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Hustler Turf 3500 User's Manual

1. en pee ee us NS Figure 4 20 midway between the water pump pulley and the alternator pulley a correctly tightened belt will deflect 40 60 10mm 15mm If the fan belt is slipping fan efficiency is lowered resulting in the engine running too hot If the belt is too tight the life of the alternator bearing will be shortened If the fan belt shows signs of cracking or fraying install a new one To adjust fan belt tension 1 Loosen the alternator mounting bolts Figure 4 21 1 WARNING Never attempt to loosen or tighten alternator mounting bolts with the engine running 2 Pry the alternator away from the engine and tighten the mounting bolts 3 Recheck belt deflection 109627_0910 Figure 4 21 Transmission front axle and hydraulic system may have sufficient force to penetrate skin and cause serious injury Foreign fluid injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result Before applying pressure to hydraulic system make sure all connections are tight and all hoses and lines are in good condition To find a leak under pressure use a piece of cardboard or wood never use your hands Relieve all pressure in the system before dis connecting or working on hydraulic lines To relieve pressure lower all attachments and shut off engine Checking Oil Level Check the oil level every 50 hours 1 With th
2. Figure 3 6 The park brake should be applied whenever the tractor is parked or when the operator 1s out of the seat To set the park brake pull up on the park brake lever To release the park brake press on the brake lever release button while pushing down on the park brake lever Figure 3 4 B Master brake pedal Reverse travel pedal E HST foot pedals vo Figure 3 5 park on a slope fully engage the park brake and be sure to block or chock the wheels to prevent acci dental rolling of the machine WARNING Do not park on a slope If necessary to D Differential lock pedal Figure 3 7 Depressing the pedal locks the front axle shafts together providing additional traction in wet or loose soil with the differential lock applied WARNING The tractor is very difficult to steer E Hydrostatic transmission HST foot pedals Figure 3 5 The ground speed of the unit is continuously 109627_0910 Park brake lever Release button Figure 3 6 Q LH TR REIFE 2 LAO Differential lock pedal gt GE A ELA Lo lt I Dz N ELE 2 KE sd SS LL IR S YN BLISS MT 3 7 variable from zero to full rated speed in each range The ground speed is controlled by these pedals Depress the forward travel pedal to progressively increase forward speed For reverse travel depress the reverse travel pedal NOTE These pedals must be in neutral not depressed to start the engine
3. To find a leak under pressure use a piece of cardboard or wood never use your hands To relieve all pressure in system lower attachment and turn engine off e Do not allow open flame near the battery when charging e Avoid skin contact with battery acid e Always wear eye protection when checking the battery acid can cause serious injury to skin and eyes If contact occurs flush area with clean water and call physician imme diately Acid will also damage clothing 109627_0910 WARNING Read Owner s Manual and decals before attempting to operate or service this machine L O 601625 No e Wear ear protection eye protection and safety shoes when operat ing this equipment Ne WARNING Thrown e Never operate the mower deck with side objects deflector damaged altered removed or in raised position except when the entire grass catcher attachment or mulching sys tem is being used WARNING DANGER Rotating blades Thrown objects pulleys amp belts xO O 601603 A e Always maintain a e Keep hands feet and clothing away safe distance from e Always keep shields or covers in place people and pets while machine is in operation when mowing e Always stop machine if some one enters the area WARNING Rotating driveshaft AA a O 601623 e Keep hands feet and clothing clear of this area e Keep a safe distance from the ma
4. Turn the key switch to the START position When the engine starts release the key Check to be sure the warning lights go out IMPORTANT In cold weather below 23 degrees F 5 degrees C start the engine after holding the key switch to the HEAT position for approximately 10 seconds even if the glow plug indicator warning light has gone out Starting the engine with jumper cables If it is necessary to use jumper cables to start the engine follow the instructions below 1 Bring helper vehicle with a battery of the same voltage as disabled machine within easy cable reach The WARNING Start engine only from the operator s seat WARNING If ice is present or the battery is cracked Do not attempt to jump start the vehicle 109627_0910 vehicles must not touch Shield eyes Connect one end of the jumper cable to the battery positive terminal and the other to the auxiliary battery positive terminal Connect one end of the other cable first to the auxiliary battery negative terminal and the other end to the Hustler tractor frame Follow the starting procedures above after the jumper cables are connected as instructed After engine has started disconnect the negative jumper cable before disconnecting the positive jumper cable s WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm
5. Wash hands after handling WARNING Charge batteries in an open well venti lated area away from spark and flames Unplug charger before connecting or disconnecting from the battery Wear protective clothing and use insulated tools WARNING Avoid skin and clothing contact with battery acid WARNING Always wear eye protection when checking the battery acid can cause serious injury to skin and eyes If contact occurs flush area with clean water and call physician immediately Acid will also damage clothing Do not drink the battery electrolyte Do not allow open flame near the battery when charging Hydrogen gas forms inside the battery This gas is both toxic and flammable and may cause an explo sion if exposed to flame Always remove the nega tive ground first and replace it last Do not overfill battery Electrolyte may overflow and damage paint wiring or structure When cleaning the battery use soap and water Be careful not to get soap and water into the battery Clean the battery terminals with a solu tion of four parts water and one part baking soda when they become corroded WARNING Shorts caused by battery terminals or metal tools touching metal tractor components can cause sparks Sparks can cause a battery gas explo sion which will result in personal injury Prevent the battery terminals from touching any metal tractor parts when removing or installing the battery Do not allow metal tools to sho
6. e Allow engine to cool before storing machine inside a building Store away from open flame or spark Clean up any gasoline spills Do not refuel while in enclosed trailer or other enclosed areas WARNING Hot surface e Keep a safe distance from the machine WARNING Rotating fan e Keep hands feet and clothing clear blade of this area e Always keep shields or covers in place while machine is in operation e Hydrogen gas forms inside the battery This gas is both toxic and flammable and may cause an explosion if exposed to flame Always remove the negative ground first and replace it last DANGER Battery Hazards WARNING Hot fluid under pressure e Do not open while engine is hot Wait until the system has fully cooled to ser vice e Always keep shields or covers in place WARNING Fluid under pressure Avoid hydraulic fluid escaping under pressure Hydraulic fluid escaping under pressure can penetrate skin Hydraulic fluid escaping under pressure may have sufficient force to penetrate skin and cause serious injury Foreign fluid injected into the skin must be surgi cally removed within a few hours by a doctor familiar with this form of injury or gangrene may result 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
7. show wear or damage The two post ROPS can be pivoted down by removing the right and left retaining rings and pulling out on the pins so that the machine can operate under low hanging tree limbs or other obstructions Figure 3 22 Do not wear the seat belt 3 11 Figure 3 21 when the ROPS is in the lowered position Use the ROPS in the folded position only when it is absolutely necessary ROPS folded lowered position as a standard oper ating mode A folded ROPS does not provide roll over protection WARNING Do not operate the mower with the tractor is not equipped with aROPS or safety cab or if the ROPS is folded down In this case the seat belt should never be worn WARNING Always wear your seat belt unless the WARNING To minimize chance of injury or death from rollover keep ROPS in the raised and locked position and use the seat belt Never operate machine on a slope with the ROPS folded down lowered position There is no roll over protection when the ROPS is in the lowered position Lower the ROPS only when absolutely necessary Drive slowly and carefully Raise the ROPS as soon as clearance permits Read and follow slope opera tion instructions and warnings Do not wear seat belt when the ROPS is in the low ered position not attach chains or ropes to the ROPS for pulling purposes as the machine can tip backwards WARNING Always pull from the tractor hitch Do Always fasten
8. the attaching bolts WARNING If the ROPS or cab is removed or WARNING The ROPS structure s protective capability may be impaired by structural dam 109627_0910 age overturn or alteration If any of these conditions uneven terrain To prevent personal injury observe the fol occur this structure must be replaced lowing precautions when driving the unit WARNING Do not remove or alter any of the A Watch where you are going especially at row ends on A ROPS parts Failure to adhere to these instructions roads and around the trees could result in severe injury or death Do not A Reduce speed before turning or applying brakes attempt to weld or straighten ROPS Failure to A Avoid sudden starts and stops on slopes adhere to these instructions could result in severe A Be careful when changing direction on slopes injury or death A Stay alert for holes rocks roots and other hidden haz ards in the terrain Keep away from drop offs A Do not park on slopes A Avoid quick stops especially when an attachment is not installed or raised Quick stops will cause upsets DANGER Use extreme care when operating on Slopes Inexperienced operators may have a ten dency to oversteer and lose control Slow moving practice maneuvers are recommended to become familiar with these characteristics before attempting normal speed operation peeing Pin bee N WARNING Sharp depressions or raised obstacles A such as gutte
9. 12 C below the expected ambient temperature to prevent fuel flow problems in cold weather Keep dirt from entering the fuel tank e Sulfur content of the fuel should be no more than 0 05 e Sediment and water content should not exceed 0 05 e Minimum cetane number is 40 Low temperature or high altitude operation may require use of fuel with a higher Cetane number Use properly mixed winter fuel when temperatures are extremely cold In most areas diesel fuel is prop erly blended for summer and winter grades as ambi ent temperatures change In winter use winter grade diesel fuel only Otherwise the fuel may cloud and block the fuel system Refueling the Tractor The fuel tank filler cap is located at the left side of the tractor hood Before removing the cap wipe all dust and dirt from around the cap to prevent debris from falling into the tank while filling Figure 4 10 Use an approved fuel container and check the inside of the container periodically for cleanliness Fuel tank capacity is 13 33 gallons 50 5L NOTE The fuel cap is a vented type Use only an approved Hustler replacement cap to prevent fuel system related problems If there is no filter on the storage tank or fuel container filter the fuel through a 100 mesh or finer screen when filling the mower fuel tank Keep the mower tank as full as possible without filling to capacity to minimize condensation NOTE It is a good practice to fill the fuel t
10. 4 Run engine for a minimum of 15 minutes Drain oil from crankcase while engine is still warm Refill with fresh oil of proper viscosity Special precautions should be taken to protect the fuel injection pump and injector nozzle against corrosion and gumming Flush the fuel system with a special oil a quantity of which will remain in the system when the engine is shutdown Special diesel fuel system flushing oils are available from most oil companies If this oil is not 9 10 11 available mix 0 5 qts 0 5 liters of SAE 10 non detergent engine oil with 2 64 gal 10 liters of No 2 diesel fuel Drain the fuel tank and pour 1 85 gal 7 liters of the special flushing oil or lubricating mixture into the fuel tank Run the engine for 10 minutes to ensure complete distribution of the special oil through the injection pump and fuel injectors There is no need to remove the injector nozzles Fill the fuel tank with No 1 diesel fuel IMPORTANT Do not use No 2 diesel fuel for winter storage because of wax separation and setting at low temperature Open the drain valve on the radiator Flush the system close the drain valve and fill with a 50 50 solution of permanent antifreeze and clear water Clean exterior surface of engine Spread a light film of oil over any exposed metal surfaces of engine that are subject to corrosion Clean dirt and chaff from radiator fins and muffler Check oil filler cap and fuel tank cap to
11. F 12 2 48 9 C SAE 15W 40 20 60 F 28 9 15 6 C SAE 5W 30 NOTE Engine originally shipped with 10W 30 oil Lubrication fittings NOTE After every 50 hours of normal operation apply a good quality grease to the lubrication points listed below refer to the Recommended Lubricants chart When operat ing under extremely dirty conditions lubricate more fre quently than every 50 hours e Lift cylinder e Front Lift arm e Power Steering Cylinder e Brake pedal shaft e Differential Lock pedal shaft To lubricate these points 1 Wipe away all old grease and dirt from the lubrication fittings to prevent dirt or foreign material from entering as new grease is applied 2 Use a high pressure grease gun to force in the new grease Apply pressure until clean grease oozes from each lubrication point 3 Wipe away any excess grease Service access Opening the hood A WARNING To avoid personal injury from contact with moving parts Never open the hood and seat while the engine is running Do not touch the muffler or exhaust pipe while they are hot severe burns could result Unlock the hood latch Raise the hood using the hood handle Figure 4 1 Close the hood and clamp the hood latch Opening the seat platform Pull out on the seat release knob and pivot the seat platform forward Figure 4 2 Electrical system The electrical system is a 12 volt DC system with negative ground The rec
12. and all decals before operating this machine It is also the owner s responsibility to make certain that the operators and mechanics are qualified and physically able individuals properly trained in the operation of this equipment All operator and mechanics must become familiar with the safe operation of the equipment operator controls and safety signs Never let children or untrained people operate or service the equipment Local regulations may restrict the age of the operator For more detailed maintenance and adjustment information refer to the proper parts manual for your machine Refer to the Product Literature section of this manual for ordering information The owner user can prevent and is responsible for accidents or injuries occurring to themselves other people or property 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 seated on tractor facing forward unless otherwise stated Photographs and illustrations used were current at the time of 109627_0910 1 1 printing but subsequent production changes may cause your machine to vary slightly in d
13. cleaner element is clogged by foreign substances such as dust and clean air is restricted to the engine this light will lluminate Refer to the Engine Air Filter section of this manual for detailed information Parking brake warning light Figure 3 1 When the parking brake 1s applied this light will lluminate Switches A Ignition switch Figure 3 2 A four position switch off run pre heat and start With key inserted rotate it clockwise to PRE HEAT position and the START position release key when engine starts and switch will automatically return to the RUN position Turning the key to the RUN position activates the warning lights and instruments Figure 3 3 B Head light switch Figure 3 3 This switch is located under the instrument panel Push the switch in and rotate the ignition key to the RUN position to turn on the head lights Controls A Throttle control Figure 3 4 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 NOTE Always operate the mower deck or attachment at full engine RPM Master brake pedal Figure 3 5 Depress the master brake pedal to stop the unit NOTE The cruise control switch will be returned to the OFF position by depressing the master brake pedal if the cruise control switch is in the SET posi tion Park brake
14. dusted engine Do not clean element replace with a new element only Cleaning used air filter elements through improper cleaning procedures can get dust on the inside of the filter causing dirt ingestion and engine failure 109627_0910 It is important to note that whenever an air filter element is cleaned by any method the person or company performing the cleaning assumes responsibility for the integrity of the filter from then on The warranty for air filters expires upon cleaning or servicing in any manner because the condition of the filter after servicing is completely out of their control Therefore on a dust ingested engine failure there will be no warranty consideration if the air filter element has been cleaned or serviced in any manner A partially dirty air filter element works better than a new element Therefore a dirty filter element is not bad for the engine unless it is excessively restricting the air flow and engine performance is affected The reason 1s simple The media in the filter must be porous to allow air to pass through it When dirty air passes through the filter the dirt plugs some of the holes in the media and actually acts as part of the filter media When the next round of dirt enters the first dirt helps filter out even smaller particles making the filter more efficient at stopping dirt from entering the engine This is referred to as barrier filtration Of course at some point the filter media becomes
15. have been properly adjusted check to make sure they are working correctly on the tractor in a safe area away from any obstructions or bystanders Make sure the braking Pa lt oe force on both front drive wheels is equal Re adjust if Brake adjusting rod left side necessary da If you find that the brakes are dragging check the park brake Po Sos adjustment If this does not fix the problem and your brakes continue to work incorrectly do not operate the tractor and contact your Hustler Dealer Rear wheel toe adjustment 1 Park the tractor on a flat level surface with the rear wheels oriented so the tractor will drive a straight line forward 2 Fully engage the park brake lower the front end attachment and turn off the tractor Remove the keys Chock the front drive tires of the tractor Figure 4 35 3 Measure F and R dimensions The distance between the inside of the rim edge of the RH wheel to the LH on the wheel rims horizontal with the axle center Figure 4 37 wheel This measurement needs to be taken at the points 4 14 109627_0910 4 The F dimension should be between 0 075 and 0 175 1 9 mm 4 4 mm less than R dimension Tie rod 5 If the toe n must be re adjusted to meet the dimensional requirements loosen the jam nuts on either end of the tie rod Figure 4 38 6 Once the jam nuts are both loose and backed off rotate the tie rod in the appropriate direction and adjust accordingly to meet t
16. is in this position the rear axle drive 1s activated for improved traction in adverse conditions NOTE When mower is in Locked AWD mode only low range is engaged WARNING When driving on slopes always oper A ate in the Locked AWD mode H PTO Control lever Figure 3 11 This lever engages and disengages the PTO Move the lever forward and hold it to engage the PTO Move the lever rearward to disengage the PTO a PTO must be in disengaged position to start the engine See PTO stop system on page3 7 IMPORTANT Do not repeatedly engage and dis engage the PTO when Mower becomes clogged Doing so may cause PTO clutch failure If Mower becomes clogged stop the engine remove starter key and clean underside of deck using a probe not your hand IMPORTANT When PTO lever is engaged and operator raises the front attachment if attachment is raised all the way up the PTO will automatically be disengaged This is a tractor safety feature I Tool Bar Lift Control lever Figure 3 11 The front mounted equipment can be raised and lowered by the tool bar lift control lever Place handle in the forward position to lower and to the rearward position to raise front mounted equipment To lower and float the equipment push the lever forward To raise the equipment pull the lever rearward and hold it until the equipment is raised to the desired position WARNING To avoid personal injury disengage A the PTO Control lev
17. protection and air cleaner service life install a new inner safety element every third primary element change or after every 1000 hours of operation whichever comes first NOTE The safety filter does not require servicing unless it becomes contaminated with dirt or moisture Recommended service procedure 1 Release clamps and remove element canister with a damp cloth 2 Before installing a new element inspect 1t by placing a bright light inside and rotate the element slowly looking for any holes or tears in the paper Also check gaskets for cuts or tears Do not attempt to use a damaged element which will allow abrasive particles to enter the engine 3 Install the new element and reinstall the dust cup Make sure 1t seals all the way around the air cleaner body then tighten the clamps 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 dust Locate and repair the source of ingested dirt 6 Never operate a machine without an air filter installed Clean the Overservicing Overservicing occurs when an air filter element is removed for cleaning or replacement before it is necessary Each time the filter is removed a small amount of dirt and dust could fall in the intake system This accumulated dirt can cause a dusted engine It only takes a few grams of ingested dirt over the normal service life of an engine to cause a
18. station clean of accumulated trash grass clippings and other debris Always clean up spilled fuel and oil Using a ramp A Use extreme caution when loading and unloading a unit onto a truck or trailer with a ramp A Use only a single full width ramp do not use individ ual ramps for each side of the unit Having a full width ramp provides a surface for the tractor frame to contact 1f the unit starts to tip backwards It also reduces the risk of a wheel going off and the machine tipping over A Do not exceed a 15 degree angle between the ramp and the ground or between the ramp and the trailer or truck A When on a ramp avoid sudden acceleration Slope Operation Slopes are a major factor in loss of control and tip over accidents which can result in severe injury or death All slopes require extra caution REMINDER Only operate on slopes of 15 degrees or less A Use extreme caution when operating on slopes e Be extremely careful changing directions on a slope Slow down Do not operate where the machine could slip or tip Turn slowly e Turn on the most level part of the slope e While driving on slopes always run in AWD All wheel drive locked position e Never make sudden changes in speed or direction e If it becomes necessary to turn downhill turn slowly and gradually if possible A Watch for holes ruts bumps rocks or other hidden objects Uneven terrain could overturn the machine Tall grass can hide obstacles A R
19. 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 2 Correct part number 3 Correct model number 4 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 1 2 109627_0910 3500 3700 TRACTORS HUSTLER TURF COMMERCIAL PRODUCT TWO YEAR 1500 HOURS LIMITED WARRANTY WHAT IS COVERED BY THIS WARRANTY Hustler Turf Equipment makes the following warranty to the original pur chaser only a Hustler Turf Equipment Tractors and Power Units are warranted for two 2 years or 1500 hours whichever comes first from date of delivery on all defects in materials and workmanship If the Purchaser discovers within this warranty period a defect in materials or workmanship O 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 30 days after expiration of warranty O Within a reasonable time after such notification Hustler Turf Equip ment will correct any defect in material or workmanship on the Hus tler Turf
20. the wire to the main wiring harness 4 Remove the old fusible link wire from the starter terminal 5 Replace the old fusible link wire with a new one first attaching to starter terminal and then connecting into the main wire harness IMPORTANT Always replace the fusible link wire with the appropriate fusible link wire for this tractor Auxiliary P T O Work lamp opt back buzzer opt Head lamp meter back light stop solenoid safety switch starter cruise control opt Head lamp Temperature gauge fuel gauge fuel If a head lamp fails to operate the bulb must be replaced pump monitor lamp To change the bulb Alarm buzzer amp relay 1 Pull the lower cover frontward and remove it Figure 4 6 2 Turn the socket counterclockwise and remove the socket from the headlamp housing 3 Remove the bulb Figure 4 7 4 Install a new bulb in the socket and install the socket with bulb in the housing 5 Install the front cover Replacement bulb Head Lamp Bulb Type JIS S25 BAI5 12V 23W Instrument panel light To change a burned out instrument bulb 1 Pullthe lower cover frontward and remove it Figure 4 I 2 Remove the four screws that connect the front cover to the dashboard Figure 4 8 3 Remove the front cover of the dashboard Figure 4 8 4 Turn the burned out bulb together with the socket half a Figure 4 4 turn counterclockwise and pull it out Figure 4 9 Fusible link 5 Replace the bulb with ne
21. unit at the end of the operating season the following steps should be taken to ensure readiness for the next season SOPA EN Remove all grass dirt and trash from tractor and mower Clean tractor and mower and touch up all scrapes with Hustler spray paint IMPORTANT Wash the machine with a mild detergent and water Do not pressure wash the machine Avoid excessive use of water Install new air filter per Engine Owner s Manual Check thoroughly for any worn or damaged parts that need replacing and order them from your dealer If the tractor does not have a deck mounted raise the lift arms hydraulically to their fully raised position so that the lift cylinder is fully retracted This will protect the cylinder rod surfaces from corrosion Lubricate the unit Drain and refill the transmission hydraulic system and front axle with new oil Block tractor up so weight is off tires Do not deflate tires Perform separate engine preparation as listed below Store tractor in a clean dry place Remove the battery from machine a Clean battery b Check the electrolyte level c Charge the battery if necessary d Store battery in a cool dry place do not expose to freezing temperatures e Always keep the battery fully charged Especially important to prevent battery damage when the temperature is below 32 F 0 C Preparation of engine for storage When engine is to be unused for long periods proceed as follows L 2 3
22. 109627_0910 Hustler 3500 3700 Owner s Manual HUSUUER TURF EQUIPMENT PO Box 7000 000 Hesston Kansas 67062 2097 A WARNING A 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 Sec tion 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 A spark arrester is a device constructed of nonflammable materials specifically for the purpose of removing and retaining carbon and other flammable particles over 0 0232 of an inch in size from the exhaust flow of an internal combustion engine that uses hydrocarbon fuels or which is qualified and rated by the United States For est Service Other states or federal areas may have similar laws The Operator Should Contact Local Fire Agencies For Laws or Regulations Relating to Fire Prevention Requirements THIS EQUIPMENT DOES NOT HAVE A SPARK ARRESTER AND YOU SHOULD CONTACT YOUR AUTHORIZED DEALER FOR THE PURCHASE OF A SPARK ARRESTER Inspect spark arrester daily replace every 500 hours or as needed The Engine Owner s Manual provides information regarding the U
23. 4 28 Supply new ISO VG46 hydraulic oil into the fill hole until oil level is between the two marks on the dipstick Figure 4 26 To fill the final reduction gear cases with new ISO VG46 hydraulic oil a Remove the right and left rear wheels b Oil supply plugs are located on the front side of the right and left final reduction gear case Remove the plugs Figure 4 29 c Pour the hydraulic oil in the plug holes until the final reduction gear cases are full d Re install plugs PTO control lever adjustment NOTE Adjust the PTO control lever linkage every 100 hours 4 12 Rear axle oil fill amp dipstick Rear axle oil drain case drain plug Figure 4 28 The PTO control lever must move easily soft through the first 50 of travel The remaining 50 of control lever travel must have a resistance hard At the point of resistance 50 into the control lever stroke attach a pull scale to the PTO control lever A reading of 11 5 lbs 5 kg is correct at the point of 109627_0910 Final reduction gear case fill plug dd A A ME Figure 4 29 resistance 50 into the control lever stroke A reading of 26 4 28 6 lbs 12 13 kg is correct at the full engagement point the final 50 of control lever travel If the control lever stroke is not correct or the amount of resistance on the pull scale at the point of resistance is incorrect proceed to step 3 NOTE The adjustment bolt on the PTO adjustment linka
24. Equipment by repairing or replacing part s with either new or used replacement parts O Such repair including parts and labor shall be at the expense of Hustler Turf Equipment and b Rental Units 90 days Within 90 days of date of delivery Hustler Turf Equipment provides a limited warranty on all materials and workman ship for units used for rental purposes O Ifthe Purchaser discovers within this warranty period a defect in mate rials or workmanship O 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 O Within a reasonable time after such notification Hustler Turf Equip ment will correct any defect in material or workmanship on the Hus tler Turf Equipment by repairing or replacing part s with either new or used replacement parts O Such repair including parts and labor shall be at the expense of Hustler Turf Equipment and c The Shibaura diesel engine is covered by a three 3 year or 2000 hour whichever comes first limited warranty to the original owner only and d 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 pro
25. F Cruise control switch Figure 3 8 Used to maintain a constant forward speed After attaining the desired speed with the forward travel pedal put the switch to the ON position and the unit will maintain the set speed when the pedal is released To cancel the speed setting or stop the unit put the cruise control switch to the OFF position or firmly depress the master brake pedal WARNING To avoid injury the cruise control switch should not be put in the ON position when operating at transport speed or when in reverse 109627_0910 3 5 Transmission selector lever shown in the Automatic AWD position Figure 3 9 Low range Transmission selector lever shown in the locked AWD position Figure 3 10 G Transmission Selector lever Figure 3 9 amp Figure 3 10 The Range Selection and the All Wheel Drive AWD Selection are controlled by the Transmission Selector lever This lever can only be shifted when the HST foot pedal is in the Neutral position When the Transmission Selector lever is located in the inside slot the tractor will run in Automatic AWD mode When the lever is in this position there are three settings High range H Low range L and Neutral Range Forward Reverse Low 0 6mph 0 9 7kph O 4 mph 0 6 3kph High 0 15 2 mph 0 24 5kph 0 9 9 mph 0 15 8kph When the lever is placed in the outer slot the tractor will run in Locked AWD mode When the lever
26. 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 illegi ble replace immediately Replacements may be ordered per the information found in the Product Informa tion section of the owner s manual 109627_0910 GENERAL INFORMATION This manual applies to the following Hustler equipment lines Hustler 3500 Hustler 3700 To the new owner The purpose of this manual is to assist owners and operators in maintaining and operating the 3500 3700 tractor Please read 1t carefully information and instructions furnished can help you achieve years of dependable performance A separate Engine Owner s 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 decals are designed to give the operator brief information needed in the daily operation and service 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 removed or obliterated Replace these decals if they become unreadable It is the owner s responsibility to make certain that the operators and mechanics read and understand this manual
27. Sioppine MESAS o coa er as 3 9 SWHONES se rasak err tico ide arde ea A 3 3 DEN aq oe ne ela e oe ed Me a 4 2 To the new owner 2 2542 46 a a he 1 1 Tore val s Sorrir a Gree ed 4 2 Transmission front axle and hydraulic system 4 11 Using a ramp AAA 3 2 Using this manual zu osos cia 1 1 WW GEM saie ol eee e o e 1 1 6 1 109627_0910
28. This free play distance should be 0 38 in 10mm to 0 75 in 19mm To adjust the park brake free play raise the seat platform and secure it in the up position IMPORTANT Make sure the seat platform is secured properly in the up position to prevent it from falling back down on you as you are working Loosen the jam nuts on each of the park brake cable in line cable adjuster barrels as shown in Figure 4 32 Back the jam nuts off several turns Turn the in line cable adjuster barrel Figure 4 32 on each cable accordingly to properly adjust the cable Lengthening the in line cable adjuster assembly exposing more threads will tighten the cable and reduce the free play Shortening the in line cable adjuster assembly length less exposed threads will loosen the cable and create more free play Both cables should be adjusted so they are providing equal free play when the brake is off and equal brake force on each brake when the park brake is applied Re check the free play step 2 Re adjust as necessary Tighten the jam nuts e the park brake is adjusted properly check to make sure it s working effectively and does not drag If any problems persist do NOT operate the tractor and contact your dealer 38 75 P 10 mm 19 mm fo Figure 4 31 Inspecting and adjusting the service brake The service brake must be adjusted when a There is less than 0 38 in 10mm or more than 0 75 in 19mm of free travel in the b
29. ack stands Use only appropriate jack stands with a mini mum weight rating of 3500 pounds to block the unit up Use in pairs only Follow the instructions supplied with the vehicle stands A Do not touch hot parts of machine A Keep nuts and bolts tight especially the blade attach ment bolts Keep equipment in good working condi tion A Never tamper with safety devices Check their proper operation daily A Stop the engine before removing the grass catcher or unclogging the discharge chute Never clear the dis charge 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 A 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 A Exercise caution when working under the deck as the mower blades are extremely sharp Wrap the blade s or wear gloves and use extra caution when servicing them Take care as the rotation of one blade can cause the other blades to rotate A Use only genuine Hustler replacement parts to ensure that original standards are maintained Introduction Regular maintenance is the best prevention for costly downtime or expensive premature repair The following pages contain suggested maintenance information and sch
30. ank at the end of each day as this will reduce overnight condensation Figure 4 10 109627_0910 Fuel filter Draining the fuel filter NOTE The fuel filter should be drained after every 100 hours of operation 1 Make sure there is adequate fuel in the fuel tank and close the fuel shutoff valve the handle should be pointing to the C position Remove the fuel sediment bowl Figure 4 12 2 Open the fuel shutoff valve until all water has been removed and only fuel flows from the filter base 3 Install the fuel sediment bowel The fuel system is auto bleeding And does not require any manual bleeding procedures Changing the fuel filter NOTE Change the diesel fuel filter every 200 operating hour 1 Close the shutoff valve the handle should be pointing to the C position Figure 4 12 2 Remove the sediment bowl by rotating the retaining nut Ref No 1 Figure 4 12 Shown in Open position Shut off valve Sediment bowl Figure 4 11 3 Open the fuel shutoff valve Ref No 2 to drain any remaining water from the tank Figure 4 12 4 Discard the fuel element Ref No 3 and install a new element Figure 4 12 5 Inspect the O rings Ref No 4 amp 5 and replace if necessary Figure 4 12 6 Install and securely tighten the sediment bowl 7 Open the fuel shutoff valve the handle should be pointing to the O position so fuel will flow to the filter Figure 4 12 8 Bleed the fuel fi
31. atchful care of a responsible adult other than the operator A Be alert and turn the machine off if children enter the area A Before and while backing look behind and down for small children A Never carry children even with the blades off They may fall off and be seriously injured or interfere with safe machine operation Children who have been given rides in the past may suddenly appear in the mowing area for another ride and be run over or backed over by the machine A Never allow children to operate the machine A Use care when approaching blind corners shrubs trees the end of a fence or other objects that may obscure vision A Never allow children or others in or on towed equip ment Instrument Panel A Electronic hour meter Figure 3 1 Registers 1 10 hour increments up to 9 999 9 total hours Connected to the ignition switch the meter records the accumulative time while the ignition key is switched to the RUN position B Temperature gauge and alarm Figure 3 1 When the needle is in the middle area the engine is at its normal operating temperature When the needle reaches the H side of the gauge it indicates the engine coolant has reached an unsafe temperature If this occurs shut down the machine as soon as possible Never risk continued operation high temperatures can severely damage the engine The coolant temperature fluctuates depending on ambient temperatures and working loads If the needle
32. belts blades blade sharpening bearings brake or steering adjustments O Repairs necessary due to improper fuel contaminates in the fuel sys tem or failure to properly prepare the fuel system prior to any period of non use over three months O Damage caused by foam filled or solid filled tires 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 inciden tal 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 O 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 O The claims of third
33. brake pedal while the machine is in forward motion because machine may tip forward causing loss of control A Never push down suddenly on the HST reverse pedal while the machine is in forward motion because machine may tip forward causing loss of control A Never drive the tractor at high speeds without a front end attachment mounted to the tool bars Keep the attachment as low to the ground as possible mower decks should rest on the gauge wheels A Never operate a poorly maintained machine A Never attempt high speed maneuvering especially in crowded or congested areas A Never allow persons to operate this machine without proper instruction or allow children to operate machine Allow only responsible adults who are famil iar with these instructions to operate this machine A Never put hands or feet under any part of the machine while it is running A Never carry passengers A Never direct discharged material toward anyone Avoid discharging material against a wall or obstruc tion Material may ricochet back toward the operator Always disengage the blades and wait for them to stop before crossing gravel drives walks or roads A Always keep clear of the mower blades and attach ments during their operation A Turn off blades when not mowing A Slow down before turning A Stop the engine before removing the grass catcher or unclogging the discharge chute Never clear the dis charge chute with the engine running Turn off the
34. c or Locked All Wheel Drive AWD The transmission selector lever is used to select Automatic Four Wheel Drive or Locked Four Wheel Drive When the Transmission Selector lever is located in the inside slot the tractor will run in Automatic AWD mode Figure 3 9 When the lever is placed in the outer slot the mower will run in Locked AWD mode and low range Figure 3 10 When in motion always bring the unit to a complete stop before moving the transmission selector lever Automatic All Wheel Drive AWD means that the four wheel drive line is engaged automatically when the front wheels start to slip but in normal operation reverts to 2WD this provides sharp and smooth turns without damaging turf Locked Four Wheel Drive should be used when additional traction is required while operating in loose soil wet slippery conditions or slopes NOTE The steering rear axle is not powered in reverse when tractor is operating in Automatic AWD Power take off operation The power take off PTO transfers engine power directly to the PTO equipment PTO is controlled through the PTO lever To engage the PTO push the lever forward To disengage the PTO pull the lever rearward Figure 3 11 WARNING To avoid personal injury keep chil A dren and others away when operating PTO equip ment NOTE The PTO lever must be placed in the disengaged position to start the tractor Operating the differential lock Do not engage the differentia
35. chine e Keep shields or covers in place while machine is in operation WARNING This structure s protective capability may be impaired by struc tural damage overturn or alteration If any ofthese conditions occur this structure must be replaced Avoid crushing use seat belt Do not jump if machine tips e To minimize chance of injury or death from rollover keep ROPS in the raised and locked position and use the seat belt Never operate machine on a slope with the ROPS folded down lowered position e There is no roll over protection when the ROPS is in the lowered position e Lower the ROPS only when abso lutely necessary Drive slowly and carefully Raise the ROPS as soon as clearance permits e Read and follow slopes operation instructions and warnings e Do not wear seat belt when the ROPS is in the lowered position Always pull from the tractor hitch e Do not attach chains or ropes to the ROPS for pulling purposes as the machine can tip backwards Part Number 601635 109627_0910 2 3 a WARNING Rollover 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 WARNING Back over Always be aware of what is behind the machine before backing up Do not mow in reverse
36. duct to and from the authorized dealer for warranty work will be paid by the owner of the product For warranty service contact an authorized dealer WHAT IS NOT COVERED BY THIS WARRANTY Hustler Turf Equipment does not warranty O Some product components or parts not manufactured by Hustler Turf Equipment O Repairs made by unauthorized persons O Damage caused by use of the Hustler Turf Equipment for purposes other than those for which 1t was designed O Damages caused by disasters such as fire flood wind and lightening O Damages caused by neglect abuse abnormal use improper or unrea sonable use accident negligence misuse or foam filled solid filled tires O Repairs or replacement resulting from the use of unauthorized parts accessories or attachments O 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 O Hustler Turf Equipment which has the serial number removed or made illegible O Depreciation or damage caused by normal wear lack of reasonable and proper maintenance failure to follow the product s owner s manual 109627_0910 1 3 operating maintenance and adjustment instructions or other opera tional instructions provided by Hustler Turf Equipment O Normal maintenance parts and service including but not limited to fil ters fuel lubricants tune up parts
37. e tractor standing level and the engine off check the o1l level with the dipstick Figure 4 22 2 The oil is at the correct level when the oil level 1s within the mark at the lower end of the dipstick If low add ISO VG46 hydraulic oil through the filler hole Do not fill beyond the mark on the stick as the transmission will be overfilled 3 Install the dipstick Changing Oil amp Filters NOTE Replace the filters after the first 50 hours of opera tion and every 500 hours or annually thereafter following the procedure below WARNING Hydraulic fluid escaping under pressure Change the oil every 500 hours or annually 1 With the oil at normal operating temperature drain and discard the oil by removing the transmission drain plug Reinstall the plug after the oil has drained Figure 4 23 vent skin coming in contact with hot oil WARNING The oil will be hot Use caution to pre 2 Unscrew the oil filters and discard Figure 4 24 amp Figure 4 25 3 Coat the gasket on the new filters with a film of oil 109627_0910 4 11 Figure 4 22 Screw the filters into place until the gasket contacts the sealing surface then tighten the filters approximately 3 4 of a turn by hand Do not over tighten Figure 4 24 amp Figure 4 25 4 Remove the filler plug and dipstick and fill with ISO VG46 hydraulic oil 5 The transmission is filled to the correct level when the oil level is within the mark at the lower end of the dip
38. ed or direction 109627_0910 INTERNATIONAL SYMBOLS As a guide to the operation of your tractor various international symbols have been used on instruments and controls These symbols are depicted and described below 109627_0910 x Hours Recorded Engine Water Temperature Air Filter Engine Oil Pressure izi Qi Full Time AWD Fa A Auto AWD g e oo Ze Continously Variable Increase Decrease Fuel Level High Range Low Range OSO pPaaae Bz Neutral Diesel Fuel Glow Engine Stop Engine Oil Engine Start Parking Brake Lock Release Lock Differential Lock Volume Empty Battery p e Power Take off AA HTT ON p gt Power Take off 7 OFF gt Slow fetes Control Lever Hold E Attachment Raised L _ Attachment Lowered Remote Cylinder Retracted E Remote Cylinder Extended o Volume Full 109627_0910 SLOPE GUIDE Use this diagram when determining the degree of slope to be mowed E 15 Slope Guide Lines D 10 Hold this sheet of paper in front of you Make sure that Line A is horizontal Align Line B with a vertical surface such as pole tree or building Fold the paper along the slope guide lines C D or E Align the closest slope guide line with the ground slope This will give you a close estimation of the ground slope to be mowed u ae al 109627_0910 2 7 109627_0910 OPERATION Sa
39. edules which the operator should follow on a routine basis For more detailed information order the correct parts manual for your unit Refer to the Product Literature section of this manual Remain alert for unusual noises they could be signaling a problem Visually inspect the machine for any abnormal wear or damage A good time to detect potential problems is while performing scheduled maintenance service Correcting the problem as quickly as possible is the best insurance Clear away heavy build up of grease oil and dirt especially in the engine and under the seat platform areas minute dust particle are abrasive to close tolerance engine and hydraulic assemblies Daily inspect mower for grass clippings and wire and string tangles The underside of the mower deck will collect a build up of grass clippings and dirt especially when grass is wet or has high moisture content This build up will harden restricting blade and air movement and will probably show a poorer quality of cutting Therefore 1t should be removed routinely To do this it will be necessary to raise and block the deck using jack stands or blocks in the full up position and scrape the build up from underneath Refer to the deck owner s manual for more detailed information Some repairs require the assistance of a trained service mechanic and should not be attempted by unskilled personnel Consult your Hustler service center when assistance is needed Torque value
40. emove obstacles such as rocks tree limbs etc A Keep all movement on slopes slow and gradual Do not make sudden changes in speed or direction A Avoid starting and stopping on a slope If tires lose traction disengage the blades and proceed slowly straight down the slope A Mow a safe distance minimum of 10 feet away from drop offs retaining walls drainage ditches embank ments water and other types of hazards to avoid a wheel dropping over the edge or to avoid the ground from breaking away This will reduce the risk of the machine suddenly rolling over causing serious injury or death 3 2 A Use a walk behind push mower or hand held trimmer on slopes and near drop offs retaining walls drainage ditches embankments and water to avoid machine roll over and serious injury or death A Do not mow on wet grass Reduced traction could cause sliding and loss of steering control A If the mower s tires lose traction when operating on slopes disengage the blades engage the park brake turn the engine off and get help A 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 steering wheel or HST foot pedals in either direction could result in a reaction of the tractor that can cause serious injury A Never stop suddenly while going down slopes This action may result in a reaction of the tractor that can cause
41. engine and be sure the blades have stopped before cleaning Use a stick to clear a plugged discharge area Never use your hand A Do not operate the machine while under the influence of alcohol or drugs A Exercise caution when loading or unloading the machine onto a trailer or truck A Always wear safety goggles or safety glasses with side shields when operating the tractor A Data indicates that operators age 60 years and above are involved in a large percentage of riding mower related injuries These operators should evaluate their ability to operate the mower safely enough to protect themselves and others from serious injury A Follow the manufacturer s recommendation for wheel weights or rear counter balance weights A If any attachment or additional weight is mounted on the front of the unit any rapid movement of the HST pedals in either direction could result in a reaction of the tractor that can cause serious Injury A When desconnection on attachment that uses the trac tor PTO output shaft to power the attachment the pow ered shaft of device must also be disconnected from the tractor PTO output shaft Never leave an unsupported PTO device attached to the tractor PTO output shaft 1f it is not completely and properly assembled to the attachment on which it s use is intended A Clean flammable material from machine Prevent fires by keeping engine compartment exhaust area battery fuel line fuel tank and operator s
42. er before operating the Tool Bar Lift Control lever J Weight Transfer Control Figure 3 11 This feature enables the operator to transfer the weight of the deck or other equipment to the tractor unit Turn the knob clockwise the effort of weight transfer is increased refer to the Weight Transfer Valve section for additional information Seat adjustment The seat can be adjusted four different ways to obtain the most comfortable position 1 Back angle Figure 3 12 Forward and rearward travel Figure 3 13 Weight Figure 3 13 Lumbar Figure 3 14 u Steering wheel adjustment The 3500 3700 is equipped with an adjustable steering wheel which can telescope and tilt To telescope the wheel turn the wheel hub to the left and raise or lower the steering wheel to the desired height Then turn the hub to the right to lock it into position Figure 3 15 NOTE When locking the hub into position do not overtighten To tilt the wheel pull up on the lever and move the steering wheel fore or aft the desired position If the wheel is not held in position when the lever 1s raised the steering wheel will spring to its most forward position Use this feature to gain additional clearance when mounting and dismounting the tractor Figure 3 16 Safety start interlock system The tractor is equipped with a safety start interlock system consisting of the brake switch seat switch PTO switch and transmission neutral switch Weight Trans
43. er in your area NOTICE Ether or other starting fluids must never be used as a Starting aid with this engine Warranty will be denied when engine damage results from such use Warm weather starting To start a cold engine in warm weather or to start an engine that is warm 1 Depress the master brake pedal fully and move the PTO and transmission selector levers to the off and neutral positions Move the hand throttle forward to a near half open position Turn the key switch to the START position When the engine starts release the key Check to be sure the warning lights go out If the engine fails to start after cranking for approximately 10 seconds refer to the following COLD WEATHER STARTING information Allow the engine to idle a few minutes before advancing the throttle and or engaging the PTO In cold weather run the engine at half throttle for a few minutes to allow engine oil and transmission oil to warm up Cold weather starting If the engine fails to start using the preceding warm weather starting procedure or when starting the engine in cold weather 1 Depress master brake pedal fully and move the PTO and transmission selector levers to the off and neutral positions Move the hand throttle forward to the full open position Turn the key switch to HEAT to preheat the precombustion chamber and wait until the glow plug indicator warning light on the instrument panel goes out approximately 5 seconds
44. ered equipment is potentially danger ous 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 opera tion and safety of the machine as well as all safety warnings on the machine itself WARRANTY REGISTRATION 2 For validation the completed Warranty registration form MUST be for 1 Dealers must register the unit on line at www Hustlerdealer com or by fill warded to Hustler Turf Equipment within ten 10 days following date of ing out the Warranty registration form provided in the owner s packet If purchase l l using the Warranty registration form it MUST be completed and signed by 3 The date of purchase constitutes delivery the authorized dealer and original purchaser 1 4 109627_0910 SAFETY PRECAUTIONS 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 This manual uses two other words to highlight information IMPORTANT calls attention to special mechanical information and NOTE emphasizes general informati
45. ervoir DANGER Never remove radiator cap or overflow reservoir cap when engine is hot Pressurized hot steam and water may be released causing serious burns or possible blindness The cooling system operates under pressure controlled by the radiator cap It is dangerous to remove the cap while the system is hot Always cover the cap with a thick cloth and turn it slowly counter clockwise to the first stop Allow all pressure to escape before remov ing the cap completely Be sure that the radiator fins are clear of chaff and dirt to allow free air movement Radiator screen recovery reservoir gt Figure 4 17 Draining and flushing the cooling system NOTE Drain and flush the radiator and engine block every 12 months Refill with a 50 50 mixture of permanent antifreeze and clear water before draining and flushing the system WARNING Allow the engine and radiator to cool To drain the cooling system 1 Use a suitable receptacle to catch the used coolant Remove the radiator cap and open the drain valve to drain the radiator and engine block Figure 4 18 2 After the coolant has drained place a water hose in the radiator filler neck and run water through the system When water is flowing from the block drain valve start the engine When the water flowing from the drain valve is free of discoloration and sediment stop the engine and remove the hose Allow all water to drain from the system through the drai
46. etail Hustler Turf Equipment reserves the right to redesign and change the machine as deemed necessary without notification and without incurring any obligation to make changes or additions to equipment sold previously 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 tractor plus each attachment that displays a model and serial identification number plate 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 Tractor gross vehicle weight GVW This tractor has a maximum gross vehicle weight GVW of 3500 Ibs which must not be exceeded Use only Hustler approved attachments and accessories Model and serial number Tractor model and serial numbers are found on the serial identification plate located on the frame directly in front of the left rear wheel These numbers are required on the Warranty Registration form They will also assure you of
47. f the wheels or equipment do not follow ground contour the operation will be affected 5 To correct this condition turn the knob 1 4 turn clockwise at a time until the mower deck s front gauge wheels follow the ground contour Auxiliary hydraulic valve kit optional An Auxiliary Hydraulic Valve kit is available from your Hustler Dealer as an option When using the auxiliary valve 109627_0910 the lift control lever must remain in neutral Figure 3 17 and Figure 3 18 Auxiliary control valvelevers ee ER KIEN Outside lever Inside lever Port B Figure 3 18 This kit includes control valves hoses and quick connect couplers for supplying hydraulics power to optional attachments When not in use the coupler dust covers must be in place to prevent contamination Always replace them immediately if damaged or lost Note the hydraulic circuit connectors called out in Figure 3 18 Once connected the operator has control of the attachment s hydraulic cylinder by means of the valve control levers If stroking the valve lever produces the wrong cylinder movement up down right left etc reverse the attachment hoses at the quick connect couplers Use of the valve control lever varies with each attachment and is described in more detail in the operating instructions provided with the attachment 109627_0910 WARNING Never attempt to connect or discon nect the couplers with the hydraulics engaged and the syste
48. fe Operating Practices This product is capable of amputating hands and feet and throwing objects Always follow all safety instructions to avoid serious injury or death Operation A Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job Only use accessories and attachments approved by the manufacturer A Never leave a running machine unattended Park the machine on level ground Place park brake lever in the brake engaged position place the PTO lever in the OFF position lower attachment remove ignition switch key before leaving operator s seat for any rea son including unclogging the chute A Do not change the engine governor setting or over speed the engine A Always remain seated while operating machine A Always keep safety shields and covers in place except for servicing A Always maintain a safe distance from people and pets when mowing Always stop machine if someone enters the area A Always operate machine in daylight or with adequate working lights A Follow daily and weekly checklists making sure hoses are tightly secured and bolts are tightened A Always observe traffic laws while driving machine from one location to another Watch for traffic when operating near or crossing roadways A 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 depress
49. fer au Control 1 Tool Bar Lift Control Lever Figure 3 11 Check tractor safety start interlock system daily prior to operation This system is an important tractor safety feature It should be repaired immediately if it malfunctions The machine incorporates a separate seat switch which will stop the tractor engine when the operator is unseated for any reason while the tractor is operating This is a safety feature designed to prevent runaway or accidental entanglement Raising off the seat the engine will stop whenever operating PTO driven equipment such as the mower deck Also the engine will stop when raising off the seat unless the parking brake or master brake pedal is applied 109627_0910 7 Forward amp rearward travel Figure 3 14 To inspect the safety start interlock system 1 Park the unit on a flat level surface 2 The operator must be on the seat when testing the seat switch 3 Engage the park brake 4 Start the engine and allow it to warm up to operating temperature 5 With the PTO disengaged slowly raise off of the seat The engine should continue to run 109627_0910 6 Disengage the park brake and with the PTO disengaged slowly raise off of the seat The engine should stop 7 Engage the park brake and the PTO slowly raise off of the seat The engine should stop 8 If the engine fails to stop and the operator is off the seat check the function of the seat switch If the seat
50. ge uses left hand threads 3 Loosen the locknuts on the PTO adjustment linkage Figure 4 30 4 Turn the adjustment rod and recheck the resistance on the pull scale and the control lever stroke Repeat this step until the control lever stroke and the pull resistance are correct 5 Tighten the locknuts Figure 4 30 General engine maintenance Detailed instructions and recommendations for break n and regular maintenance are specified in the Engine Owner s manual Please refer to this manual for engine servicing lubricating oil levels with the proper SAE rating and viscosity recommendations bolt torques etc The engine warranty 1s backed by the manufacturer Special attention should be paid to applicable data which will not be duplicated here Park brake adjustment The park brake must be adjusted when there is less than 0 38 109627_0910 4 13 in 10mm or more than 0 75 in 19mm of free play in the park brake lever Figure 4 31 the park brake is dragging or the park brake is not working effectively 1 6 Te Onc Park tractor on level ground lower the mower deck or front mount attachment to the ground turn off tractor and remove key Chock the front drive tires to keep machine from rolling Check the park brake lever free travel distance With the park brake lever all the way down Off pull the lever up until you notice resistance from brake engagement measure this distance as shown in Figure 4 31
51. he dimensional requirements of step 4 7 Tighten the jam nuts on either end of the tie rod Make sure the ball joints on each end move freely once jam nuts are tightened Jam nut Brake linkage Figure 4 38 F Dimension Front of TE tractor Adjustable tie rod F R in mm 0 125 in 3 175 mm Figure 4 37 109627_0910 4 15 109627_0910 3500 3700 Maintenance Schedule Refer to Figures 4 39 8 4 40 SERVICE AT Dail ej P piel ges Seasonal INTERVALS INDICATED y ae Hours hours hours RARA e ee EEE eee Visually inspect unit for loose a fo fo ff hardware and or damaged parts A X C E O E HE E E sr A A ingineoirn p s RO A EEE HE Engineers BEE BEE HE HE ES EEE KEE A EEE SE ur EN EEE EEE EEE mesa RO TT HERE AS A O E FOTO PS E SON O O EEE sa O E ES P rfp raspa OR Transmission oil check level KI xK x le gt Lift arm grease fittings lubricate Lift cylinder grease fittings lubricate Brake pedal shaft grease fitting lubricate x Power steering cylinder grease fitting lubricate Differential lock pedal shaft grease fitting lubricate A AO a a AO EE II BEE aaa PTO control lever adjustment Refer to PTO Control Lever Adjustment section Check hydraulic hoses amp fuel lines for cracks and leaks Fuel filter element Fuel filter element replace Fa AAA Rear axle 4WD oil Rear axle 4WD oil replace Air ee element replace Refer to Eng
52. he hydraulic lift system provides hydraulic power for raising front mounted equipment whenever the engine is running To raise the front mounted equipment pull the lift control lever rearward and hold it until the desired equipment height is reached Figure 3 11 To lower the equipment push the lever forward When pushed all the way forward the lever will remain in a lowered float detent position IMPORTANT Always set the lift control lever in the float detent position when mowing WARNING Make sure the area is clear of people A before raising or lowering equipment WARNING Always lower the hydraulic lift and A equipment before stopping the unit Weight transfer valve The weight transfer valve is used to transfer the front attachment weight to the tractor unit to reduce equipment weight on turf and prevent damage and improve front drive wheel traction Figure 3 11 The weight transfer valve should be used according to the following procedures 1 With the engine running push the hydraulic lift lever forward to the floating position 2 Turn the adjusting knob clockwise until the mower or other equipment lifts off the ground 3 Turn the adjusting knob counter clockwise slowly until the mower deck front gauge wheels or other equipment just touches the ground then turn the knob counter clockwise 1 4 turn more 4 Operate the unit over uneven terrain at desired travel speed and observe the mower deck s front gauge wheels I
53. ine Air Filter section Radiator coolant replace Frame Pen NOTE A Trash and clipping buildup around engine could cause a fire Keep engine compartment and muffler area clean B Torque wheel lug bolts to the following torques after the first 2 hours of operation Front wheel lug bolts 85 95 ft Ibs 115 129 Nm Rear wheel lug bolts 65 75 ft Ibs 88 1 101 7 Nm 109627_0910 4 17 MAINTENANCE LOCATOR CHART 1 Engine Oil Fill 2 Engine Air Cleaner 3 Radiator Cap 4 HST Filter 5 Hydraulic Oil Filter 6 Engine Oil Filter amp Dipstick 7 Wheels amp Tires 8 Fuel Filter 9 Battery 10 Fan Belt 11 Transmission Oil Fill 12 Lift Arm 13 Lift Cylinder 14 Brake Pedal Shaft 15 Power Steering Cylinder 16 Differential Lock Pedal Shaft 17 Rear Axle 4WD Oil Fill Dipstick 18 Radiator Screen Figure 4 39 4 18 109627_0910 MAINTENANCE LOCATOR CHART 5 aa AA A 4 MSs rs ed I e y E gt Engine Oil Fill Engine Air Cleaner Radiator Cap HST Filter Hydraulic Oil Filter Engine Oil Filter amp Dipstick Wheels amp Tires Fuel Filter Battery 10 Fan Belt 11 Transmission Oil Fill 12 Lift Arm 13 Lift Cylinder 14 Brake Pedal Shaft 15 Power Steering Cylinder 16 Differential Lock Pedal Shaft 17 Rear Axle 4WD Oil Fill Dipstick 18 Radiator Screen CP Ben Figure 4 40 109627_0910 4 19 4 20 109627_0910 STORAGE When storing the
54. ions A Inspect area to be mowed for hazards such as rocks metal objects and other debris which may be thrown or entangled by mower blades Remove these objects before mowing A Always inspect machine for damage after striking a foreign object If damage is found repair machine immediately Be sure to stop on level ground place park brake lever in the brake engaged position place the PTO lever in the OFF position lower attachment remove ignition switch key before leaving operator s seat to inspect damage A Never engage the PTO Control Lever unless the PTO shaft is securely connected to a power driven attach ment A Always wear 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 head phones while operating the machinery Safe operation requires your full attention A Do not operate the equipment while wearing sandals tennis shoes sneakers shorts or any type of loose fit ting clothing Long hair loose clothing or jewelry may 109627_0910 3 1 get tangled in moving parts Always wear long pants safety glasses ear protection and safety shoes when operating this machine A Always be aware of what is behind the machine before backing up Do not mow in reverse unless absolutely necessary Always look down and behind before and while backing up A Never push down suddenly on
55. is at the H side during operation the overheat alarm buzzer sounds 109627_0910 3 3 Es D H Figure 3 1 Fuel gauge Figure 3 1 This gauge indicates the amount of fuel in the tank Glo plug warning light Figure 3 1 Comes on when turning the key switch to the HEAT position or START position This light will stay on for approximately 5 seconds in the HEAT Position Oil pressure warning light and alarm Figure 3 1 This light comes on when the ignition switch is placed in the RUN position and stays lit until the engine is running and a safe oil pressure is developed If light comes on during operation shut engine off immediately and locate and correct the problem When oil pressure falls below 4 25 ps 29 4 kPa the alarm buzzer will sound IMPORTANT The operator must occasionally check the crankcase for proper oil level NOTE The alarm buzzer will sound when engine stops with key left inserted at RUN position In order to stop the alarm buzzer return the key to STOP position Charge indicator warning light Figure 3 1 This light comes on when the ignition switch is placed in the RUN position and stays lit until the engine is running If it remains lit the charging system is not operating normally Investigate the cause as soon as possible otherwise the battery will fully discharge Air cleaner restriction warning light Figure 3 1 When the air
56. l lock when ground speed is above 5 mph 8 kmh Figure 3 7 The differential lock is engaged by depressing the differential lock pedal Depressing the pedal locks both differential gears together preventing one wheel from rotating independently of the other The lock should be used to obtain additional traction from the opposite wheel whenever one wheel begins to slip in wet or loose soil NOTE The differential lock pedal only locks the front axle when applied The rear axle is not lockable when turning the unit If the lock is engage when turning a loss of steering control will result WARNING Do not engage the differential lock 3 10 To operate the differential lock depress and hold down the pedal until the lock is positively engaged It is best to engage the differential lock while the wheels are turning slowly to minimize shock loads to the drive line If a wheel spins at high speed as on ice reduce engine speed to idle before engaging the lock or damage may occur The differential lock 1s released when the pedal releases as the loads equalizes on both drive wheels NOTE In some instances the lock may remain engaged after the pedal is released This may occur if one front wheel tends to turn at a faster speed than the other Should this hap pen the lock may be disengaged by decreasing the drawbar pull by raising or disengaging the implement so that neither wheel tends to slip Operating the hydraulic lift system T
57. ld be repaired before using the unit A Engine starting The 3500 3700 safety start interlock system is designed to protect the operator and others from accidental injury due to unintentional engine starting The engine starting motor will not engage until 1 The operator is seated HST foot pedals are released neutral position PTO lever is in the disengaged OFF position The master brake pedal is depressed or park brake lever is engaged NOTE For safe operation the front mounted equipment should be lowered prior to starting the engine 2 3 4 WARNING Never attempt to start the engine while standing beside the unit Always sit in the seat when starting the engine A IMPORTANT Do not engage the starter continuously for more than 30 seconds doing so may cause starter failure An interval of at least two minutes should be allowed between such cranking periods to protect the starter from overheating and burn out WARNING The safety interlock system must not be disconnected or bypassed Doing so could cause the machine to operate unexpectedly resulting in personal injury A NOTE The operator s seat is equipped with a separate safety switch If for any reason the operator should become unseated when the brake is disengaged or the PTO is engaged the engine will stop 3 8 The following steps are the correct procedures for starting the engine If difficulty is encountered contact the Hustler Deal
58. lter and injection pump as described below in Bleeding the Fuel System Bleeding the fuel system IMPORTANT The 3500 3700 fuel automatically 1 When the fuel tank is empty Fill until the fuel level of the tank is at least half full then wait about one minute for air to dissipate system is designed to bleed 109627_0910 4 7 Figure 4 12 2 When the fuel filter has been replaced After replacing the filter open the fuel shutoff valve Air will dissipate for about one minute NOTE Fuel tank fuel level must be half full or more for auto bleed system to function correctly NOTE The 3500 3700 is an auto bleeding system No manual bleeding procedures needed Engine oil and filter Checking the Engine Oil Level Check engine oil daily Tractor must be setting level and the engine stopped for a period of time when checking oil level Refer to engine manual and maintenance schedule for oil recommendation and capacities Change the engine oil and filter every 100 hours or annually whichever comes first NOTE If tractor is being operated in extremely dirty con ditions then it is recommended oil be changed more fre quently If the engine is operated for extended periods of time at maximum rated power and speed or under other types of continuous severe operating conditions the oil and filter should be changed at 70 hours intervals following the initial oil change Refer to Figure 4 13 for the engine oil filter and dipstick loca
59. m oil under pressure Rear counter balance weights WARNING Improper operation on slopes can cause injury Install rear counter balance weights when the attachment is installed to increase stabil ity Use extreme care when operating on slopes Rear counter balance weights are required to improve stability steering and traction They also reduce tire lift off when attachments are raised operated on slopes or during an abrupt stop Refer to Figure 3 19 for weight attachment Refer to the attachment s owner s manual for the proper weight amount and weight part number Weights AIR Figure 3 19 ROPS Roll Over Protective Structure A Roll Over Protective Structure ROPS and seat belt are standard equipment Do not remove the ROPS and seat belt ROPS when used with seat belt is effective in reducing injuries during unit overturn accidents Overturning the unit without ROPS can result in serious injury or death NOTE Inspect the ROPS after the first 20 hours of opera tion Following the initial inspection check the ROPS after every 500 hours of operation or every six months whichever comes first Figure 3 20 1 Check the torque of the ROPS mounting bolts Tighten the bolts to the correct torque of 72 ft lbs 97 Nm if necessary Figure 3 21 2 Inspect the operator s seat and the mounting parts for the seat belt Tighten the bolts to the correct torque of 72 ft Ibs 50 0 Nm if necessary and replace parts that
60. make certain they are securely in place Refer to engine manual for more information New season preparation Before starting the tractor following post season storage the following servicing is required L 2 sd 10 Clean tractor removing trash and dirt accumulation Check engine oil level and common sump for the hydraulic lift transmission front axle and power steering and the rear axle Install a fully charged battery Check the cooling system for proper level of 50 50 solution of anti freeze and clear water Tighten any bolts that have loosened and make sure all hair pins cotter pins and clevis pins are in place Install all safety shields and review safety precautions listed in this manual Check and inflate tires to 14 18 psi 96 124 KPA Refer to engine manual for more information Start the engine and allow it to idle a few minutes Be sure the engine has proper oil pressure and that each control is functioning properly Drive the unit without load and check to be sure it is operating satisfactorily PRODUCT LITERATURE If you would like to view or print a copy of the Hustler 3500 3700 product manuals go online to www hustlerturf com and click on the MANUALS button 109627_0910 5 1 109627_0910 INDEX Auxiliary valve kit optional 3 10 a ake ee apie a er a were or 3 3 CONO ee ae Dee 64 eee rro 3 4 Cooling system rata ek a ek aa 4 9 Driving the tractor ss serge nun 3 13 Elect
61. n 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 1 e lake river 2 Cliffs retaining walls 3 Roads highways 4 Buildings 5 Rocks These are just a few examples of situations when cau tion must be used when operating on a slope There are 109627_0910 many other possibilities too numerous to mention Just remember to always exercise extreme caution when operating on any slope A The ROPS will minimize chance of injury or death from rollover Seat belt must be fastened while oper ating a machine equipped with ROPS in the raised and secured position Both retaining pins and hair pins must be installed Failure to use seat belt will result in serious injury in the event of a roll over Children Tragic accidents can occur if the operator is not alert to the presence of children Children are often attracted to the machine and the mowing activity Never assume that children will remain where you last saw them A Never leave machine unattended with ignition key in switch especially with children present A Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended Always disengage PTO lever engage park brake stop tractor engine and remove ignition key when leaving operator s seat A Keep children out of the mowing area and under the w
62. n valve 3 Close the drain valve and slowly refill the system with a 50 50 solution of permanent antifreeze and clear water Fill until the coolant level is approximately 1 5 2 0 3 8cm 5cm below the bottom of the filler neck Do not fill beyond this level 4 Clean the radiator cap and cap seal and install the cap Figure 4 19 5 Fill the coolant recovery reservoir bringing the fluid level up until it is between the full and low marks on the reservoir 6 Open the front screen and remove chaff dust or other foreign substances The foreign substances can be dropped onto the ground through the rubber at the lower part Figure 4 20 7 Pull out on the radiator screen and clean it Figure 4 17 8 Run the engine until normal operating temperature is reached then stop the engine Recheck the coolant level when the engine is cold and add additional coolant as necessary IMPORTANT Never run the engine when the cooling system is empty Do not add cold water or cold antifreeze solution if the engine is hot Figure 4 18 Fan belt NOTE Check the condition of the fan belt after every 50 hours of operation Check fan belt tension after every 200 hours of operation Figure 4 21 A belt driven fan located at the front of the engine draws air through the fins of the radiator to lower the temperature of the radiator coolant When 20 25 lbs 9 11 kg of thumb pressure is applied 4 10 Radiator Radiator screen z open position
63. nals to ensure they are clean and tight The alternator cooling fins should also be cleaned periodically When working on or checking the alternator adhere to following precautions or alternator damage may occur e Do not under any circumstances short the field terminal of the alternator to ground e Do not disconnect the alternator output lead or bat tery cables while the alternator is operating e Do not remove the alternator from the tractor with out first disconnecting the negative battery cable When removing the battery disconnect the negative cable first e To install a battery make sure that the positive cable is connected first and that the negative terminal is connected to ground Reverse polarity will destroy the rectifier diodes in the alternator If the battery charge warning light illuminates indicating that the alternator is not charging the battery check the fan belt and the wiring connections If these items are in satisfactory condition and the warning light continues to indicate no charge consult your Hustler Dealer Fuse block The fuse block is located on the left side of the tractor compartment Always replace blown fuses with the size specified for that circuit Figure 4 4 that links into the main wiring harness To replace the fusible link wire Figure 4 5 1 Order Hustler part number 385603370 2 Disconnect the negative battery cable from the battery 3 Unplug the connector linking
64. nd operator s station clean of accumulated trash grass clippings and other debris Always clean up spilled fuel and oil A Always wear adequate eye protection when servicing the hydraulic system cooling system battery or when grinding mower blades and removing accumulated debris A Use extra caution when handling diesel fuel It is flam mable and vapors are explosive A Never attempt to start engine when there is a strong odor of diesel fumes present Locate and correct cause A Never remove fuel cap or refuel tractor while engine is running never refuel near an open flame or near devices which can create a spark Refuel outdoors Never refuel or drain the fuel from the machine indoors 109627_0910 4 1 A 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 A Never attempt to make any adjustments or repairs to the tractor drive system mower deck or any attachment while the tractor engine is running or PTO is engaged Repairs or maintenance requiring engine power should be performed by trained maintenance personnel only A Never work under the machine or attachment unless it is safely supported with jack stands Make certain machine is secure when it is raised and placed on the jack stands The jack stands should not allow the machine to move when the engine is running and the drive wheels are rotating Use only certified j
65. ommended battery size is a BCI group 35 12 volt battery with a minimum cold cranking ability of 490 amps at 18 C 0 F A maintenance free battery is recommended Otherwise follow battery manufacturer s maintenance safety storing and charging specifications Refer to Maintenance Locator Chart found elsewhere in this manual 109627_0910 Hood latch Seat release knob Figure 4 2 WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling A WARNING Charge batteries in an open well venti lated area away from spark and flames Unplug charger before connecting or disconnecting from the battery Wear protective clothing and use insulated tools WARNING Avoid skin and clothing contact with battery acid Always wear eye protection when checking the bat tery acid can cause serious injury to skin and eyes If contact occurs flush area with clean water and call physician immediately Acid will also damage clothing Do not drink the battery electrolyte Do not allow open flame near the battery when charging Hydrogen gas forms inside the battery This gas is both toxic and flammable and may cause an explo sion 1f exposed to flame Always remove the nega tive ground first and replace it last Do not overfill battery Electrolyte may overflow and damage paint wiring or
66. on worthy of special attention All operators and mechanics should read this manual and be instructed about safe operating and maintenance procedures If the operators or mechanics cannot read and understand English it is the owner s responsibility to explain this material to them Improper use or maintenance of this machine by the operator or owner can result in injury To reduce the potential for injury comply with these safety instructions and always pay attention to the safety alert A symbol which means DANGER or WARNING personal safety instructions Failure to comply with the instructions may result in personal injury or death Safety and Instruction Decals 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 decals are designed to give the operator brief information needed in the daily operation and service 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 removed or obliterated Replace these decals ifthey become unreadable e Itis the owner s responsibility to make certain that the operators and mechanics read and understand this man ual and all decals before operating this machine It is al
67. out 2 minutes to allow engine to cool down Operating the hydrostatic transmission and PTO Hydrostatic transmission The hydrostatic transmission is controlled by the HST foot pedals cruise control switch and transmission selector lever Figure 3 5 Figure 3 8 amp Figure 3 9 When operating the transmission selector lever place the HST foot pedals in the neutral position If it is difficult to engage slightly depress the Forward or Reverse foot pedal for smooth engagement Never engage or disengage the transmission selector lever when the unit is in motion With the transmission selector lever in H range Figure 3 10 ground speed can be varied from zero to maximum by depressing the forward or reverse travel pedal In L range speeds are about 60 of H range Maximum speeds in reverse are about a 65 of maximum forward speeds To stop the unit release the pedal gradually except on an emergency When released the pedal returns to the Neutral position automatically stopping the unit Sudden release can result in an abrupt and possibly dangerous stop For prolonged operation at a fixed forward speed use the forward travel pedal to attain the desired speed then move the cruise control switch to the ON position Speed will remain at the set value when the pedal is released To cancel the speed setting or stop push the switch to the OFF position or firmly depress the master brake pedal Automati
68. parties including customers and injury to property Some states do not allow the exclusion or limitation of incidental or conse quential damages so the above limitation or exclusion may not apply to you TIME LIMIT Any action for breach of warranty must be commenced within 30 days after expiration of warranty in a non rental application Any action for breach of warranty must be commenced within 30 days after expiration of warranty 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 Commerical Product following the maintenance procedures described in your owner s manual Such routine main tenance whether performed by a dealer or by you 1s at your expense This machine like any other pow
69. rake pedal Figure 4 33 amp Figure 4 34 or b When the brakes do not work effectively or 4 _ 9 4 lt 7 as y y A WA TRIE me poze Park brake lt a ba AA linkage Qu E Bottom edge of brake pedal Jam nut ec Figure 4 32 c When the brakes are dragging 1 Park tractor on level ground lower the mower deck or Figure 4 33 attachment to the ground turn off tractor and remove key Chock the front drive tires to keep machine from rolling Bottom edge of MN Make sure the park brake is in the OFF position brake pedal 2 Check the free travel of the brake pedal Figure 4 33 amp Figure 4 34 This is determined by the distance the brake pedal travels from its rear most position pushing forward on the pedal until you feel the brakes beginning to engage Measure this distance if 1t is more than 0 75 in 19mm or less than 0 38 in 10mm the brakes must be adjusted 3 The brake linkage rods are located underneath the floor pan Figure 4 35 Loosen the jam nuts located behind Bottom edge of the front clevis on each of the brake linkage rod brake pedal assemblies Back the jam nuts off Figure 4 36 4 Adjust the brake linkage rods accordingly until the proper brake pedal free play is achieved Make sure the right and left brake linkage rod lengths are adjusted equally 5 Re check the pedal free play step 2 Re adjust as necessary 6 Tighten the jam nuts against the clevis base Once the brakes
70. rical System ne aria aa e do ot ee 4 2 A pe ern 4 8 Engine oil and filter e cui irren 4 7 OMS starne ra en as 3 8 Puel syslen seo cau d fae ad et da wee ake we 4 5 General engine maintenance 0 4 13 Inspecting and adjusting the service brake 4 13 Instrument Panel os uae a sen rear 3 3 International Symbols 0 000000 eae 2 5 TUDRICAMOM pu eho eee oe eo eee BES eo ae pes 4 2 Maintenance amp Adjustments Introduction 4 1 Maintenance Schedule ooooooooooo 4 17 Manual version 0 4400 ae aro 1 2 Model and serial number 2 22 momo oo 1 1 New season preparation nennen 5 1 Operating suggestions 2 22m none o 3 13 Operating the hydrostatic transmission and PTO 3 9 A A re er ae ae 3 1 109627 _0910 PAGE PAGE Park brake adjustment zu rara ra aan 4 13 Preparation of engine for storage 2 2 2 22 5 1 PTO control lever adjustment 4 12 Rear counter balance weights 005 3 11 Rear wheel toe adjustment 0 4 14 ROPS Roll Over Protective Structure 3 11 Sale Servicing Practices suicidas ear bv Eee wx 4 1 Safety and instruction decals 22 222 2 1 Safety start interlock system o0o ooo ooo 3 6 Seat adjustment 6 ecos a e bad a 3 6 SEVICE ACCESS ves rue era rt ire re 4 2 Slope Operation airada e aa ia 3 2 Steering wheel adjustment o o oooooooooo 3 6
71. rom diesel fuel can burn you and others and can damage property Never refuel or drain the diesel fuel from the machine indoors Never attempt to start engine when there is a strong odor of diesel fuel fumes present Locate and cor rect cause Figure 4 7 Indicator Bulb Type JIS T5 13 5V 2W Qty 1 Figure 4 9 109627_0910 4 5 Store diesel fuel in an approved container and keep it out of the reach of children Do not fill diesel fuel containers inside a vehicle or on a truck or trailer bed with interior carpets or plas tic truck bed liners Always place diesel fuel con tainers on the ground away from your vehicle before filling When practical remove diesel fuel powered equip ment from the truck or trailer and refuel the equip ment with its wheels on the ground If this is not possible then refuel such equipment on the truck or trailer using a portable container and not a fuel dis penser nozzle If a fuel dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fuel ing 1s complete Do not use a nozzle lock open device Never use diesel fuel or gasoline for cleaning parts Read and observe safety precautions elsewhere in this manual lowed Long term exposure to vapors can cause serious Injury and illness Avoid prolonged breathing of vapors Keep face away from nozzle and fuel tank or diesel fuel container opening Keep diesel fuel a
72. rs or curbs should not be directly approached at high speed in an attempt to jump them as the operator could be thrown from the equipment Approach at a slow speed and angle one drive wheel at the obstruction Continue at an angle until the wheel clears and then pivot the opposite wheel around Figure 3 22 Tractor performance is maximum when the throttle is set at full rpm This gives maximum power to the drive wheels and Driving the tractor deck when needed Use the HST pedals to control ground speed rather than engine rpm Operating suggestions ator should be thoroughly familiar with the proper use and operation of the equipment should read the manual completely and thoroughly and should have attempted slow moving maneuvers to become familiar with the operation of the equipment before attempting normal speed operation An inexperi enced operator should not mow on slopes or on WARNING Prior to operating the tractor the oper 109627_0910 3 13 109627_0910 MAINTENANCE amp ADJUSTMENTS Safe Servicing Practices IMPORTANT This product is capable of amputating hands and feet and throwing objects Always follow all safety instructions to avoid serious injury or death Service A Unless specifically required DO NOT have engine running when servicing or making adjustments to trac tor Park the machine on level ground Place park brake lever in the brake engaged position place the PTO lever in the OFF posi
73. rt between the bat tery terminals and metal tractor parts 109627_0910 WARNING Incorrect battery cable routing could cause damage to the tractor and battery cables This can cause sparks which can cause a battery gas explosion which will result in personal injury A Always disconnect the negative black battery cable s before disconnecting the positive red cable s WARNING Always connect the positive red bat tery cable s before connecting the negative black cable s A Engine warm up In cold weather run the engine at half throttle for a few minutes to allow engine oil and transmission oil to warm up A Stopping the engine A Stopping the engine should be done according to the following procedures 1 Pull the throttle lever fully rearward to the low idle position Release the HST foot pedals Engage the parking brake Place the transmission selector and lift control levers in the N position Turn the key start switch to the OFF position Remove the key WARNING Never leave the machine running unat tended WARNING Always apply the park brake when leaving the seat a S 6 IMPORTANT Failure to turn the key start switch to the OFF position after the engine stops will allow the warning lights to remain on causing the battery to discharge IMPORTANT Do not stop the engine immediately after hard or extended operation Keep the engine running at slow idle for ab
74. s IMPORTANT WARNING Particular attention must be given to tightening the drive wheel lug bolts and blade spin dle bolts Failure to correctly torque these items may result in the loss of a wheel or blade which can cause serious damage or personal injury A Torque values are given below Ft Ibs Nm Wheel lug bolts front 85 95 115 129 Wheel lug bolts rear 65 75 88 1 101 7 Deck blade top bolts o A 88 1 101 7 Deck blade bottom bolts 118 160 01 Lug bolts only It is recommended that these be checked after the first 2 hours of operation initially every 50 hours and following removal for repair or replacement For all other torques refer to the various tractor parts manuals for standard torque chart See the Product Literature section of this manual for ordering information For engine torque values see engine service manual Tires It is important that the tires have an equal amount of air pressure The recommended pressure are Front wheels 4 od 2 lt 044 14 18 psi 96 124 KPa Rear wheels 14 18 psi 96 124 KPa Solid fill tires are not recommended for Hustler turf equipment On any machine with solid filled tires the warranty claim will be denied Lubrication Focie Oils genvraden ey deed See Chart below Transmission Oil ISO VG 46 Hear aaa rro rias SAE multi purpose grease 4 2 Recommended oils Ambient Temperature Recommended oil 10 120
75. seat belt during operation of the machine with ROPS in raised up position Figure 3 20 Inspect the area to be mowed for proper overhead clearance tree limbs guy wires doorways etc Do not contact any overhead object with the ROPS Inspect the seat belt system all seat seat belt parts seat pan and seat pan latch daily prior to mowing for signs of any damage These parts should be replaced if any parts indicate signs of 1 cuts 2 fraying 3 extreme or unusual wear 4 significant discoloration due to UV exposure 5 dirt or stiffness 6 abrasion to the seat belt webbing 7 damage to the buckle latch plate or hardware 8 or any other problem If the seat belt is to be cleaned use soap and water Do not use carbon tetrachloride naphtha etc as these will weaken the webbing For the same reason do not bleach or dye the webbing Replace seat belt if worn or damaged Possible damage to the ROPS If the unit has rolled over or the ROPS has been in some other type of accident such as hitting an overhead object during transport the ROPS must be replaced to retain the best protection Following an accident check the ROPS the operator s seat and the seat belt and seat belt mountings for possible damage Before operating the machine replace all damaged parts IMPORTANT Do not attempt to weld or straighten the ROPS replaced make sure that the proper hardware is used and the recommended torque values are applied to
76. serious physical injury A The Hustler mower is capable of operating horizontally traverse on moderately steep slopes When operating on slopes up to 15 degrees be aware of any conditions that may cause the tractor 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 Do not operate on slopes greater than 15 degrees Refer to Slope Guide page 2 7 when determining the degree of slope to be mowed 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 con dition that caused the problem is resolved before attempting to operate on the slope again Terrain conditions can affect traction resulting in possi ble loss of control of the machine Some of the condi tions to be aware of are 1 Wet terrain 2 Depressions in the ground 1 e holes ruts washouts 3 Mounds of dirt 4 Soil type 1 e sand loose dirt gravel clay 5 Grass type density and height 6 Extremely dry conditions of grass 7 Tire pressure The attachments mounted to the tractor will also affect the way it handles on a slope Be aware that each attachment s characteristics vary Do not tow on slopes The weight of the towed equip ment may cause loss of traction and loss of steering control Another consideration to safe mowing o
77. so the owner s responsibility to make certain that the operators and mechanics are qualified and physically able individuals properly trained in the operation of this equipment All operators and mechanics must become familiar with the safe operation of the equipment operator controls and safety signs Never let children or untrained people operate or service the equipment Local regulations may restrict the age of the operator The owner user can prevent and is responsible for acci dents or injuries occurring to themselves other people or property 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 occurring to other people or their property ASpecific 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 decals that are located on the machine A brief explanation for those requiring one is shown to help the operator understand the meanings of these decals e Read Owner s Manual and decals before attempting to operate this machine u 109627_0910 2 1 Do not smoke while refueling Do not fill tank with engine running or while the engine is hot
78. stick Do not fill beyond the mark on the stick as the transmission will be overfilled 6 Install the dipstick and filler plug 7 Start the engine and check the hydraulic oil filter for leaks 8 Stop the engine and check the hydraulic oil level Replenish if necessary IMPORTANT The transmission front axle and hydraulic system operate from a common oil sump Special attention must be given to keeping oil clean a Figure 4 23 Rear axle case and final reduction gear cases Check the oil level every 100 hours 1 Clean the area around the dipstick filler plug to prevent dirt from entering the rear axle housing With the engine off and the tractor standing level check the oil level using the combined dipstick filler plug The oil is at the correct level when it reads between the two marks on the dipstick Ze 3 Hydraulic oil filter Figure 4 25 NOTE Place the dipstick filler plug into the oil inlet to measure the oil level Do not screw dipstick into housing when checking oil level Figure 4 26 If the level is low add ISO VG46 hydraulic oil through the filler hole Do not fill above the dipstick full mark Reinstall the dipstick filler plug Change the oil every 500 hours or annually 1 With the oil at normal operating temperature drain the oil by removing the rear axle and final reduction gear case drain plugs Reinstall the plugs after the oil has drained Discard the oil Figure 4 27 amp Figure
79. structure When cleaning the battery use soap 109627_0910 4 3 and water Be careful not to get soap and water into the battery Clean the battery terminals with a solu tion of four parts water and one part baking soda when they become corroded WARNING Shorts caused by battery terminals or metal tools touching metal tractor components can cause sparks Sparks can cause a battery gas explo sion which will result in personal injury Prevent the battery terminals from touching any metal tractor parts when removing or installing the battery Do not allow metal tools to short between the bat tery terminals and metal tractor parts WARNING Incorrect battery cable routing could cause damage to the tractor and battery cables This can cause sparks which can cause a battery gas explosion which will result in personal injury Always disconnect the negative black battery cable before disconnecting the positive red cable Always connect the positive red battery cable before connecting the negative black cable A Alternator The 3500 3700 40 amp alternator is belt driven from the engine crankshaft pulley It is important that belt slippage does not occur or the charging system will be affected Figure 4 3 To adjust the belt see the instructions given under the Fan Belt section located elsewhere in this manual Other than belt adjustment the only alternator maintenance required is to periodically inspect the termi
80. switch 1s not operating properly is not opening or closing and if the cause can not be determined replace the seat switch If the problem can not be located contact your Hustler Dealer always function per steps 2 thru 6 If t does not function properly it should be corrected immedi ately Do not operate machine without properly functioning seat safety switch WARNING The safety interlock system should PTO stop system While operating PTO driven equipment the PTO will disengage automatically when the equipment is raised by the lift control lever to the maximum lift height NOTE The PTO control lever remains in the engaged position after activating the PTO stop device the PTO shaft will no longer rotate To re engage the PTO the PTO control lever must be moved to the OFF position then pushed for ward again To inspect the PTO stop system 1 The operator must be on the seat when testing the PTO switch WARNING Perform this test in an area free of any A bystanders 2 Set the park brake 3 Start the engine and allow 1t to warm up to operating temperature gt Figure 3 15 4 With the PTO engaged slowly raise the attachment using the Tool Bar Lift Control Lever The PTO should stop when the attachment is raised to it s maximum lift height Figure 3 16 WARNING For safe operation do not attempt to override or bypass either of these systems If either system fails to function it shou
81. tion Refer to Figure 4 14 for the engine oil fill location Refer to Figure 4 15 for the engine oil drain location Changing the oil 1 Before adding engine oil place the unit on a level surface then remove the dipstick to provide crankcase ventilation 2 Add oil at the oil fill shown Figure 4 14 NOTE When changing the engine oil add the exact amount specified in the engine owner s manual NOTE Use CD grade or better by API classification engine oil 3 Wait about fifteen minutes until the oil gets down to the oil pan Then check the oil level with a dipstick A certain period of time is required before the engine oil completely flows down from the oil filler to the crankcase 4 Check the oil level accounting for the higher oil level due to the oil filter oil capacity f Engine oil filler N E FW BA nt 3 TE PAP a wowsy ELITY Pa gt D X y la Py 5 anne Engine oil fill cap Reg 5 Figure 4 14 Engine air filter Perform engine air filter maintenance per the Service Interval chart shown elsewhere in this manual A specially designed dry filter is standard equipment on these tractors and supplies clean combustion air to the engine Figure 4 16 Change the filter whenever the Air Cleaner Restriction Warning Light comes on Figure 3 1 These units are equipped with a safety filter The filter element slides over the safety filter NOTE For maximum 4 8 Figure 4 15 engine
82. tion lower attachment remove ignition switch key and disconnect negative battery cable before doing any maintenance Wait for all movement to stop before adjusting cleaning or repairing Repairs or maintenance requiring engine power should be performed by trained maintenance personnel only To prevent carbon monoxide poison ing be sure proper ventilation is available when engine must be operated in an enclosed area Read and observe safety warnings in front of manual A Before working on or under the deck make certain engine cannot be accidentally started Shut engine off remove ignition switch key engage park brake and dis connect negative battery cable for maximum safety Repairs or maintenance requiring engine power should be performed by trained maintenance personnel only A Except when changing or checking belt always keep safety shields and covers in place A Use a stick or similar instrument to clean under the mower making sure that no part of the body especially arms and hands are under mower A Keep your machine clean and remove any deposits of trash and clippings which can cause engine fires and cooling system overheating as well as excessive belt wear Clean up oil or fuel spillage Allow machine to cool before storing A Clean flammable material from machine Prevent fires by keeping the top of the deck engine com partment radiator screen front screen exhaust area battery hydraulic lines fuel line fuel tank a
83. too clogged to allow air to pass The mowing conditions will determine the frequency of air filter element changing Air filter Cooling system The 3500 3700 engine must operate at the correct temperature to obtain maximum efficiency and service life This is dependent on the cooling system Always fill the system with a 50 50 solution of permanent antifreeze and clear water Checking the coolant level WARNING Always wear eye protection when ser vicing the cooling system NOTE Visually inspect the system daily prior to operating tractor Be sure the engine is level Open the hood and check the coolant recovery reservoir located next to the battery Check the coolant level only when the system is cold Check the 109627_0910 4 9 coolant level only at the overflow reservoir Figure 4 16 The cooling system is a closed type Never open the radiator cap Doing so may induce air into the cooling system and may cause overheating The coolant level should be between the low and full marks on the reservoir If the coolant recovery reservoir is low refill system with the proper coolant mixture through the recovery reservoir It is not necessary to remove the radiator cap to replenish the coolant Engine cooling is accomplished with a 50 50 mixture of clear water and Ethylene Glycol anti freeze This mixture will provide freeze protection to 32 F 34 C The radiator is equipped with a pressure cap and overflow res
84. unless absolutely neces sary Always look down and behind before and while backing up Do not carry passengers Always stop machine if someone enters the area WARNING Rollover Do not operate on slopes greater than 15 degrees Keep all movement on slopes slow and gradual Never make sudden changes in speed and direction WARNING Ejection e Never push down suddenly on reverse or brake pedal while the machine is in forward motion because machine may tip forward causing loss of control e Slow down before turning e Wear seat belt WARNING Ejection e Never drive the tractor at high speeds without a front end attachment mounted to the tool bars e Never push down suddenly on reverse or brake pedal while the machine is in forward motion because machine may tip forward causing loss of control WARNING Ejection e Never push down suddenly on reverse or brake pedal while the machine is in forward motion because machine may tip forward causing loss of control e Keep all movement on slopes slow and gradual e Do not make sudden changes in speed or direction e Keep attachment as low to the ground as possible mower decks should rest on the gauge wheels e Keep deck gauge wheels on the ground during transport WARNING Loss of traction e While driving on slopes always run in AWD All wheel drive locked position e Keep all movement on slopes slow and gradual e Never make sudden changes in spe
85. w one and return the bulb and A fusible link wire is used to protect the mower s entire socket to the original place electrical system If too much amperage passes through this 6 Re attach the front cover and lower cover wire it will melt down so that it will no longer allow current to pass similar to the way a fuse works The fusible link wire is a red wire that goes from the starter terminal to a connector Replacement bulbs Indicator Bulb Type JIS T6 4 14V 3W Qty 5 4 4 109627_0910 Lower cover me men N I s EE e EEE eiii Figure 4 8 Fuel system DANGER To avoid personal injury or property damage use extreme care in handling diesel fuel Diesel fuel is extremely flammable and the vapors are explosive Light bulb amp socket DANGER Observe usual fuel handling precau tions Do not smoke while refueling or anywhere near fuel Extinguish all cigarettes cigars pipes and other sources of ignition Do not remove fuel cap or fill tank with engine run ning or while engine is hot Clean up any diesel fuel spills immediately Always tighten the fuel cap securely Allow engine to cool before storing machine inside a building Keep fuel 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 other appliances Use extreme care when handling diesel fuel It is extremely flammable and vapors are explosive A fire or explosion f
86. way from eyes and skin If diesel fuel is spilled on clothing change clothing immediately WARNING Diesel fuel is harmful or fatal if swal WARNING Under no circumstances should gas oline alcohol or gasohol be added to diesel fuel These combinations can create an increased fire or explosive hazard WARNING Fuel System Under Pressure Fuel in the injection system is under high pressure and can penetrate the skin Unqualified persons should not remove or attempt to adjust a pump injector nozzle or any part of the fuel injection system Do not use your hand to check for leaks Use a piece of cardboard or paper to search for leaks If any fluid is injected into the skin obtain medical attention immediately or gangrene may result Failure to follow these instructions can result in seri ous injury Check the fuel line periodically as it is subject to wear and aging fuel may leak onto the engine which could cause a fire IMPORTANT Do not fill tank to capacity Allow room for expansion IMPORTANT If the original fuel tank cap is lost always replace it with a Hustler approved cap A will fit cap may not be safe Diesel fuel e Use clean quality No 1 D or No 2 D fuel 4 6 e Use No 1 D fuel if the ambient temperature is expected to be lower than 39 degrees F 4 degrees C or if the tractor is to be used at an altitude exceeding 5000 ft 1524 m Use diesel fuel with a pour point of at least 10 F

Hustler Turf 3500 User's Manual

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