fuel system for any crack or leaks including but not...

Page 44: ...Deck Pusher Arm Zerks 2 17 Deck Belt Deck Drive 18 Spindle Housing Zerk 5 19 Blades 20 Fuel Evaporation System Filter 21 Hydraulic Oil Heat Exchanger 22 Deck Belt Side Deck 23 Side Deck Pivot Zerks 4...

Page 45: ...11 Deck Height Pivot Zerks 4 12 Park Brake Switch 13 Drive Tires 14 Pump Idler Zerk 1 15 Pump Belt 16 Deck Pusher Arm Zerks 2 17 Deck Belt Deck Drive 18 Spindle Housing Zerk 5 19 Blades 20 Fuel Evapo...

Page 46: ...r 11 Deck Height Pivot Zerks 4 12 Park Brake Switch 13 Drive Tires 14 Pump Idler Zerk 1 15 Pump Belt 16 Deck Pusher Arm Zerks 2 17 Deck Belt Deck Drive 18 Spindle Housing Zerk 5 19 Blades 20 Fuel Evap...

Page 47: ...e Maintenance Service Performed Dealer Hour Meter Reading Date Maintenance Service Performed Dealer Hour Meter Reading Date Maintenance Service Performed Dealer Hour Meter Reading Date Maintenance Ser...

Page 48: ...REV B 4 16 606835...

Page 49: ...se or broken Install a new traction drive belt Air in system Check filter and fittings For additional causes See engine manual Low engine oil pressure Low oil level Add oil Oil diluted or too light Ch...

Page 50: ...ght adjustment section of the General Service Manual An anti scalp wheel is not set correctly Adjust the height of the anti scalp wheel The underside of the deck is dirty Clean the underside of the de...

Page 51: ...harge channel on affected cutting CHAMBERS Uneven cutting height The deck is not level Level the deck per the Deck Leveling and Height Adjustment section Tires are improperly inflated Adjust air press...

Page 52: ...end side deck cylinders Push the deck clutch switch down to the disengaged OFF position Then pull the deck clutch switch up to engage the blade clutch and resume mowing Side deck transport switch is e...

Page 53: ...BER 1 CHAMBER 2 CHAMBER 3 CHAMBER 4 CHAMBER 5 Zone 1 Zone 1 Zone 1 Zone 1 Zone 1 Zone 2 Zone 2 Zone 2 Zone 2 Zone 2 0 12 24 34 43 52 62 71 80 92 104 Left Side Right Side Deck Front Inches from left ed...

Page 54: ...REV B 5 6 606835...

Page 55: ...e for a minimum of 10 minutes 4 Drain the oil from the crankcase while the engine is still warm 5 Replace the engine oil filter 6 Refill with fresh oil of the proper viscosity 7 Close the fuel shut of...

Page 56: ...view safety precautions listed in this manual 6 Check and inflate front tires to 20 25 psi 138 172 KPa and drive tires to 15 20 psi 103 138 KPa 7 Install fully charged battery and attach the battery c...

Page 57: ...you would like to view or print a copy of the product manuals Operator s Manual Parts Manual or General Service Manual for these mowers go online to www hustlerturf com Contact your local Hustler deal...

Page 58: ...REV B 6 4 606835...

Page 59: ...nce Record 4 15 Maintenance Schedule 4 10 Model and Serial Number 1 1 Moving the Mower with Stalled Engine 3 3 Mower Blade 4 7 Mower Blade Maintenance 4 7 Mower Blade Maintenance Precautions 2 5 Mower...

Page 60: ...REV B i 2 606835...

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