HUSTLER Super 104 Operator's Manual

Hide thumbs Also See for Super 104:

Operator's manual (56 pages)

Service manual (53 pages)

General service manual (62 pages)

Table Of Contents

Table of Contents

Quick Links

Need help?

Do you have a question about the Super 104 and is the answer not in the manual?

Questions and answers

Roy Clayton Millsap

June 25, 2025

What does it mean by pulling the transport lever to release it

Summary of Contents for HUSTLER Super 104

Page 1 Hustler Super 104™ ® Operator’s Manual 200 South Ridge Road Hesston, Kansas 67062 606835 REV B...
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. NOTICE OF REQUIREMENT OF SPARK ARRESTER MUFFLER This equipment 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 forest-covered, brush-covered, or grass-covered land unless the engine is equipped with a spark arrester maintained in effective working order.
Page 3: Table Of Contents
Table of Contents General Information ........1-1 To the New Owner .
Page 4 Engine Oil and Filter ........4-4 Engine Air Filter ........4-5 General Engine Maintenance .
Page 5: General Information
To activate your warranty policy the mower must be service. registered, by your Dealer, with the Manufacturer of Hustler ® The Engine Owner’s Manual, included in the owner’s Turf Equipment within ten (10) days following the date of packet, contains engine information that will not be repeated purchase.
Page 6 REV B 606835...
Page 7: Safety Precautions
SAFETY PRECAUTIONS Incorrect usage of this equipment may result in severe injury or death. Personnel operating and maintaining it should be trained in its proper use. They should read this manual completely and thoroughly before attempting to set-up, operate, adjust, or service this equipment. Safe Operating Practices This safety alert symbol is used to call attention to a This product is capable of amputating hands and feet and...
Page 8 • Do not wear radios or music headphones while discharge chute with the engine running. Turn off the operating this mower. Safe operation requires engine and be sure the blades have stopped before your full attention. cleaning. Use a stick to clear a plugged discharge area.
Page 9 REMINDER: Only operate on slopes of 15 degrees or less. cause serious physical injury.  Use extreme caution when operating on slopes. ®  The Hustler mower capable operating • Be extremely careful changing directions on a horizontally (traverse) on moderately steep slopes.
Page 10: Service Precautions
Service Precautions hazard located at the bottom of the slope. Some examples are:  Unless specifically required, DO NOT have the engine • Water; i.e. lake, river running when servicing or making adjustments to the • Cliffs, retaining walls mower. •...
Page 11 ® Sparks can cause a battery gas explosion which will are equivalent in overall performance, that are result in personal injury. available from your local Hustler Dealer. ® • Prevent the battery terminals from touching any • The mower may not comply with the appropriate...
Page 12: Safety And Instructions Decals
of spillage and avoid creating any source of It is the owner’s responsibility to make certain that the ignition until gasoline vapors have dissipated. operators and mechanics read and understand all decals before operating this machine. • Keep gasoline away from open flame or spark and store machine away from open flame or spark or pilot light such as on a water heater or appliances.
Page 13 DANGER: Thrown objects! 601967 WARNING: Fire! • Clean flammable material from • Never operate the mower deck with the machine. Prevent fires by keeping rear deflector damaged, altered, or engine compartment, top of deck, removed. Part Number 601967 exhaust area, battery, fuel line, fuel tank and operator’s station clean of 603391 accumulated trash, grass clippings,...
Page 14 DANGER: Battery Hazards! Part Number 601815 601815 • Avoid skin contact • Do not overfill battery. • Do not allow open flame near the with battery acid battery when charging. • Electrolyte may overflow and damage • Hydrogen gas forms inside the paint, wiring or structure.
Page 15 Part Number 601993 WARNING: Read operator’s Manual and decals before attempting to operate this machine. WARNING: Roll over! • Mow a safe distance (minimum of 10 feet) away from drop-offs, retaining walls, drainage ditches, embankments, water, and other types of hazards to avoid a wheel dropping over the edge or to avoid the ground from breaking away.
Page 16 Part Number 604906 604906 Fast Wear ear protection, eye protection and safety shoes Slow when operating this equipment. For maximum electric clutch life engage at 1/2 - 3/4 Before starting the engine: throttle position. • Read Operator’s Manual For maximum electric clutch life disengage at low •...
Page 17 Part Number 606233 606233 Mower blade engage/disengage switch Raise side decks Engine start position Lower side decks If warning light comes on, check engine oil. Read Engine Owner’s Manual before attempting to Ignition switch - insert key operate this machine. 606835 2-11 REV B...
Page 18 REV B 2-12 606835...
Page 19 Slope Guide Use this diagram when determining the degree of slope to be mowed. E (15 Slope Guide Lines D (10 C (5 Line A 1. Hold this sheet of paper in front of you. Make sure that Line A is horizontal. 2.
Page 20 REV B 2-14 606835...
Page 21: Operation
OPERATION Safe Operating Practices Mowers with Vanguard and Kawasaki engines Refer to the Safety Precautions section of this manual for operational and personal safety information. Control Panel Mowers with Vanguard EFI engines A. Deck clutch switch G. 20 amp fuse B.
Page 22: Controls
the left gauge indicates the fuel level in the left fuel Shown with steering control levers in neutral position tank. A. Electronic hour meter B. Fuel tank gauge Figure 3-3 A. Steering control levers Side deck lift switch (Figure 3-1 & Figure 3-2) — this Figure 3-4 switch raises and lowers the side decks.
Page 23: Engine Starting
7. Allow the engine to idle two minutes before advancing be determined. the throttle and/or engaging the deck clutch. If you cannot locate the problem contact your Hustler ® Stopping the Engine Dealer.
Page 24: Rops (Roll Over Protective Structure)
Always make certain the two bypass valves are returned to their operating position before running the mower following repairs. A. ROPS C. Pin B. Hair pin Figure 3-7 Always wear your seat belt unless the mower is A. Bypass valve not equipped with a ROPS or if the ROPS is folded Figure 3-6 down.
Page 25 Inspect the area prior to mowing for proper overhead Inspect the operator’s seat and the mounting parts for the clearance (tree limbs, guy wires, doorways, etc). seat belt. Tighten the bolts to the correct torque as shown below if necessary and replace parts that show wear or Do not contact any overhead object with the ROPS.
Page 26: Mower Operation
Mower Operation For emergency stop, when traveling forward or rearward, place the steering control levers in the park brake position immediately. This mower is equipped with the SmoothTrak™ steering system. The following provides you with detailed information on how to operate the mower efficiently. When moving in the rearward direction push forward gently on steering control levers and avoid sudden Driving the Mower...
Page 27 FRONT OF MOWER FACES THIS DIRECTION THREE POINT TURN FORWARD TRAVEL ZERO RADIUS TURN Step 1 FORWARD TRAVEL RIGHT TURN Step 2 REVERSE TRAVEL RIGHT TURN Step 3 REVERSE TRAVEL N = NEUTRAL POSITION Direction of arrows indicate direction of mower movement Neutral Right control lever...
Page 28 Inspect the machine and Direct grass discharge to the right, away from the involve your Hustler® dealer to resolve the problem unmowed area. Generally, this means using a pattern of left before continuing to operate.
Page 29: Mower Deck Operation
IMPORTANT: Both side decks must be released from the transport position before lowering them with the side deck lift switch. Side deck shown in raised and locked transport position A. Rubber flap B. Deflector guard Figure 3-11 Mower Deck Operation A.
Page 30: Deck Cutting Height Adjustment
Hustler Dealer. ® 5. Shut the engine off. Follow these procedures to maximize clutch life. 6. Use the illustration to establish which height adjusting holes on the side decks to use. Figure 3-14 1.
Page 31: Anti-Scalp Wheels
A. Top hole C. Bottom hole B. Middle hole D. Side deck wheel Figure 3-17 Anti-scalp Wheels A. Hair pin B. Clevis pin Anti-scalp wheels are standard on this mower. These anti- scalp wheels are designed to minimize scalping when Figure 3-15 mowing on rough uneven terrain.
Page 32 REV B 3-12 606835...
Page 33: Maintenance & Adjustments
If you wish to use non-pneumatic tires on your Hustler ® Some repairs require the assistance of a trained service mower, the tire must be a Hustler approved tire.
Page 34: Hydraulic System
Hydraulic Oil Heat Exchanger sufficient force to penetrate skin and cause serious The Super 104™ is equipped with a hydraulic oil heat injury. Foreign fluid injected into the skin must be exchanger. The heat exchanger coils must be kept clean to...
Page 35 Use of replacement parts not equivalent to the original parts may result in system failure and pose a safety hazard. The fuel tanks are located in the mower’s fenders. Park the mower on level ground before filling the fuel tank. Clean the area around the fuel cap before removing the cap.
Page 36: Fuel Evaporation System Filter
Some Hustler Super 104™ mowers have a fuel evaporation ® Draining the engine oil: system filter. This filter must be checked and replaced every 1.
Page 37: Engine Air Filter
Kawasaki engine shown A. Oil drain valve Figure 4-9 A. Safety filter Figure 4-11 Engine Air Filter Recommended Service Procedure Perform engine air filter maintenance per the Maintenance 1. Release clamps and remove element. Clean the air Schedule shown elsewhere in this manual. cleaner canister with a damp cloth.
Page 38: General Engine Maintenance
and replace element as needed or annually whichever occurs first. Reset the indicator by pushing in on the yellow button after each element change. Figure 4-13 A. Air cleaner canister C. Clamp B. Dust cap Figure 4-12 the cleaning assumes responsibility for the integrity of the filter from then on.
Page 39: Mower Blade
If you lose steering control while operating the machine, place the steering control levers in the park brake position immediately. Inspect the machine and involve your Hustler Dealer to resolve the problem before ® continuing to operate.
Page 40 A 15/16" wrench is required to remove the 5/8" cap screw holding the blade to the spindle shaft. NOTE: A blade holding tool (P/N 381442) is available from Hustler Turf Equipment. ® A. Re-sharpening pattern It is designed to prevent the blades from rotating when they B.
Page 41: Seat Adjustment
When mounting blades, rotate them after installation to ensure blade tips do not touch each other or sides of the mower. Seat Adjustment This seat can be adjusted five different ways to obtain the most comfortable position: 1. Back angle (Figure 4-18) 2.
Page 42: Maintenance Schedule
Maintenance Schedule Figure 4-21, Figure 4-22, Figure 4-23, Figure 4-24, Figure 4-25 & Figure 4-26 WEEKLY MONTHLY * ANNUALLY SERVICE AT OR 50 OR 100 OR 500 INTERVALS INDICATED HOURS HOURS HOURS Verify safety start interlock system Prior to each use Visually inspect unit for loose hardware and/or damaged parts Prior to each use Visually inspect tires...
Page 43 10. Refer to engine owner’s manual for engine service information. 11. If caster fork tapered bearing seals leak, refer to the Super 104™ General Service Manual (p/n 123942) for repair procedures. * After completing maintenance cycle (500 hours), repeat cycle.
Page 44: Maintenance Locator Chart
Maintenance Locator Chart Mowers with Vanguard engines Figure 4-21 Mowers with Kawasaki engines 1. Engine Oil Fill & Dipstick (Kawasaki) 2. Fuel Filter 3. Engine Air Cleaner 4. Engine Oil Drain Plug 5. Battery 6. Fuel Tanks 7. Hydraulic Oil Reservoir 8.
Page 45 Figure 4-23 Figure 4-24 1. Engine Oil Fill & Dipstick (Kawasaki) 16. Deck Pusher Arm Zerks (2) 2. Fuel Filter 17. Deck Belt - Deck Drive 3. Engine Air Cleaner 18. Spindle Housing Zerk (5) 4. Engine Oil Drain Plug 19.
Page 46 Figure 4-25 1. Engine Oil Fill & Dipstick (Kawasaki) 11. Deck Height Pivot Zerks (4) 21. Hydraulic Oil Heat Exchanger 2. Fuel Filter 12. Park Brake Switch 22. Deck Belt - Side Deck 3. Engine Air Cleaner 13. Drive Tires 23.
Page 47: Maintenance Record
Maintenance Record Date: Maintenance/Service Performed: Dealer: Date: Maintenance/Service Performed: Dealer: Hour Meter Reading: Hour Meter Reading: Date: Maintenance/Service Performed: Dealer: Date: Maintenance/Service Performed: Dealer: Hour Meter Reading: Hour Meter Reading: Date: Maintenance/Service Performed: Dealer: Date: Maintenance/Service Performed: Dealer: Hour Meter Reading: Hour Meter Reading: Date: Maintenance/Service Performed:...
Page 48 REV B 4-16 606835...
Page 49: Troubleshooting
TROUBLESHOOTING The majority of operating problems that occur with a system can be traced to improper adjustments or delayed service. A consistently applied preventative maintenance program, as outlined in the Maintenance section of this manual, will prevent many problems. The following chart is designed to help you locate a problem by suggesting probable causes and the recommended solutions.
Page 50 SUGGESTED SYMPTOMS PROBABLE CAUSES REMEDIES Uneven cutting height The blade(s) are not sharp Sharpen the blades A cutting blade(s) is/are Install new cutting blade(s) bent The deck is not level Level the deck per the Deck leveling and height adjustment section of the General Service Manual An anti-scalp wheel is not Adjust the height of the...
Page 51 The blades are not sharp. Sharpen the blades. Cutting blade(s) are damaged or bent. Install new cutting blade(s). A blade spindle is bent. Contact your Hustler ® dealer. The underside of the deck is dirty. Clean the underside of the deck.
Page 52 Deck Functionality Symptoms Probable causes Suggested Remedies Grass is not being cut by side deck when mow- Side deck hydraulic cylinders are not fully Fully extend the side deck hydraulic cylinders ing crown of hills or other undulations. extended to allow ±15 degree articulation. using the side deck lift switch.
Page 53: Deck Zone Chart
Deck Zone Chart Deck Front Left Right Side Side BLADE IDENTIFICATION TABLE BLADE CHAMBER COLOR BLADE LENGTH (IN) 23.86 20.5 BLACK 20.5 BLACK 20.5 BLACK 23.86 CHAMBER CHAMBER CHAMBER CHAMBER CHAMBER Inches from left edge of cut DETAIL A Deck Front See Detail A Right Left...
Page 54 REV B 606835...
Page 55: Storage
1. Clean mower, removing trash and dirt accumulation. proceeding. 2. Check engine oil and hydraulic oil levels. 1. Add a Hustler approved fuel stabilizer to the fuel ® system. Refer to the instructions shown on the fuel 3.
Page 56 5. Install all safety shields and review safety precautions 7. Install fully charged battery and attach the battery listed in this manual. cables. 6. Check and inflate front tires to 20–25 psi (138–172 8. Refer to engine manual for more information. KPa) and drive tires to 15–20 psi (103–138 KPa).
Page 57: Product Literature
If 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 dealer if you require another engine manual.
Page 58 REV B 606835...
Page 59 INDEX PAGE PAGE Anti-scalp Wheels ............3-11 Mower Blade Maintenance Precautions ..... 2-5 Battery Service Precautions Mower Blade Replacement ........2-5 ........4-8 Belts Mower Deck Operation ................4-6 ..........3-9 Carbon Canister Mower Operation ............4-6 ............3-6 Children ..............2-4 New Season Preparation ...........
Page 60 REV B 606835...