HUSTLER 3500 manual

109627_0910 Hustler 3500/3700 Owner ’ s Manual ••••• P .O. Box 7000 ••• Hesston, Kansas • 67062-2097[...]

109627_0910 NO T I CE OF RE Q UI R E ME NT OF SP AR K A R RE ST ER MUF F L ER T his e q ui pme nt may c re ate sp ar ks that c a n s t art f ire s aro und d ry ve g e t atio n. C alif o rnia P ub l ic R es o urces C ode S ec - t i on 444 2. 6 prov i de s t h at i t is un law f u l t o u se or op era t e a n in t er n al combu st i on en gin e on an[...]

109627_0910 1-1 GENERAL INFORMA TION This manual applies to the following Hustler equipment lines: Hustler 3500 Hustler 3700 T o the new owner The purpose of this manu al is to assist owners and operators in maintaining and operating the 35 00/3700 tractor . Please read it carefully; info rmation and instruction s furnished can help you achieve yea[...]

1-2 109627_0910[...]

109627_0910 1-3 3500/3700 T RACTORS HUSTLER TURF COMMERCIAL PRODUCT TWO YEAR (1500 HOURS) LIMITED W ARRANTY WHA T IS COVERED BY THIS W ARRANTY Hustler Turf Equipment, makes the follo wing warranty to the original pur- chaser only: a. Hustler Turf Equipment T ractors an d Power Units are warranted for two (2) years or 1500 hours whichever comes firs[...]

1-4 109627_0910 W ARRANTY REGISTRA TION 1. Dealers must register the unit on-line at www .Hustlerdealer .com or by fill- ing out the W arranty regi stration form, provided in the owner ’ s packet. If using the W arranty r egistration form it MUST be completed and signed by the authorized de aler and original purchaser . 2. For validation, the com[...]

109627_0910 2-1 SAFETY PRECAUTIONS This safety alert symbol is used to call attention to a message intended to provide a reasonable degr ee of PERSONAL SAFETY for opera tors and other persons during the normal operati on and servicing of this equipment. DANGER: denotes immediate hazards which WILL result in sever e personal injury or death. W ARNIN[...]

2-2 109627_0910 W ARNING: Hot surface! • Keep a safe distance from the machine. • Do not open while engine is hot. Wait until the system has fully cooled to ser- vice. • Always keep shields or covers in place W ARNING: Hot fluid under pre ssure • Keep hands, feet and clothing clear of this area. • Always keep shields or covers in place wh[...]

109627_0910 2-3 W ARNING: Read Owner ’ s Manual and decals before attempting to operate or service this machine. • Wear ear protection, eye protection and safety shoes when operat- ing this equipment. 601623 • Keep hands, feet and clothing clear of this area. • Keep a safe distance from the machine. • Keep shields or covers in place while[...]

2-4 109627_0910 601415 601415 W ARN ING: 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 . W ARN ING: Back over! • Always be aware of what is behind the ma[...]

109627_0910 2-5 INTERNA TIONAL SYMBOLS As a guide to the operation of your tract or , vario us international symbols have been used on i nstruments and controls. These symbols are depicted and described below . Hours Recorded Engine W ater T emperature Increase Decrease Fuel Level High Range Low Range Auto A WD Full Time A WD Engine Oil Pressure Ai[...]

2-6 109627_0910[...]

109627_0910 2-7 SLOPE GUIDE . 1. Hold this sheet of paper in front of you. Make sure that Line A is hori zontal. 2. Align Line B with a vertical su rface such as pole, tree or building. 3. Fold the paper along the slope guide li nes (C, D or E). 4. Align the closest slope guide line with the ground slope. This will give you a close estimation of th[...]

2-8 109627_0910[...]

109627_0910 3-1 OPERA TION Safe 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 V Evaluate the terrain to de termine what accessories and attachments are needed to properly and safely perform the job. Only use accessories[...]

3-2 109627_0910 pedals in either direction could result in a reaction of the tractor that can cause serious injury . V When desconnection on attach ment that uses the trac- tor PTO output shaft to power the attachment, the pow- ered shaft of device must also be d isconnected from the tractor PTO output shaft. Never leave an unsupported PTO device a[...]

109627_0910 3-3 many other possibilities too numerous to mention. Just remember to always exercise extreme caution when operating on any slope. V The ROPS will minimize chan ce 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 hai[...]

3-4 109627_0910 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 contr ol (Figur e 3-4 — A cable is linked to engine throttle for con trolling engine speed. Mo ve lever forward to increa[...]

109627_0910 3-5 variable from zero to full rated speed in each range. The ground speed is controlled by these pedals. Depress the forward travel pedal to pr ogressively increase forward speed. For reverse travel, depress the reverse travel pedal. NOTE: These pedals must be in neutral (not depressed) to start the engine. F . Cruise control switch (F[...]

3-6 109627_0910 Range Forward Reverse Low . . . . 0 - 6 mph (0 - 9.7kph) . . . . 0 - 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 A WD mode. When the lever is in this position, the rear axle drive is activated for improved traction in ad[...]

109627_0910 3-7 T o inspect the safety st art interlock system: 1. Park the unit on a flat, level surface. 2. The operator must be on th e 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. W ith the PT O disengaged, slowly raise off of the seat. The engine should co[...]

3-8 109627_0910 WA R N I N G : For safe operation, do not attempt to override or bypass either of these systems. If either system fails to function, it should be repaired before using the unit. Engine st arting The 3500/3700 safety start interlock system is designed to protect the operator and others from accidental injury due to unintentional engi[...]

109627_0910 3-9 vehicles must not touch. 2. Shield eyes. 3. Connect one end of the jumper cable to the battery positive (+) terminal and the other to the auxiliary battery positive (+) terminal. Connect on e end of the other cable first to the au xiliary battery (-) negati ve terminal, and the other end to the Hustler tractor frame. Follow the star[...]

3-10 109627_0910 reverse are about a 65% of maximum fo rward speeds. T o stop the unit, release the pedal gradually (except on an emergency). When released, the pedal returns to the Neutral position autom atically , stop ping the unit. Sudden release can result in an abrupt, and possibly dangerous stop. For prolonged operation at a fixed forward sp[...]

109627_0910 3-11 the lift control lever must remain in neut ral. Figure 3-17 and Figure 3-18 This kit includes control valves, hoses and quick connect couplers for supplying hydraulics power to o ptional attachments. When not in use, the coupler dust covers must be in place to prevent contamin ation. Always replace them immediately if damaged o r l[...]

3-12 109627_0910 when the ROPS is in the lowered position. Use the ROPS in the “folde d” position on ly when it is absolutely necessary . W ARNING: Do not operate the mower with the ROPS folded (lowered position) as a standard oper - ating mode. A folded ROPS do es not provide roll- over protection. W ARNING: Always wear your seat belt unless t[...]

109627_0910 3-13 age, overturn or alteration. If any of these conditi ons occur , this structure must be r eplaced. W ARNING: Do not remove or alter any of the ROPS parts. Failure to adhere to these instructions could resul t in sever e injury or death. Do not attempt to weld or straighten ROPS. Failure t o adhere to these instructions coul d resul[...]

3-14 109627_0910[...]

109627_0910 4-1 MAINTENANCE & ADJUSTMENTS Safe Servicing Practices IMPORT A NT : This product is capabl e of amputating hands and feet and thro wing objects. Always follow all safety instructions to avoid serious injury or death. Service V Unless specifically required, DO NOT have engine running when servicin g or making adjustments to trac- to[...]

4-2 109627_0910 particle are abrasive to clos e-tolerance engi ne and hydraulic assemblies. Daily inspect mower for grass clippings and wire and string tangles. The underside of the mower deck will coll ect a build-up of grass clippi ngs a nd dirt, especially when grass is wet or has high moisture content. This build-up will harden, restricting bla[...]

109627_0910 4-3 W ARNING: Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the Stat e of California to cause cancer and reproductive harm . W ash hand s after handling. W ARNING: Charge batteries in an open well v enti- lated area, away from sp ark and flames. Unplug charger before connecting or [...]

4-4 109627_0910 Fusible link A fusible link wire is used to p rotect the mower ’ s entire electrical system. If too much amperage passes through t his wire it will melt dow n so that it will no longer allo w 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 th[...]

109627_0910 4-5 Indicator Bulb T ype . . . . . . . JI S T5 13.5V 2W (Qty 1) Fuel system DANGER: T o avo id personal injury or property damage, use extreme care in handling diesel fuel. Diesel fuel is extremely flammable and the vapors are explosive. DANGER: Observe usual fuel handling precau- tions: Do not smoke while refueling or anywhere near fue[...]

4-6 109627_0910 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. Alwa ys place diesel fuel con- tainers on the ground aw ay from your vehicle before filling. When practical, remove[...]

109627_0910 4-7 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” p osition.) Remove the fuel sediment bowl. Figure 4-12 2. Open the fuel shutoff valve un[...]

4-8 109627_0910 certain period of time is required before the engine oil completely flows dow n from th e oil fill er to the crankcase. 4. Check the oil level, accounting for the higher oil level due to the oil filter oil capacity . Engine air filter Perform engine air filter m aintenance per the Service Interval chart shown elsewhere in this manua[...]

109627_0910 4-9 It is important to note that wh enever an air filter element is cleaned by any method, the person or company performing the cleaning assumes responsibility for the inte grity 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 i[...]

4-10 109627_0910 W ARNIN G: Allow the engin e and radiator to cool before draining and flushing th e system. T o 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 i[...]

109627_0910 4-11 T ransmission, front axle and hydraulic system W ARNING: Hydraulic fluid escaping u nder pressure may have sufficient force to penetrate skin and cause serious injury . Foreign fluid injected into t he skin must be surgically removed within a few hours by a doctor, familiar with this form of injury , or gangrene may result. Before [...]

4-12 109627_0910 NOTE: Place the dipstick/filler plug into the oil inlet to measure the oil level. Do not screw d ipstick into housing when checking oil level. Figure 4-26 2. If the level is low , add ISO VG46 hydraulic oil through the filler hole. Do not fill above the dipstick full mark. 3. Reinstall the dipstick/filler plug. Change the oil every[...]

109627_0910 4-13 resistance (50% into the cont rol lever stroke). A reading of 26.4-28.6 lbs. (12-13 kg) is correct at th e full engagement point (the final 50% of control leve r 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 ad[...]

4-14 109627_0910 c. When the brakes are dragging. 1. Park tractor on level ground, lower the mower deck or attachment to the ground, turn of f tractor and remove key . Chock the front drive ti res to keep machine from rolling. Make sure the park brake is in the OFF position. 2. Check the free travel of the brake pedal (Figure 4-33 & Figure 4-34[...]

109627_0910 4-15 4. The 'F' dimension should be between 0.075" and 0.175" (1.9 mm - 4.4 mm) less than 'R' dimension. 5. If the toe-i n must be r e-adjuste d to meet th e dimensional requirements, loosen the jam nuts on either end of the tie rod. Figure 4-38 6. Once the jam nuts are both lo ose and backed off, rotate th[...]

4-16 109627_0910[...]

109627_0910 4-17 3500/3700 Maintenance Schedule Refer to Figures 4-39 & 4-40 SERVICE A T INTERV ALS INDICA TED Daily First 50 hours Every 50 hours Every 100 Hours Every 200 hours Every 500 hours Seasonal Engine oil level X Radiator coolant level X Radiator screen X V isually inspect unit for loose hardware and/or damaged parts (A) X Hydraulic f[...]

4-18 109627_0910 MAINTENANCE LOCATOR CHAR T 2 3 1 5 4 6 6 7 7 9 10 8 18 1. Engine Oil Fill 2. Engine Air Cleaner 3. Radiator Cap 4. HST Filter 5. Hydraulic Oil Filter 6. Engine Oil Filter & Dipstick 7. Wheels & T ires 8. Fuel Filter 9. Battery 10. Fan Belt 11 . Transmission Oil Fill 12. Lift Arm 13. Lift Cylinder 14. Brake Pedal Shaft 15. P[...]

109627_0910 4-19 17 MAINTENANCE LOCATOR CHART 11 1. Engine Oil Fill 2. Engine Air Cleaner 3. Radiator Cap 4. HST Filter 5. Hydraulic Oil Fi lter 6. Engine Oil Filter & Dipstick 7. Wheels & Tires 8. Fuel Filter 9. Battery 10. Fan Belt 11 . Trans mission Oil Fill 12. Lift Arm 13. Lift Cylinder 14. Brake Pedal Shaft 15. Power S teering Cylinde[...]

4-20 109627_0910[...]

109627_0910 5-1 STORAGE When storing the unit at th e end of the operating season, the following steps should be taken to ensure read iness for the next season. 1. Remove all grass, dirt, and trash from tractor and mower . Clean tractor and mower and touch up all scrapes with Hustler spray paint. IMPORT ANT : W ash the machine with a mild detergent[...]

5-2 109627_0910[...]

INDEX PAGE PAGE 109627_0910 6-1 Auxiliary valve kit (opti onal) . . . . . . . . . . . . . . . . . . 3-10 Children . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Drivin[...]

6-2 109627_0910[...]