Hustler 778837 User Manual
Hydro WalkBehind
Parts Manual
778837 Rev. 6/06
•••••••
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, brus h-covered, or grass-co vered unimproved land. Other
states or federal areas may have similar laws.
This spark ignition system complies with Canadian ICES-002.
The Engine Owner’s Manual provides information regarding the U.S. Environmental Protection Agency (EPA) and the
California Emission Control Regulation of emission systems, maintenance and warranty.
Keep Engine Owner’s Manual with your unit. Should the Engine Owner’s Manual become damaged or illegible, replace immediately. Replacements may be ordered pe r the information found in the Produc t Information sec tion of the
owner’s manual.
Chapter 1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Chapter 2 Contents
Frame Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Pump Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Upper H-Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Lower H-Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
H-Bar Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Chapter 3 Contents
Hydraulic Installation—37" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Hydraulic Installation—48" & 54" . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Hydraulic Hose Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Chapter 4 Contents
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Chapter 5 Contents
Pump Drive Assembly—15 & 17 HP. . . . . . . . . . . . . . . . . . . . . . . . 5-2
Pump Drive Assembly (23 & 25HP) . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Table of Contents
Chapter 6 Contents
Console Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Chapter 7 Contents
Engine Installation—Electric Start. . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Engine Installation—23 & 25 HP. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Battery Installation—Electric Start. . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Chapter 8 Contents
Electrical Schematic—Recoil Start—778498 . . . . . . . . . . . . . . . . . 8-2
Electrical Schematic—Electric Start—779991 . . . . . . . . . . . . . . . . 8-4
Chapter 9 Contents
Deck Carrier Frame Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Chapter 10 Contents
Deck Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
37" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
37" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
48" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
48" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
54" Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
54" Deck Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
37" Deck Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
48" Deck Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
54" Deck Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Chapter 11 Contents
Tractor Decal Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
925651 6/06 c-1
37" Deck Decal Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
48" Deck Decal Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
54" Deck Decal Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
Chapter 12 Contents
Drive Wheel Assembly—48" & 54". . . . . . . . . . . . . . . . . . . . . . . . . 12-2
Drive Wheel Assembly—37" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
Front Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
Spindle Housing Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1
c-2 925651 6/06
Chapter 1
General Information
This Manual covers Hydro Walk Behind mowers models: 925651, 17HP Pull Start 48" Deck;
925669, 15HP Pull Start 48" Deck; 925644, 17 HP Pull Start 54" Deck; 925677, 15HP Pull Start 37"
Deck; 926238, 17HP Electric Start 48" Deck; 926246, 17HP Electric Start 54" Deck; 927129, 23HP
Electric Start 48" Deck; & 927137, 25HP Electric Start 54" Deck.
Frequently Ordered Parts
PART NO. DESCRIPTION
027912 Lubrizol 7 oz. Bottle
768341 Hydraulic Oil Filter
776435 Pump Drive Belt
779694 37" WB DECK DRIVE BELT
776724 48” WB Deck Drive Belt
777185 54" WB Deck Drive Belt
068478 Fuel Filter
772111 Precleaner Air Filter
772103 Paper Element Air Filter
785261 Main Air Filter Element - Remote
772079 Engine Oil Filter
770339 19" Clockwise Rotation Blade
767111 17" Clockwise Rotation Blade
Service Literature
PART NO. DESCRIPTION
778845 Walk Behind Owner’s Manual
771501 Kawasaki 15 & 17 HP Engine Manual
778423 Kawasaki 19 thru 23 HP 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 necessary, 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.
778837 6/06 1-1
Hardware Description Codes & Abbreviations
The following codes are used throughout this parts manual. Refer to this list when ordering parts.
ABBREVIATION DESCRIPTION
CB Carriage Bolt
CE Clevis Pin
CP Cotter Pin
CS Cap Screw
CW Cup Washer
FW Flat Washer
HX Hex Head
LW Lock Washer
MB Machine Bushing
MS Machine Screw
NT Nut
SC Self Tapping Cap Screw
SB Shoulder Bolt
SS Set Screw
Standard Torques
The following chart is the standard torque values for the threaded fasteners found in this man-
ual.Torque all cap screws, nuts and set screws to these values unless a different
torque is shown in the Notes section nest to the fastener.
SIZE FT-LBS NM SIZE FT-LBS NM
.250 8.2 11.1 M3 1 1.3
.312 17 23 M4 2.2 3
.375 30 40 M5 4.5 6.1
.438 48 65 M6 7.7 10.4
.500 73 99 M8 18.5 25
.562 105 143 M10 37 50
.625 145 200 M12 64 87
.750 260 350 M16 160 215
.875 420 565 M20 320 435
1.00 625 850 M24 555 750
NOTE:
Loctite 592 to be used on all pipe threads.
Lubricate all grease zerks.
1-2 778837 6/06
Chapter 2 Contents
Rivet Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Upper H-Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Lower H-Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
H-Bar Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
778837 6/06 2-1
Frame Rivet Nut Installation
2
1
1
3
2
4
2
5
5
6
5
8
7
5
3
2-2 778837 6/06
Frame Rivet Nut Installation
INDEX NOSERVICE
PAR T NO.
1 N/A 335273 1 HYDRO WALK BEHIND FRAME
2 N/A 808493 14 NUTSERT, 3/8-16
3 N/A 808485 6 NUTSERT, 5/16-18
4 330498 330498 1 STEERING PIVOT
5 N/A 808477 6 NUTSERT, 1/4-20
6 340182 340182 1 LOWER CONSOLE PANEL
7 340174 340174 1 CONSOLE SUPPORT
8 341693 341693 1 NEUTRAL LOCK
MFG.
PART NO.
QTY DESCRIPTION
NOTES:
778837 6/06 2-3
Pump Installation
4
1
6
15
7
12
5
11
4
14
12
1
2
3
6
2
3
9
8
11
12
14
12
7
9
15
13
10
8
13
10
TRACTOR FRAME
3
16
3
16
2-4 778837 6/06
Pump Installation
INDEX
NO.
1 768226 768226 2 HYDRO GEAR PUMP BDP10L137P
2 041707 041707 4 NT .437-14 HX G5 ZN
3 704742 704742 8 FW .453X .812X.060 ZN
4 075994 075994 2 CS .250-20X3.250 ZN
5 778514 778514 2 PUMP ROD ASSEMBLY
6 068551 068551 2 NT .250-20 HX NL ZN
7 341289 341289 2 PUMP ARM
8 778621 778621 2 TORSION PUMP SPRING
9 715599 715599 2 CS 10-24X1.000 HX G5 ZN
10 059832 059832 2 NT #10-24 HX NL ZN
11 041152 041152 2 NT .312-24 HX ZN
12 768523 768523 6 FW .343X.687X.051X.080 HD ZN/YL
13 341487 341487 2 NEUTRAL ADJUSTER PLATE
14 034272 034272 4 NT .312-18 HX G5 ZN
15 712919 712919 8 FW .406X 1.00X.12 HRD ZN
16 705186 705186 4 CS .437-14X1.375 HX G5 ZN
SERVICE
PAR T NO.
MFG.
PART NO.
QTY. DESCRIPTION
NOTES:
778837 6/06 2-5
Upper H-Bar Assembly
4
3
1
9
2
11
10
10
8
9
2
14
15
10
13
10
12
16
5
1
12
11
12
1
5
1
6
17
2
3
7
4
18
14
2-6 778837 6/06
Upper H-Bar Assembly
ITEM
NO.
1 341446 341446 1 STEERING PIVOT TUBE
2 333047 333047 1 STEERING BAR
3 773556 773556 2 STEERING BEARING
4 771139 771139 2 GRIP, .875 X 4.562 BLACK
5 779157 779157 2 CB .312-18X 1.750 ZN G5
6 068551 068551 1 NT .250-20 HX NL ZN
7 772483 772483 1 SB .312X .750 SH .250-20TD ZN/YL
8 077842 077842 4 MS # 6-32 X1.000 RD SL ZN
9 058776 058776 2 NT .312-18 HX NL ZN
10 768523 768523 6 FW .343X.687X.051/.080 HD ZN/YL
11 341826 341826 2 OPC ARM
12 769299 769299 6 SC #10 X.750 PHILLIPS TYPE AB ZN
13 342378 342378 2 SWITCH SPACER
14 778506 778506 1 OPERATOR PRESENCE WIRE HARNESS
15 779165 779165 4 RP .078X .50 LONG ZN
16 039693 039693 2 WN #6-32 X 1.00 TP 1116
17 341149 341149 1 SPEED BAR
18 794412 N/A 1 HBAR MICRO SWITCH LEVER
SERVICE
PART NO.
MFG PART
NO.
QTY DESCRIPTION
NOTES:
1. Screw will be self tapped into steering handle bearing.
2. Must be tight but must not be so tight as to cause binding of item 2
(333047 Steering Bar) within item 3 (773556 Steering Bearing). Items 11
(341826 OPC Arm) must move freely.
778837 6/06 2-7
Lower H-Bar Assembly
1
3
4
22
SPEED
BAR
15
13
23
26
STEERING
13
PIVOT
NEUTRAL
LOCK
19
21
6
7
8
4
10
12
11
14
9
16
13
13
5
8
9
22
23
2
17
18
20
PUMP
ROD
ASSEMBLIES
24
25
2-8 778837 6/06
Lower H-Bar Assembly
INDEX
NO.
1 332072 332072 1 LOCK COLLAR
2 038828 038828 1 CS .312-18X2.250 HX G5 ZN
3 754317 754317 1 NT .312-18 LOW CROWN ACORN ZN
4 728584 728584 2 PIVOT TUBE BUSHING
5 341651 341651 1 NEUTRAL LOCK HANDLE
6 768499 768499 1 KNOB, 1.00 RDX.312-18 FE BLACK
7 778522 778522 2 SB .375X1.000 SH.312-18TD ZN
8 779173 779173 4 FW .312X .562X .06 SPL HD ZN/YL
9 034272 034272 4 NT .312-18 HX G5 ZN
10 778530 778530 1 TORSION SPRING
11 342857 342857 1 STEERING SPACER
12 034280 034280 2 CS .312-18X .750 HX G5 ZN
13 768523 768523 6 FW .343X.687X.051/.080 HD ZN/YL
14 341743 341743 1 STEERING SUPPORT
15 004416 004416 1 RP .375 X 2.25 ZN
16 765339 765339 2 BUSHING, INGUS#MFI-0608_05
17 726711 726711 1 SWITCH
2
3
18 049346 049346 1 FW .375X .870X.078 ZN
19 726778 726778 1 SWITCH BOOT
20 017251 017251 2 CP .156DX1.000 LG HML ZN
21 341503 341503 1 NEUTRAL LOCK ROD
22 041152 041152 2 NT .312-24 HX ZN
23 754358 754358 2 SB .375X.375 SH .312-18
24 341156 341156 1 SPEED CONTROL YOKE
25 772483 772483 1 SB .312X.750 SH .250-20TD ZN/YL
26 068551 068551 1 NT .250-20 HX NL ZN
SERVICE
PAR T NO.
023002 023002 1 DOUBLE POLE SWITCH
MFG.
PART NO.
QTY DESCRIPTION
NOTES:
1. For H-Bar in lower position, install Item 1 (Lock Collar) and item 14
(Steering Support) in upper holes in (Upper H-Bar Assembly). Install
Speed Bar) using upper hole of the two lower holes in Speed Bar).
2. Used on pull start models only.
3. Used on electric start models only.
778837 6/06 2-9
H-Bar Installation
H-BAR
ASSEMBLY
5
CONSOLE
SUPPORT
4
2
1
3
2
2
TRACTOR
FRAME
6
1
2-10 778837 6/06
H-Bar Installation
ITEM
NO.
1 036244 036244 9 CS .375-16X1.000 HX G5 ZN
2 767954 767954 13 FW .406X .812 X.060 SAE HD ZN
3 778738 778738 1 WIRING CLAMP
4 054502 054502 1 NT .375-16 HX GRD 5 ZN
5 052860 052860 2 CS .375-16X1.250 HX G5 ZN
6 080655 080655 1 CS .375-16X1.500 HX G5 ZN
SERVICE
PART NO.
MFG.
PART NO.
QTY DESCRIPTION
NOTES:
778837 6/06 2-11
2-12 778837 6/06
Chapter 3 Contents
Hydraulic Installation—37”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Hydraulic Installation—48" & 54" . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Hydraulic Hose Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
778837 6/06 3-1
Hydraulic Installation—37"
9
2
1
2
4
3
5
6
7
8
TRACTOR
FRAME
10
13
11
12
17
14
15
16
P/O
WHEEL
MOTOR
18
19
4
3
20
21
3-2 778837 6/06
Hydraulic Installation—37"
ITEM
NO.
1 079178 079178 1 CS .250-20X .375 HX G5 ZN
2 768515 768515 3 FW .281X.625X.051/.080 HD ZN/YL
3 342055 342055 1 OIL CAP LOCK ANGLE,
4 032763 032763 1 BREATHER CAP
5 032771 032771 1 STRAINER
6 036244 036244 2 CS .375-16X1.000 HX G5 ZN
7 767954 767954 2 FW .406X .812 X.060 SAE HD ZN
8 340026 340026 1 HYD OIL RESERVOIR
9 055947 055947 2 CS .250-20X .500 HX G5 ZN
10 748681 748681 1 .75X1.35X1.06X.18 GROMMET
11 768333 768333 1 FILTER HEAD
12 768341 768341 1 FILTER ELEMENT
13 779132 N/A 1 FITTING, STR-6MORB/-6JIC
1
14 763953 N/A 1 FITTING T,-6 O-RING/-6JIC/6JIC
1
15 070037 070037 8 FW .530 X 1.06 X .19 HRD ZNYC
16 779959 N/A 4 FITTING, -10MORB/-8MJIC
2
17 779926 779926 2 ROSS WHEEL MOTOR
18 767962 767962 8 FW .531X 1.063X.090 SAE HD ZN
19 008573 008573 8 CS .500-13X2.500 HX G5 ZN
20 782276 782276 2 HUB, 4-ON-4
21 061077 061077 8 LN ZN 1/2-20 DICO 5082
SERVICE
PART NO.
MFG.
PART NO.
QTY DESCRIPTION
NOTES:
1. Items contained in WB Hydraulic Hose and Fitting Kit (778480).
2. Items contained in WB Hydraulic Unique Fittings Kit for Narrow Tractor
(779934).
3. Torque to 70–75 ft.lbs.
4. Torque to 200–225 ft-lbs.
778837 6/06 3-3
Hydraulic Installation—48" & 54"
4
5
9
2
10
1
2
3
6
7
8
TRACTOR
FRAME
13
11
12
16
15
17
A
14
P/O
WHEEL
4
MOTOR
3-4 778837 6/06
18
19
3
20
21
Hydraulic Installation—48" & 54"
ITEM
NO.
1 079178 079178 1 CS .250-20X .375 HX G5 ZN
2 768515 768515 3 FW .281X.625X.051/.080 HD ZN/YL
3 342055 342055 1 OIL CAP LOCK ANGLE,
4 032763 032763 1 BREATHER CAP
5 032771 032771 1 STRAINER
6 036244 036244 2 CS .375-16X1.000 HX G5 ZN
7 767954 767954 2 FW .406X .812 X.060 SAE HD ZN
8 340026 340026 1 HYD OIL RESERVOIR
9 055947 055947 2 CS .250-20X .500 HX G5 ZN
10 748681 748681 1 .75X1.35X1.06X.18 GROMMET
11 768333 768333 1 FILTER HEAD
12 768341 768341 1 FILTER ELEMENT
13 779132 N/A 1 FITTING, STR-6MORB/-6JIC
1
14 763953 N/A 1 FITTING T,-6 O-RING/-6JIC/6JIC
1
15 771311 N/A 4 FITTING, 90-8MORB/-8MJIC
2
16 314674 314674 8 MOTOR MOUNT BUSHING
17 768234 768234 2 ROSS WHEEL MOTOR
18 767962 767962 8 FW .531X 1.063X.090 SAE HD ZN
19 042630 042630 8 CS .500-13X6.50 HX G5 ZN
20 782276 782276 2 HUB, 4-ON-4
21 061077 061077 8 LN ZN 1/2-20 DICO 5082
SERVICE
PART NO.
MFG.
PART NO.
QTY DESCRIPTION
NOTES:
1. Items contained in WB Hydraulic Hose and Fitting Kit (778480).
2. Items contained in WB Unique Fittings Kit for Wide Tractor (779942).
3. Torque to 70–75 ft.lbs.
4. Torque to 200–225 ft-lbs.
778837 6/06 3-5
Hydraulic Hose Routing
RIGHT
PUMP
RIGHT WHEEL
MOTOR, 48" (& US 54")
6
4
11
OIL
RESERVOIR
1
3
2
12
5
SEE
HYDRAULIC
INSTALLATION
RIGHT WHEEL
MOTOR , 37"
10
SEE
HYDRAULIC
INSTALLATION
SEE
HYDRAULIC
INSTALLATION
12
9
7
8
LEFT WHEEL
MOTOR, 48" (& US 54")
13
14
LEFT
PUMP
LEFT WHEEL
MOTOR, 37"
3-6 778837 6/06
Hydraulic Hose Routing
ITEM
NO.
1 778977 N/A 1 HOSE, -6 90 -6 90, PL 15.00
2 779108 N/A 1 HOSE, -6STR-6STR , PL 18.50
3 779116 N/A 1 HOSE, -6STR -6 90, PL 16.37
4 778936 N/A 1 HOSE, -8STR-8STR 17.00
5 778944 N/A 1 HOSE, -8STR-8STR 15.00
6 778985 N/A 1 HOSE, -6STR -6 90, PL 13.00
7 778951 N/A 1 HOSE, -8STR-8 90 24.75
8 778969 N/A 1 HOSE, -8STR-8 90 22.75
9 778993 N/A 1 HOSE, -6STR -6 90, PL 18.50
10 779124 N/A 1 FITTING, 90-4MORB/-6MJIC
11 771337 N/A 2 FITTING, STR-8MORB/-8MJIC
12 763946 N/A 2 FITTING 90, -6 O-RING/-6 JIC
13 771311 N/A 2 FITTING, 90-8MORB/-8MJIC
14 771303 N/A 1 FITTING, STR-4MORB/-6MJIC
SERVICE
PART NO.
MFG.
PART NO.
QTY DESCRIPTION
NOTES:
1. All items contained in WB Hydraulic Hose and Fitting Kit (778480).
2. Hydraulic system oil capacity 5.3 qts.(10W40).
3. Add 3 oz. of Lubrizol® (027912) to oil reservoir when hydraulic oil is
changed.
778837 6/06 3-7
3-8 778837 6/06
Chapter 4 Contents
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
778837 6/06 4-1
Fuel System
P/O TANK
1
2
3
4
9
VIEW A
ROTATED 180
8
°
TRACTOR
FRAME
3
4
8
7
6
9
5
A
6
5
4-2 778837 6/06
Fuel System
ITEM
NO.
1 779306 N/A 1 FUEL CAP
2 775825 775825 1 FUEL TANK
3 339838 339838 2 FUEL TANK MOUNT STRAP
4 704924 704924 2 CS .250-20X1.375 HX G5 ZN
5 068551 068551 2 NT .250-20 HX NL ZN
6 000323 000323 2 HOSE CLIP
7 015818 015818 16” FUEL LINE
1
8 785295 785295 1 FUEL SHUTOFF VALVE GROMMET
9 785287 785287 1 FUEL SHUTOFF VALVE
SERVICE
PART NO.
MFG.
PART NO.
QTY DESCRIPTION
NOTES:
1. Order quantity of 2 ft. as service part.
778837 6/06 4-3
4-4 778837 6/06
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