Hustler 778845 User Manual

•••••••

Hustler Turf Equipment

•••••

P.O. Box 7000

•••

Hesston, Kansas

•

67062-2097

Hustler Hydro WalkBehind

Owner’s Manual

778845 Rev. 7/04

The engine exhaust from this product

contains chemicals known to the State

of California to cause cancer, birth

defects or other reproductive harm.

WARNING:

778845 Rev. 7/04

TABLE OF CONTENTS

1. General Information.............................................................Sect. 1

2. Safety Precautions................................................................Sect. 2

3. Operation..............................................................................Sect. 3

4. Maintenance .........................................................................Sect. 4

5. Adjustments .........................................................................Sect. 5

6. Troubleshooting ...................................................................Sect. 6

7. Storage .................................................................................Sect. 7

8. Product Literature ................................................................Sect. 8

9. Technical Specifications ......................................................Sect. 9

10. Index...................................................................................Sect. 10

778845 Rev. 7/04
778845 Rev. 7/04

1-1

This manual applies to the following equipment:
Hydro WalkBehind, Kawasaki 17HP recoil start,

54” SD deck (925644)

Hydro WalkBehind, Kawasaki 17HP recoil start,

48” SD deck (925651)

Hydro WalkBehind, Kawasaki 15HP recoil start,

48” SD deck (925669)

Hydro WalkBehind, Kawasaki 15HP

recoil start,

37” SD deck (925677)

Hydro WalkBehind, Kawasaki 17HPelectric start,

48” SD deck (926238)

Hydro WalkBehind, Kawasaki 17HPelectric start,

54” SD deck (926246)

Hydro WalkBehind, Kawasaki 23HPelectric start,

48” SD deck (927129)

Hydro WalkBehind, Kawasaki 25

HP electric start,

54” SD deck (927137)

To the new owner

The purpose of this manual is to assist owners and
operators in maintaining and operating the Hustler Hydro
WalkBehind. Please read it carefully; information and
instructions furnished can help you achieve years of
dependable performance.

A separate Engine Manual is included with your owner’s
packet which contains additional engine information that
will not be repeated in this manual. You are urged to read it
before attempting any operation or repair of the engine.

The Quick Reference Decals located on the unit are
designed to give the operator brief information needed in the
daily operation of the machine. These decals are not
intended to be used in place of this manual but instead are to
be used as an extension of this manual. These decals should
not be remove or obliterated. Replace these decals if they
become unreadable.

It is the owner’s responsibility to make certain that the
operator reads and understands this manual and the Quick
Reference Decals before operating this machine. It is also
the owner’s responsibility to make certain that the operator
is a qualified and physically able individual, properly
trained in the operation of this equipment.

Using this manual

General operation, adjustment and maintenance guidance
is outlined for both the experienced and novice Hustler user.
Operating conditions vary considerably and cannot all be
addressed individually. Through experience, however,
operators should find no difficulty in developing good
operating skills suitable to most conditions.

Directions used in this manual, for example RIGHT or
LEFT, refer to directions when facing forward while
operating the unit, unless otherwise stated.

Photographs and illustrations used were current at the
time of printing, but subsequent production changes may
cause your machine to vary slightly in detail. Hustler Turf
Equipment 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 owner’s manual, or the parts manual, see
your Hustler dealer for current information and parts.

Warranty registration

The Delivery and Warranty Registration form must be
completed and signed to validate your warranty protection.
As the new equipment owner, you are expected to see that
the form is completed and forwarded to Hustler Turf
Equipment at time of delivery.

Be sure to register the unit with Hustler Turf Equipment.

IMPORTANT: Any unauthorized modification,
alteration, or use of non-approved attachments voids the
warranty and releases Hustler Turf Equipment from any
liability arising from subsequent use of this equipment.

Model and serial number

Unit model and serial numbers are found on the serial
identification plate, located on the left side of the frame next
to the fuel tank.

These numbers are required on the Warranty Registration
form. They will also assure you of the correct service parts
when replacement becomes necessary.

Parts and service

Use original Hustler replacement parts only. These parts
are available through your local Hustler dealer. To obtain
prompt, efficient service, always provide the following
information when ordering parts:

1. Correct part description and number, as given in the
parts manual supplied with your owner’s packet.

2. Correct model number.

3. Correct serial number.

All warranty repair and service must be handled through
an authorized Hustler dealer. Arrangements should be made
through your local service center.

For location of nearest dealer, or should you need further
assistance, contact:

Customer Service Department
Hustler Turf Equipment
P.O. Box 7000
Hesston, KS 67062
Telephone [phone]
FAX [phone]

GENERAL INFORMATION

778845 Rev. 7/04

1-2

HYDRO WALKBEHIND

TWO YEAR LIMITED WARRANTY FOR POWER UNITS AND DECKS

(THREE YEAR (1200 HOURS OF USE) LIMITED WARRANTY ON DECK

SPINDLE BEARING & DECK GAUGE FORK BEARING)

WHAT IS COVERED BY THIS WARRANTY

Hustler Turf Equipment, makes the following warranty to
the original purchaser only:

a. First and Second Year: Hustler Turf Equipment

Tractors and Power Units are warranted for two (2)

years or 1200 hours of use, whichever comes first,
from date of delivery on all materials and

workmanship.
If the Purchaser discovers within this warranty period a
defect in materials or workmanship:

● He must promptly notify Hustler Turf Equipment, or

an authorized dealer, in writing of the defect. In no
event shall such notification be received by Hustler
Turf Equipment, or an authorized dealer later than
twenty-five (25) months from date of delivery.

● Within a reasonable time after such notification,

Hustler Turf Equipment, will correct any defect in
material or workmanship on the Hustler Turf
Equipment, with either new or used replacement
parts.

● Such repair, including parts and labor shall be at the

expense of Hustler Turf Equipment, and,

b. Third Year: At the conclusion of the two year limited

warranty, if the 1200 hour of use limit has not been
reached, described in paragraph (a) above, there shall
be an additional one year limited warranty on deck
gauge fork bearings and deck spindle bearings only, no
labor. The third year of the warranty will be in effect
until the 1200 hour of use limit is attained or the third
year from the date of delivery is reached, whichever
comes first.
If the Purchaser discovers within this warranty period a
defect in either of these bearings:

● He must promptly notify Hustler Turf Equipment, or

an authorized dealer, in writing of the defect. In no
event shall such notification be received by Hustler
Turf Equipment, or an authorized dealer later than
thirty-seven (37) months from date of delivery.

● Within a reasonable time after such notification,

Hustler Turf Equipment, will provide new
replacement bearing to install on the Hustler Turf
Equipment.

● The installation of the deck gauge fork bearing and

deck spindle bearing shall be at the expense of the
owner, and,

c. Rental Units (90 days): Within 90 days of date of

delivery Hustler Turf Equipment, provides a limited

warranty on all materials and workmanship for units

used for rental purposes.

If the Purchaser discovers within this warranty period a

defect in materials or workmanship:

● He must promptly notify Hustler Turf Equipment, or

an authorized dealer, in writing of the defect. In no
event shall such notification be received by Hustler
Turf Equipment, or an authorized dealer later than
120 days from date of delivery.

● Within a reasonable time after such notification,

Hustler Turf Equipment, will repair any defect in
material or workmanship on the Hustler Turf
Equipment, with either new or used replacement
parts.

● Such repair, including parts and labor shall be at the

expense of Hustler Turf Equipment, and,

d. Hustler Turf Equipment provides a limited warranty

for the entire length of ownership by the original

purchaser for the following items:

● Against all defects in the main frame resulting from

frame breakage (deck carrier frame excluded).

● Against all defects in the mowing deck which results

in the front edge of the deck being bent into the the

blades.
If the original Purchaser discovers within this warranty
period such a defect:

● He must promptly notify Hustler Turf Equipment or

an authorized dealer, in writing of the defect. Such

notification must be received by Hustler Turf

Equipment or an authorized dealer during the period

when the equipment is owned by the original

purchaser.

● Hustler Turf Equipment will repair any defect in the

frame resulting in frame breakage with either new or

used replacement parts.

● Such repair, including parts and labor, shall be at the

expense of Hustler Turf Equipment, and,

e. The engine is covered by a two (2) year limited

warranty, by the engine manufacturer, to the original
owner (commercial or residential) only, and,

f. The battery is covered by a one (1) year limited

warranty to the original owner only.

WHO MUST PERFORM THE WARRANTY SERVICE

All warranty service will be performed by dealers
authorized by Hustler Turf Equipment. Service calls
and/or transportation expense of the product to and from

the authorized dealer, for warranty work, will be paid by the
owner of the product. For warranty service you can contact
an authorized dealer or write Hustler Turf Equipment, 200
South Ridge Road, Hesston, Kansas 67062, or call 1-620­327-4911.

WHAT IS NOT COVERED BY THIS WARRANTY

Hustler Turf Equipment, does not warranty:

● Some product, components or parts not

manufactured by Hustler Turf Equipment

● Repairs made by unauthorized persons

● Damage caused by use of the Hustler Turf

Equipment for purposes other than those for which it
was designed

● Damages caused by disasters such as fire, flood,

wind, and lightening

● Damages caused by neglect, abuse, abnormal use,

improper or unreasonable use, accident, negligence
or misuse

● Repairs or replacement resulting from the use of

unauthorized parts, accessories or attachments

● Repairs or replacement as the result if any alterations

or modifications, in the determination of Hustler
Turf Equipment, which adversely affects the
operation, performance or durability of the
equipment.

● Hustler Turf Equipment which has the serial number

removed or made illegible

● Depreciation or damage caused by normal wear, lack

of reasonable and proper maintenance, failure to
follow the product’s owner’s manual operating,
maintenance and adjustment instructions or other
operational instructions provided by Hustler Turf
Equipment.

● Normal maintenance parts and service including, but

not limited to, filters, fuel, lubricants, tune-up parts,
belts, blades, blade sharpening, bearings, brake or
steering adjustments

● Repairs necessary due to improper fuel,

contaminates in the fuel system, or failure to
properly prepare the fuel system prior to any period
of non-use over three months

DISCLAIMER OF WARRANTY

The foregoing warranties are in lieu of all other
warranties, expressed or implied, including but not
limited to the implied warranties of merchantability and
fitness for a particular purpose. However, if the Hustler
Turf Equipment is purchased as a consumer product,
any implied warranty of merchantability or fitness for a
particular purpose is limited to the duration of this
limited warranty. Some states do not allow limitations
on how long an implied warranty lasts, so the above
limitation may not apply to you. This warranty gives
you specific legal rights, and you may also have other
rights which vary from state to state.

LIMITATION OF REMEDIES

In no case shall Hustler Turf Equipment, be liable for any
special, incidental, or consequential damages based upon
breach of warranty, breach of contract, negligence, strict
liability in tort, or any other legal theory.
Such damages include, but are not limited to:

● Loss of profits

● Loss of savings or revenue

● Loss of use of Hustler Turf Equipment or any

associated equipment

● Cost of capital

● Cost of any substitute equipment, facilities, services

or downtime

● The claims of third parties including customers, and

injury to property
Some states do not allow the exclusion or limitation of
incidental or consequential damages, so the above limitation
or exclusion may not apply to you.

TIME LIMIT

Any action for breach of warranty must be commenced
within twenty-five (25) months following delivery of the
goods in a non-rental application. Any action for breach of
warranty must be commenced within 120 days following
delivery of the goods in a rental application.

NO OTHER WARRANTIES

Unless modified in writing, signed by both parties, and
approved by the President of Hustler Turf Equipment, this
agreement is understood to be the complete and exclusive
agreement between the parties, superseding all prior
agreements, oral or written, and all other communications
between the parties relating to the subject matter of this
agreement. No employee of Hustler Turf Equipment, or any
other party is authorized to make any warranty in addition to
those made in this agreement.

ALLOCATION OF RISKS

This agreement allocates the risks of product failure between
Hustler Turf Equipment, and the purchaser. This allocation
is recognized by both parties and is reflected in the price of
the goods.

OWNER'S RESPONSIBILITY

You must maintain your Hustler Turf Equipment product
following the maintenance procedures described in your
owner's manual. Such routine maintenance, whether
performed by a dealer or by you, is at your expense.

This machine like any other powered equipment is
potentially dangerous unless properly operated. Any

operator must be cautious and keep safety in mind at all
times. Any operator, prior to using the Hustler Turf
Equipment, should thoroughly familiarize himself with the
owner's manual regarding operation and safety of the
machine, as well as all safety warnings on the machine
itself.

WARRANTY REGISTRATION

1. The Warranty registration form MUST be completed
and signed by the authorized dealer and original
purchaser.

2. For validation, the completed Warranty registration
form MUST be forwarded to Hustler Turf Equipment,
within ten (10) days following date of purchase.

3. The date of purchase constitutes delivery.

778845 Rev. 7/04

1-3

778845 Rev. 7/04

2-1

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.

All operators should read this manual, or be instructed
about safe operating and maintenance procedures. This is
the owner’s responsibility.

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 on the unit are
designed to give the operator brief information needed in the
daily operation of the machine. These decals are not
intended to be used in place of this manual but instead are to
be used as an extension of this manual. These decals should
not be remove or obliterated. Replace these decals if they
become unreadable.

It is the owner’s responsibility to make certain that the
operator reads and understands this manual and the Quick
Reference Decal before operating this machine. It is also
the owner’s responsibility to make certain that the operator
is a qualified and physically able individual, properly
trained in the operation of this equipment. Local regulations
may restrict the age of the operator.

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 is responsible for accidents or
hazards occuring to other people or their property.

▲

Always disengage deck clutch, place H-bar steering in
neutral, lock neutral lock lever, stop engine, and
remove ignition key when leaving the unit.

▲

Always keep safety shields and covers in place, except
for servicing.

▲

Always maintain a safe distance from people and pets
when mowing.

▲

Always operate machine in daylight or with adequate
working lights.

▲

Follow daily and weekly checklists, making sure hoses

are tightly secured and bolts are tightened.

▲

Always observe traffic laws while driving machine
from one location to another.

▲

Always keep engine and machine clean, removing
accumulated dirt, trash and other material from
machine.

▲

Always be alert for hazards such as rocks, metal
objects and other debris which may be thrown or
entangled by mower blades. Watch out for holes or
deep depressions.

▲

Always wear adequate eye protection when servicing
the hydraulic system and battery, or when grinding
mower blades and removing accumulated debris.

▲ Always use 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.

▲

Always be aware of what is behind the machine before
backing up.

▲

Always inspect machine for damage after striking a
foreign object. If damage is found, repair machine
immediately. Be sure to disengage deck clutch, place
H-bar steering in neutral, engage neutral lock lever,
stop tractor engine, and remove ignition switch key
before inspecting for damage.

▲

Never rotate forward suddenly on H-bar handle while
the machine is in rearward motion.

▲

When traveling in reverse, rotate handle forward
gently and avoid sudden movement. Any sudden
movement could cause the front of the mower to come
off of the ground resulting in possible loss of control.

▲

Never operate a poorly maintained machine.

▲

Never carry passengers.

▲

Never attempt high speed maneuvering, especially in
crowded or congested areas.

▲

Never allow persons to operate this machine without
proper instruction or allow children to operate
machine.

▲

Never put hands or feet under any part of the machine
while it is running.

▲

Never leave machine unattended with ignition key in
switch, especially with children present.

▲

Never refuel unit 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.

▲

Never attempt to start engine when there is a strong
odor of gasoline fumes present. Locate and correct
cause.

▲

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.

▲

Never attempt to make any adjustments or repairs to

SAFETY PRECAUTIONS

the drive system or mower deck while the engine is
running or deck clutch is engaged. Mower blades
cannot be seen and are located very close to the deck
housing. Fingers and toes can be cut off instantly.
Repairs or maintenance requiring engine power should
be performed by trained personnel only.

▲

Never work under the machine or attachment unless it
is safely supported with stands, blocks or a hoist and
blocks.

▲

Do not touch hot parts of machine.

▲

Never direct discharge of material from mower deck
towards bystanders.

▲

Always disengage the blades and wait for them to stop
before crossing gravel drives, walks or roads.

▲

Always keep clear of the mower blades during
operation.

▲

Never make sudden starts, stops, turns, or reverse
direction, especially when maneuvering on slopes.
The steering is designed for sensitive response. Rapid
movement of the H-bar handle in either direction could
result in a reaction of the unit that can cause serious
injury.

▲

Block or chock the machine when parked on a slope or
when trailering.

▲

If any attachment or additional weight is mounted on
the rear of the unit, any sudden movement of the H-bar
handle could cause the front of mower to come off of
the ground resulting in possible loss of control and
serious injury.

▲

Always be sure of your footing. Keep a firm hold on
the H-Bar handle and walk - never run.

▲

Use extreme caution when operating on slopes.

• Be extremely careful changing directions on a slope.
Slow down.

• Do not operate where the machine could slip or tip.

• To check a slope, attempt to back up it. If the unit
can back up the slope without the operator and drive
wheels slipping, reduce ground speed and proceed
with caution.

• Do not operate the Hydro WalkBehind on slopes
when using a stand-up sulky.

▲

The use of any other manufacturer’s attachments,
including stand-up sulkies, increases the risk of
operator injury, therefore, extreme caution must be
exercised when using these devises.

▲

The Hustler mower is capable of operating
horizontally (traverse) on moderately steep slopes.
When operating on slopes of 15 degrees or more, be
aware of any conditions that may cause the drive tires
to lose traction resulting in a possible loss of control of
the machine. An operator should not operate on a
slope until he is thoroughly familiar with the
equipment.

It is strongly recommended that the operator drive
the machine off of the slope, using extreme caution, if
any sign of loss of traction is detected. Wait until the
condition that caused the problem is resolved before
attempting to operate on the slope again.

Terrain conditions can affect traction resulting in
possible loss of control of the machine. Some of the
conditions to be aware of are:

1. Wet terrain

2. Depressions in the ground; i.e. holes, ruts,

washouts

3. Mounds of dirt

4. Soil type; i.e. sand, loose dirt, gravel, clay

5. Grass type, density, and height

6. Extremely dry conditions of grass

Another consideration to safe mowing on slopes is
to be aware of what is located at the bottom of the
slope. Extreme caution should be used when there is a
hazard located at the bottom of the slope. Some
examples are:

1. Water; i.e. lake, river

2. Cliffs, retaining walls

3. Roads, highways

4. Buildings

5. Rocks

These are just a few examples of situations when
caution must be used when operating on a slope.
There are many other possibilities too numerous to
mention. Just remember to always exercise extreme
caution when operating on any slope.

▲

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 non­readable.

778845 Rev. 7/04

2-2

778845 Rev. 7/04

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.

2-3

Read Owner’s Manual and Quick

Reference Decal before attempting to

operate this machine.

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.

Keep shields or covers in place while
machine is in operation.
Keep hands away from rotating
pulleys and belts.

Never operate the mower deck with
side deflector removed or in raised
position, except when the grass
catcher attachment is being used.

Whirling blades! Keep hands and
feet away.
Beware of thrown objects.

Hot surface!

778845 Rev. 7/04

3-1

OPERATION

Figure 3-1

Controls

For general location of the controls described in this

section, refer to Figure 3-1.

1. Ignition switch (Fig. 3-2) – (Recoil start) a two

position switch: off and run. With key inserted, rotate
it clockwise to RUN position.
(Electric start) a three position switch: off, run, and
start. With key inserted, rotate it clockwise to START
position; release key when engine starts, and switch
will automatically return to the RUN position.

2. Throttle/Choke (Fig. 3-2a) — a cable is linked to
engine throttle for controlling engine speed. Move
lever forward to increase engine rpm, move lever
rearward to decrease engine rpm.
To reach the choke position, push forward on the lever
as far as it will go. As the lever is pushed forward you
will notice a detente position, when the lever is moved
past this point, the choke is engaged.
Throttle (Fig. 3-2b) — a cable is linked to engine
throttle for controlling engine speed. Move lever
forward to increase engine rpm, move lever rearward
to decrease engine rpm.
Choke control (Fig. 3-2b) – a cable is linked to
manually operate the engine choke. When the knob 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 machine in
the on (start) position.

3. H-bar handle (Fig. 3-3) — this handle controls the
unit’s acceleration, speed, steering direction and
dynamic braking.

1. Ignition Switch 5. H-bar handle 10. Height adjusting pins 15. Left deck cover
2a. Throttle/Choke Lever 6. Deck clutch switch 11. Hydraulic reservoir 16. Center deck cover
2b. Throttle 7. Operator presence control lever 12. Discharge chute 17. Right deck cover

3. Serial number plate 8. Anti-scalp wheels 13. Pump clutch chain 18. Battery (electric start only)

4. Neutral Lock Lever 9. Hour meter 14. Fuel tank 19. Choke knob

WalkBehind

Controls

11

1

6

2a
2b

4

5

14

13

9

8

3

8

8

12

10

10

10

10

7

7

Ignition

switch

Throttle/Choke

Neutral

lock

lever

Deck clutch

lever

Hour

meter

Figure 3-2a

15

16

17

18

19

Figure 3-2b

Ignition

switch

Throttle

Neutral

lock

lever

Deck clutch

lever

Hour

meter

Choke

23/25

HP shown

15/17/19 HP shown