Hustler® 3700
60”/72” Front Mount Deck
Operator’s Manual
•••••
P.O. Box 7000
•••
Hesston, Kansas
•
67062-2097
109631CE_0612
Manual version
Original Instructions in English
Hustler® Turf Equipment Authorized Representative
Hastrac A/S
Birkegaardsvej 30
8361 Hasselager
Denmark
Mr. H. K. Hansen
Phone:+4586283366
Fax: +4586283889
Excel Industries, Inc.
Manufacturer of Hustler® Turf Equipment
200 South Ridge Road
Hesston, Kansas 67062
Telephone (620) 327-4911
FAX (620) 327-2828
109631CE_0612
GENERAL INFORMATION
This manual applies to the following Hustler® equipment lines:
Shown below is an example of a serial identification plate and how to
interpret it.
Hustler® Front Mount, Side Discharge Deck 60”
Hustler® Front Mount, Side Discharge Deck 72”
Hustler® Front Mount, Rear Discharge Deck 72”
To the new owner
The purpose of this manual is to assist owners and operators in maintaining and operating the Hustler® Front Mount Decks. Please read it carefully;
information and instructions furnished can help you achieve years of dependable performance.
It is the owner’s responsibility to make certain that the operators and
mechanics read and understand this manual 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.
IMPORTANT: For more detailed maintenance and adjustment information refer to the proper parts manual for your machine.
The owner/user can prevent and is responsible for accidents or injuries
occurring to themselves, other people or property.
Year
2003
Serial
Number
Weight of machine
without operator
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 model number.
3. Correct serial number.
All warranty repair and service must be handled through an authorized
Hustler® dealer. Arrangements should be made through your local service
center.
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 the power unit facing forward, unless otherwise
stated.
Photographs and illustrations used were current at the time of printing,
but subsequent production changes may cause your machine to vary slightly
in detail. Hustler® Turf Equipment reserves the right to redesign and change
the machine as deemed necessary, without notification. If a change has been
made to your machine which is not reflected in this operator’s manual, or the
parts manual, see your Hustler® dealer for current information and parts.
4.
Warranty registration
Your Hustler® Dealer must register this attachment on-line within ten
(10) days following date of purchase to validate your warranty protection. As
the new equipment owner, you should confirm that your Hustler® Dealer has
registered your attachment with Hustler® Turf Equipment.
Be sure to register the mower plus each attachment that displays a model
and serial identification number plate with Hustler® Turf Equipment.
IMPORTANT: Any unauthorized modification, alteration, or use of nonapproved attachments voids the warranty and releases Hustler® Turf Equipment from any liability arising from subsequent use of this equipment. Do not
use or operate any attachment which is not approved by Hustler® Turf Equipment.
Model and serial number
Model and serial numbers are found on the serial identification plate,
located on the left rear top of the deck.
These numbers are required on the Warranty Registration form. They will
also assure you of the correct service parts when replacement becomes necessary.
109631CE_0612
Month
November
1-1
1-2
109631CE_0612
SAFETY PRECAUTIONS
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.
It is the owner’s responsibility to make certain that the operators and
mechanics read and understand this manual 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.
IMPORTANT: For more detailed maintenance and adjustment information refer to the proper parts manual for your machine.
The owner/user can prevent and is responsible for accidents 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.
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. Obey
all safety messages that follow this symbol to avoid possible injury or death.
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 information worthy of special attention.
All operators and mechanics should read this manual, and be instructed
about safe operating and maintenance procedures.
Safety and Instruction Decals
 Specific safety warning decals are located on the equipment near the immediate areas of potential hazards. These decals should not be removed or obliterated. Replace them if they become 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.
WARNING:
Read Owner’s Manual before attempting
to operate or service this machine.
WARNING: Rotating driveshaft!
Part Number
601625
Part Number
601623
601623
• Keep hands, feet and clothing clear of
this area.
• Keep a safe distance from the
machine.
• Always keep shields or covers in
place.
Wear ear protection, eye protection and safety shoes when
operating this equipment.
109631CE_0612
2-1
Part Number 601624
Used on 60”/72” Side
Discharge Decks only
601624
WARNING: Thrown
objects
• Never operate the mower deck with side
deflector damaged, altered, removed or
in raised position, except when the
entire grass catcher attachment or
mulching system is being used.
WARNING:
Thrown objects
DANGER
Rotating blades, pulleys & belts
Part Number 602054
Used on 72” Rear Discharge Deck only
Part Number
601603
• Always maintain a
safe distance from
people and pets
when mowing.
• Always stop
machine if someone enters the
area.
602054
WARNING: Thrown
objects
• Never operate the mower deck with
rear deflectors damaged, altered,
removed or in raised position.
Part Number 602207
• Read Owner’s Manual.
• Engage park brake
• Remove ignition switch key
• Keep hands, feet and clothing away.
• Keep shields or covers in place while
machine is in operation.
Part Number
601603
WARNING: Crushing hazard!
• Unpin deck and lift carefully.
• Insert locking pin when deck
is in full upright position.
2-2
109631CE_0612
OPERATION
 Always be alert for hazards such as rocks, metal objects and other
debris which may be thrown or entangled by mower blades. Watch
out for holes or deep depressions.
 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.
 Always keep clear of the mower blades and attachments during their
operation.
 Always maintain a safe distance from people and pets when mowing.
Always stop machine if someone enters the area.
 Never attempt high speed maneuvering in crowded or congested areas
 Turn off blades when not mowing.
 Never raise the mower deck with the blades engaged to avoid small
obstacles, drive over curbs and so forth. Disengage the pto clutch
before raising the deck.
 Stop the engine before removing the grass catcher or unclogging the
discharge chute. Never clear the discharge 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!
 Follow the manufacturer’s recommendation for wheel weights or rear
counter-balance weights.
 Never attempt to back machine onto transport trailer with mower deck
or attachment in the raised position.
 Clean flammable material from machine. Prevent fires by keeping the
mower deck clean of accumulated trash, grass clippings, and other
debris.
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.
IMPORTANT: Any maintenance operation that requires the removal of
safety covers must be performed by a trained service technician.
Operation
 Always keep safety shields and covers in place.
 Follow daily and weekly checklists, making sure hoses are tightly
secured and bolts are tightened.
 Always inspect machine for damage after striking a foreign object. If
damage is found, consult your Hustler® dealer. 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.
 Never turn the PTO switch on unless the PTO shaft is securely connected to a power driven attachment.
 Never operate a poorly maintained machine.
 Always operate machine in daylight or with adequate working lights.
 Never put hands or feet under any part of the machine while it is running.
 Never direct discharged material toward anyone. Avoid discharging
material against a wall or obstruction. Material may ricochet back
toward the operator. Always disengage the blades and wait for them
to stop before crossing gravel drives, walks or roads.











Deck top cover


1.
2.
3.
4.
Gauge wheel assemblies
Discharge chute
Gearbox
Front height adjustment
5.
6.
7.
8.
9.
Figure 3-1
109631CE_0612


3-1
Deck carrier arm
PTO shaft
Rear height adjustment
Anti-scalp wheels
Locking pin
Deck top cover












Deck top cover
Deck top cover

1.
2.
3.
4.


Gauge wheel assemblies
Locking pin
Gearbox
Front height adjustment
5.
6.
7.
8.
Deck carrier arm
PTO shaft
Rear height adjustment
Anti-scalp wheels
Figure 3-2
Attaching mower deck to power unit
To attach the Front Mount Mower Deck to a power unit, follow one of
these two recommended procedures.
IMPORTANT: Any maintenance operation that requires the removal of
safety covers must be performed by a trained service technician.
METHOD 1 (preferred)Tool-less attachment method for 60" and 72" SD decks WITH optional
rear antiscalp wheel kits and 72" RD deck:
1. For Side Discharge deck installation to a power unit, the optional rear
antiscalp wheel kit (P/N 111056) must be properly installed on the deck
and pinned into the operating (down) position. Refer to the installation
instructions that come with the anti-scalp wheel kits for complete information. Figure 3-3
The 72" rear discharge deck comes standard with rear anti-scalp wheels,
and is ready for this mounting method from the factory. Figure 3-2
2. The deck needs to be located on a level, hard surface (concrete) so it can
be rolled on the ground freely by hand. The deck will roll on the rear
anti-scalp wheels or rear rollers and the front caster wheels - no blocks or
obstructions should be located under the deck.
3. On the deck, locate the rear height adjusting chain and pin assembly on
both sides. Pull the pin out and into the locked out position so the pinned
bracket is no longer attached to the deck and the carrier arms are free to
pivot up at the front pivot points. Figure 3-4
4. Pull the power unit up close to the deck. Park the power unit in the position in which the deck should be assembled to the power unit, with
approximately 1.22m between the deck carrier arms and the front of the
power unit. Fully engage the park brake, adjust the weight transfer control knob to the minimum setting (turn the knob counter-clockwise until it
stops), push the tool bar lift control lever forward into the detent position,
Pin in the
down position
Rear anti-scalp
wheel kit
Figure 3-3
bring the throttle to low idle, shut off the engine and remove the keys.
Figure 3-5
WARNING: Stop engine. Make sure PTO switch is off.
Engage park brake and remove ignition key before getting off
machine.
5. The tool bar receivers need to be lowered manually when the power unit
is turned off. Using two bars approximately .91m long that can fit into
the tool bar receivers, insert them into the tool bar receivers and push
3-2
109631CE_0612
6. Insert the woodruff key into the keyway on the gearbox’s input shaft.
Align the woodruff key with keyway on universal joint of PTO shaft.
Coat the gearbox input shaft with anti-seize compound. Slide universal
joint onto gearbox shaft. Secure PTO shaft to gearbox shaft with 5/16”
cap screw, flat washer, and 5/16” nut provided. Figure 3-7 and Figure 3-8
72” deck shown
60” deck shown
Roll pin
in slot
Roll pin
in slot
Woodruff key
Locking pin
Input shaft
Locking pin
Figure 3-4
Figure 3-7
Weight control
transfer
5/16” cap screw
Flat washer
Tool Bar Lift
Control Lever
Universal joint
Figure 3-8
7. Clear away any obstructions between the deck and the power unit.
Remove the tool bar hair pins and safety pins. Locate these to the side of
the power unit. Figure 3-9
Figure 3-5
them down to lower the receivers. The receivers will need to be pushed
down so they are pointed 5 to 10 degrees down from horizontal.
NOTE: It is necessary to push down on both sides of the tool bar equally
at the same time. Figure 3-6
Locking pin
Carrier arm
WARNING: Before manipulating the tool bar make sure the
power unit’s engine has been shutoff, the park brake has been
engaged and the ignition key has been removed.
Tool bar
Hair pin
Figure 3-9
8. Pushing from the front of the deck rearward toward the power unit, roll
the deck into position so the carrier arms are lined up and can be inserted
into the receivers. Starting from one side, lift the carrier arm up into position and slide the deck rearward to get the carrier arm started into the tool
bar receiver (the deck will be at a slight angle when carrier arm is inserted
so the other side carrier arm can still be inserted). Push the deck rearward
Push down on both
sides of the tool bar
Figure 3-6
109631CE_0612
3-3
on this side just far enough so the carrier arm will stay in the receiver.
Figure 3-11
Brake pedal
Driveshaft
lock collar
Reverse
travel
pedal
Carrier arm
Forward
travel
pedal
PTO shaft
HST foot pedals
Tool bar
receiver
Figure 3-12
U-joint guard
Gearbox
Figure 3-10
Carrier arm
Tool bar
receiver
Figure 3-13
15. Re-attach the rear deck lift chain bracket assemblies at the rear of the
deck on either side. Check to make sure the pins are correctly and completely inserted into the brackets and the rear of the deck is securely supported by the chains.
16. The deck is now properly assembled to the power unit and ready to be
leveled. See the deck leveling procedure in this manual.
Figure 3-11
9. Proceed to the other side, carefully lift the carrier arm and work the deck
rearward to slide the carrier arm into the receiver. Figure 3-11
10. With both carrier arms started into the receivers, push from the front of
the deck, working the deck rearward. The deck may need to be rocked
from side to side while pushing rearward to get the carrier arms pushed
far enough back into the receivers.
11. Once the deck is pushed back into position. Check to make sure the
receiver and carrier arm pin holes are lined up. Use a tapered punch if
necessary to bring the holes in alignment, insert the receiver locking pins
thru the receiver and carrier arms and install the hair pins into the bottom
holes of the receiver locking pins. Figure 3-9
12. Attach the PTO drive shaft to the transmission output PTO shaft. The
collar on the end of the PTO drive shaft yoke is spring loaded, and must
be held back as the yoke is lined up with the splines of the transmission
output PTO shaft and pushed on to the male shaft. Once the yoke has
been inserted onto the shaft, the spring loaded collar should snap into
place, which locks the yoke of the drive shaft to the male output shaft on
the transmission. Pull back on the drive shaft to check that the yoke is
locked and the drive shaft cannot slip off. Figure 3-12
13. Check to make sure the front drive shaft u-joint guard is correctly
installed and covering the u-joint.
NOTE: Never attach the PTO drive shaft to the transmission output PTO
shaft without it being attached to the mower deck gearbox. Figure 3-13
14. With operator in the seat, start the power unit and lift the deck so the front
caster tires are several centimeters off the ground. Shut the engine off,
check to make sure the PTO drive is off, parking brake is fully engaged,
and remove the keys.
METHOD 2 Deck attachment using two persons and a hoist. By this method, an
overhead hoist will be utilized to lift the deck. Two persons are required to
safely assemble the deck to the power unit.
WARNING: Make sure the hoist used is capable of lifting
453.6 kg and the chains or lifting straps are also rated accordingly! Keep all body parts out from under the deck when it is
supported by the hoist
1. Pull the power unit up close to the deck on a level surface. Park the
power unit in the position in which the deck should be assembled to the
power unit, with approximately 1.22m between the deck carrier arms and
the front of the power unit. Fully engage the park brake, adjust the
weight transfer control knob to the minimum setting (turn the knob counter-clockwise until it stops), push the hydraulic lift/lower lever forward
into the detent position, bring the throttle to low idle, shut off the engine
and remove the keys.
WARNING: Stop engine. Make sure PTO switch is off.
Engage park brake and remove ignition key before getting off
machine.
2. The tool bar receivers need to be lowered manually when the power unit
is turned off. Using two bars approximately .91m long that can fit into
the tool bar receivers, insert them into the tool bar receivers and push
them down to lower the receivers.
3-4
109631CE_0612
NOTE: It is necessary to push down on both sides of the tool bar equally
at the same time. Figure 3-6
Overhead
hoist
WARNING: Before manipulating the tool bar make sure the
power unit’s engine has been shutoff, the park brake has been
engaged and the ignition key has been removed.
3. Insert the woodruff key into the keyway on the gearbox’s input shaft.
Align the woodruff key with keyway on universal joint of PTO shaft.
Coat the gearbox input shaft with anti-seize compound. Slide universal
joint onto gearbox shaft. Secure PTO shaft to gearbox shaft with 5/16”
cap screw, flat washer, and 5/16” nut provided. Figure 3-7 and Figure 3-8
4. Remove the two top deck covers from the deck. Figure 3-1 and Figure 32
5. Attach lifting chains at the two deck lifting points. Then, using an overhead hoist, lift the deck so that the two deck carrier arms are at approximately the same height as the power unit’s tool bar. Figure 3-14 and
Figure 3-15
Lifting chains
Figure 3-15
Lift point
the transmission. Pull back on the drive shaft to check that the yoke is
locked and the drive shaft cannot slip off.
10. Check to make sure the front drive shaft u-joint guard is correctly
installed and covering the u-joint.
NOTE: Never attach the PTO drive shaft to the transmission output PTO
shaft without it being attached to the mower deck gearbox.
11. Re-attach the deck covers removed in step 4.
IMPORTANT: Never operate unit without deck covers in place.
12. The deck is now properly assembled to the power unit and ready to be
leveled. See the deck leveling procedure in this manual.
Detaching mower deck from the power unit
Use the following method to detach the deck from the power unit.
1. Park the power unit on a level, hard surface (concrete) so that the deck
can be rolled on the ground freely by hand after it is disconnected from
the power unit. The deck will roll on the rear anti-scalp wheels or rear
roller and the front caster wheels - no blocks or obstructions should be
located under the deck.
2. Fully engage the park brake, raise the deck by pulling the tool bar lift
control lever rearward, bring the throttle to low idle, shut off the engine,
and remove the key. Figure 3-5
NOTE: The deck does not need to be raised to its highest position. It
only needs to be high enough to allow the rear deck lifting chain and pin
assemblies to be released easily.
3. On the deck, locate the rear deck lifting chain and pin assembly on both
sides. Pull the pin out and into the locked out position so the pinned
bracket is no longer attached to the deck, and the deck is free to pivot
about the front pivot points. Figure 3-4
4. With the operator on the seat, push the tool bar lift control lever forward
until the deck is fully down. Do not push the tool bar lift control lever
forward rapidly as this will allow the deck to drop rapidly. Push the control lever forward slowly to release the hydraulic pressure gradually. Figure 3-5
Rear discharge deck shown.
Side discharge deck lift points
are in the same locations.
Lift point
Figure 3-14
6.
7.
8.
9.
IMPORTANT: Check to make sure the rear deck locking pins are correctly and completely inserted into the brackets and the rear of the deck is
securely supported by the chains.
With two people controlling the deck, one on each side of the deck, slide
the deck towards the power unit’s tool bar and manipulate it until the
mower deck carrier arms can be inserted into the power unit’s tool bar.
Figure 3-15 and Figure 3-9
Insert power unit’s locking pins through holes in tool bar and carrier arms
and secure the locking pins in place using hair pins provided. Figure 3-9
Using hoist, lower the deck so the front casters of the deck are touching
the ground and the chains or straps are loose. Remove lifting chains or
straps from deck and move hoist to a suitable location.
Attach the PTO drive shaft to the transmission output PTO shaft. The
collar on the end of the PTO drive shaft yoke is spring loaded, and must
be held back as the yoke is lined up with the splines of the transmission
output PTO shaft and pushed on to the male shaft. Once the yoke has
been inserted onto the shaft, the spring loaded collar should snap into
place, which locks the yoke of the drive shaft to the male output shaft on
109631CE_0612
WARNING: Keep feet and legs away from under the deck
until the deck is fully lowered.
5. Detach the PTO drive shaft from the transmission output PTO shaft. The
collar on the end of the PTO drive shaft yoke is spring loaded, and must
be held back to release the PTO drive shaft from the splines of the transmission output PTO shaft. Pull back on the drive shaft to release it from
the transmission output PTO shaft. Figure 3-12
6. Remove the tool bar locking pins and safety pins. Locate these to the
side of the power unit. Figure 3-9
7. Go to the front of the deck and pull on the deck, working the deck forward. The deck may need to be rocked from side to side while pulling to
get the carrier arms pulled far enough away from the receivers.
8. Re-insert power unit’s locking pins through holes in tool bar arms and
secure the locking pins in place using hair pins provided.
9. Once the deck is removed, the power unit can be driven away from the
deck.
3-5
5. Measure from the level ground surface to the top of the deck. Figure 317
The top of the deck is 12.9cm higher than the actual cutting height. Take
the measurements at each of the areas shown (Figure 3-17) and subtract
12.9cm from them. That will give the actual cutting height for that location.
Example: 21.8cm (top of deck height)
-12.9cm (top of deck to blade distance)
8.89cm (cutting height)
10. Re-attach the rear deck lift chain bracket assemblies at the rear of the
deck on either side. Check to make sure the pins are correctly and completely inserted into the brackets. Figure 3-16
Rear height adjusting chain
Locking pins
NOTE: The rear of the deck should be 5.08mm – 12.7mm higher than
the front of the deck.
6. If the measured cutting height is different than the 8.89cm desired height
than the front of the deck will have to be adjusted at the two front gauge
wheel forks. The rear of the deck will have to be adjusted by moving the
pins up or down in the adjusting holes. Refer to Cutting height adjustment section for more detailed information.
NOTE: Minor leveling can be accomplished by moving the 1/2” cap
screw on either front gauge arm mount forward in the slot, to raise cutting height, or backwards to lower cutting height. Figure 3-18
7. If one side of the deck is more than 6.35mm higher than the other side,
lower the high side of the deck by transferring the 6.35mm gauge wheel
spacer from under the gauge wheel fork bearing to the top side. (Figure
3-19 and Figure 3-22)
Lower the rear of the deck 6.35mm at the rear height adjustment pin one
hole. Figure 3-20 and Figure 3-24
8. The mower deck should now be level.
Figure 3-16
Rear counter-balance weights
Before operating this unit, it is recommended that rear counter-balance
weights be attached to the rear of the power unit. The following is the recommended weight that need to be added:
Power unit
Power unit
without
with
cab
cab
928721 60” SD deck . . . . . . . . . . . 57.2 kg . . . . . . . . . . . 104.3 kg
928739 72” SD deck . . . . . . . . . . . 76.2 kg . . . . . . . . . . . 123.4 kg
928754 72” RD deck . . . . . . . . . . . 93.9 kg . . . . . . . . . . . 144.1 kg)
Refer to the power units owner’s manual for more detailed information.
Order the recommended weights from your Hustler® Turf dealer.
Cutting height adjustment
WARNING: Make sure PTO clutch switch is off, engage
power unit parking brake, stop engine, and remove ignition
key before making any adjustments to mower deck.
IMPORTANT: Deck cutting height will be affected by the use of the
3700 power unit’s Weight Control Valve. This allows the operator to transfer
weight from the front gauge wheels to the front drive wheels to increase traction. Using this feature will result in the cutting height being increased and
the deck pitch (angle from front to back of deck) being decreased. Additional
cutting height adjustments may be necessary if the Weight Control feature is
used.
For best results, make cutting height adjustments on a hard flat surface.
The mower deck can be height adjusted in the back as well as in the front.
The mower deck has two different cutting height range settings: 5.08 –
15.2cm or 2.54 – 12.7cm. The deck is preset at the factory to the 5.08 –
15.2cm setting.
Both front and rear height adjustment are in 6.35mm increments.
For a quick check of height adjustments: Measure from level surface to
top of mower deck (as indicated in Figure 3-18) and subtract 8.89cm. The
balance will be blade height. To be sure mower deck is level, measure at
front and back on both left and right side of deck. Figure 3-17
WARNING: Improper operation on slopes can cause injury.
Install rear counter-balance weights, when the attachment is
installed, to increase stability. Use extreme care when operating on slopes
Leveling mower deck
NOTE: Levelness of mower deck when lifted from surface does not
affect levelness of cut in the mowing position. Mower deck will mow (cut)
level if it is level when set on level surface
IMPORTANT: The Hustler® Model 3700 power unit has a weight transfer feature that allows the operator to adjust the weight transfer of the attachment’s weight back to the power unit. If the application requires that some of
the deck’s weight shall be transferred back to the power unit, this must be
considered when leveling the deck. As weight is transferred to the power unit,
from the deck, the front of the deck will raise slightly and the rear of the deck
will lower slightly, changing the pitch of the blades. When using the weight
transfer feature the operator may find that raising the rear of the deck may
improve deck cutting performance.
Correct tire pressure will affect deck leveling. Refer to power unit’s
owner’s manual for correct power unit tire pressure.
To level mower deck use the following procedure:
1. Park the unit on a flat surface and set the park brake. Shut off power unit
engine and remove key from the igniton switch.
To adjust front cutting height
1. Park the unit on a flat surface, set the park brake and using the power
unit’s hydraulic system lift mower deck off the ground. Shut off power
unit engine. Place 20.3cm tall blocks at the four corners of the deck.
Restart engine and lower the deck onto the blocks. Shut off power unit
engine and remove key from the igniton switch..
WARNING: Stop engine. Remove ignition key before getting
off machine.
WARNING: Stop engine. Remove ignition key before getting
off machine.
WARNING: The deck must rest on the blocks to prevent the
deck from being lowered suddenly by the accidental movement of the power unit’s tool bar lift control lever.
2. Check the deck’s tire pressure and adjust it accordingly. Tire pressure
should be 55-83 KPa.
3. Set the 3700 power unit’s Tool Bar Lift Control Lever in the fully forward (detent) position. (Refer to power unit’s owner’s manual for complete information.)
4. Set the deck cutting height to 8.89cm at the two front gauge wheel forks
and at the two rear height adjusting linkages.
(Refer to Cutting Height Adjustment section to set cutting height.)
109631CE_0612
2. Pull up and forward on gauge wheel handle and lift or lower wheel to
desired height (Figure 3-21). Both gauge wheels should be adjusted to
same height for uniform cutting.
3-6
Measure
to top of
deck here
Rear height
adjustment
anchor
Measure
to top of
deck here
Rear height shown set at 6.35cm
Clevis pin
Measure
to top of
deck here
Rear height
adjusting yoke
Figure 3-20
Measure
to top of
deck here
Handle
Figure 3-17
When mower deck is set in the 5.08 – 15.2cm range.
Recesses on gauge
arm mount
Gauge wheel
assembly
5.08cm
6.35cm
7.62cm
8.89cm
10.2cm
11.4cm
12.7cm
14.0cm
15.2cm
Loosen cap screw
for adjustments of
less than 6.35mm
Gauge wheel
fork
Gauge arm
mount
Measure, then subtract 12.9cm
Figure 3-18
6.35mm Spacer
Figure 3-21
height is set at 15.2cm, when the mower deck is set in the 5.08 – 15.2cm
range (see Figure 3-18). Next mark up indicates 14.0cm, then 12.7cm and so
forth. Top mark indicates 5.08cm. Move gauge wheel assemblies all the way
to top of arms for 5.08cm cutting height.
NOTE: 2.54 – 12.7cm cutting height range: Recesses on side of gauge
arm mounts visually indicate cutting height in 1.27cm increments. When the
bottom (lowest) recess is just visible over top of gauge wheel assembly, cutting height is set at 12.7cm, when the mower deck is set in the 2.54 – 12.7cm
range. Next mark up indicates 11.4cm, then 10.2cm and so forth. Top mark
indicates 2.54cm. Move gauge wheel assemblies all the way to top of arms
for 2.54cm cutting height.
If gauge wheels do not remain securely in place when handles are in
closed (down) position, follow procedures outlined in Gauge Wheel Tension
Adjustment section of this manual.
Figure 3-19
NOTE: To change cutting height range setting to the 2.54 – 12.7cm
range, reposition the two 1.27cm spacers, located below the gauge wheel
bearings, to above the bearings. Figure 3-22 & Figure 3-23
NOTE: 5.08 – 15.2cm cutting height range: Recesses on side of gauge
arm mounts visually indicate cutting height in 1.27cm increments. Each
notch between recesses represents a 6.35mm adjustment. When the bottom
(lowest) recess is just visible over top of gauge wheel assembly, cutting
109631CE_0612
To adjust rear cutting height
1. Park the unit on a flat surface, set the park brake and using the power
unit’s hydraulic system lift mower deck off the ground. Shut off power
unit engine and remove key from the igniton switch. Place 20.3cm tall
blocks under the rear of the deck.
3-7
NOTE: The deck must be in the raised position to release pressure from
the lift chains.
+19.05mm
Rear height
+12.7mm
adjustment anchor
6.35mm
Spacer
+6.35mm
+0mm
12.7cm
1.27cm
Spacers
15.2cm
10.2cm
7.62cm
5.08cm
2.54cm
Figure 3-24
Side discharge decks - An optional rear anti-scalp wheel kit is available for the sides of the rear of the deck. Contact your Hustler® Turf dealer
for more information on Anti-scalp kit, part number 111056. Figure 3-3
Figure 3-22
Front anti-scalp wheel
1.27cm
Spacers
Mount hole
Figure 3-23
WARNING: Stop engine. Remove ignition key before getting
off machine.
Figure 3-25
Mowing suggestions
WARNING: Placing the blocks under the rear of the deck
will help prevent injury in the event the deck is lowered suddenly by the accidental movement of the power unit’s tool bar
lift control lever.
The following list is not all inclusive. Additional suggestions can be
found in operation section of power unit manual.
1. Keep blades sharp. Many professional mowing companies have additional sets of blades and change blades twice a day: once in the morning
and again at noon. Many problems with incorrect cutting patterns are
due to dull blades or blades which have been sharpened incorrectly.
Information on sharpening blades is listed in this manual’s maintenance
section. In addition, most communities have individuals or companies
which specialize in sharpening mower blades. Blade sharpness should
be checked daily.
2. Use high blade speed. Your Hustler® power unit and mower are
designed to operate at full throttle. As explained in power unit’s manual,
throttle setting directly controls blade speed. The highest blade speed
generally gives best cut.
3. Direct grass discharge to right, away from unmown area. Select a
mowing pattern that directs grass discharge towards the outside, not
towards center, of mowing area. Generally, this means using a pattern
utilizing left turns because side discharge is to right. In any case, avoid
throwing grass discharge onto unmowed area because grass is then
mowed “twice”. Mowing twice puts an unnecessary load on power unit
and reduces mowing efficiency.
4. Avoid sudden turns on wet turf. These can damage turf unnecessarily.
2. Remove the clevis pin from the rear height adjusting yoke. Locate the
appropriate hole in the yoke and in the rear height adjustment anchor and
insert the clevis pin through both and secure in place. Figure 3-20 & Figure 3-24
NOTE: Adjust the rear of the mower deck to match the front cutting
height setting.
3. Set the opposite side rear height adjustment using procedures in preceding steps.
Anti-scalp rollers
Front anti-scalp rollers are standard on Hustler® Front Mount mower
decks. These anti-scalp rollers are designed to minimize scalping when mowing on rough uneven terrain. Figure 3-1
After setting the cutting height, adjust the front anti-scalp roller so it
extends below the mower deck but does not contact the ground. It can be set
at either 19.05mm or 44.45mm below the cutting height. Figure 3-25
The rear anti-scalp roller is not adjustable. Figure 3-1 and Figure 3-2
3-8
109631CE_0612
5. Never raise the mower deck with the blades engaged to avoid small
obstacles, drive over curbs and so forth. Disengage the PTO before raising the deck, using the power unit’s tool bar lift control lever. See power
unit’s owner’s manual for additional information.
6. Always check area to be mown for rocks and other debris before mowing
and remove them from operator’s path.
109631CE_0612
3-9
3-10
109631CE_0612
MAINTENANCE
Safe Servicing Practices
cleaning. Use a stick to clear a plugged discharge area. Never use
your hand!
 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.
 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.
 Use only genuine Hustler® replacement parts to ensure that original
standards are maintained.
This product is capable of amputating hands and feet and throwing
objects. Always follow all safety instructions to avoid serious injury or death.
IMPORTANT: Any maintenance operation that requires the removal of
safety covers must be performed by a trained service technician.
Service
 Unless specifically required, DO NOT have engine running when servicing or making adjustments to power unit. Park the machine on
level ground. Place park brake lever in the brake engaged position,
place the PTO lever in the “OFF” position, lower deck, 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 poisoning, be sure proper ventilation is available when
engine must be operated in an enclosed area. Read and observe safety
warnings in front of manual.
 Before working on or under the deck, make certain engine cannot be
accidentally started. Shut engine off, remove ignition switch key and
disconnect negative battery cable for maximum safety. Repairs or
maintenance requiring engine power should be performed by trained
maintenance personnel only.
 Always keep belt covers on mower deck for safety as well as cleanliness.
 Use a stick or similar instrument to clean under the mower deck making sure that no part of the body, especially arms and hands are under
mower. It is advisable to pivot the deck up and lock in place before
cleaning.
 Clean flammable material from machine. Prevent fires by keeping the top of the deck, under deck covers, engine compartment,
exhaust area, battery, hydraulic lines, fuel line, fuel tank and operator’s station clean of accumulated trash, grass clippings, and
other debris. Always clean up spilled fuel and oil.
 Always wear adequate eye protection when servicing the hydraulic
system and battery, or when grinding mower blades and removing
accumulated debris.
 Never run the engine in an enclosed area unless exhaust is vented to
the outside. Exhaust gases contain carbon monoxide which is odorless
and deadly poison.
 Never attempt to make any adjustments or repairs to the mower deck
while the power unit engine is running or PTO is engaged. Mower
blades cannot be seen and are located very close to the deck housing.
Fingers and toes can be cut off instantly.
 Never attempt to make any adjustments or repairs to the power unit
drive system, mower deck or any attachment while the power unit
engine is running or PTO is engaged. Repairs or maintenance requiring engine power should be performed by trained maintenance personnel only.
 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 jack stands. Use only appropriate
jack stands, with a minimum weight rating of 2000 pounds to block
the unit up. Use in pairs only. Follow the instructions supplied with
the vehicle stands. NOTE: Unless the deck is in the tilted position, the
rear locking pins must remain inserted to prevent the deck from falling.
 Do not touch hot parts of machine.
 Keep nuts and bolts tight, especially the blade attachment bolts. Keep
equipment in good working condition.
 Never tamper with safety devices. Check their proper operation regularly.
 Stop the engine before removing the grass catcher or unclogging the
discharge chute. Never clear the discharge chute with the engine running. Turn off the engine and be sure the blades have stopped before
109631CE_0612
4-1
60”/72” Side Discharge Deck Maintenance Locator Chart


















Shields and covers removed for clarity
Item No.
Description
Check or
Maintain
1
Blades (3) — sharp and securely fastened
Daily
2
Tires — properly inflated
Daily
3
Gearbox — sufficient lubrication*
Daily **
4
Discharge chute — securely in place
Daily
5
Clean clippings from under side of mower hous- Daily
ing and under the deck covers. Clean more often
when grass is moist
6
Proper tension on gauge wheel arms
Every 150 hours
7
Gauge wheel bearings
Weekly or Every 50
hours.
8
Belt — proper tension, belt serviceable***
Every 100 hours
9
PTO shaft (3) — Lubricate using all purpose
lubricant. Do not force lubricant into grease
zerks.***
Every 100 hours
10
Spindle housings (3) — Lubricate using all pur- Annually or Every
pose lubricant. Do not force lubricant into grease 750 hours.
zerks.
* ISO VG 46
** Check daily and change every 6 months.
*** Any maintenance operation that requires the removal of safety covers must be performed by a trained service technician.
Figure 4-1
4-2
109631CE_0612
72” Rear Discharge Deck Maintenance Locator Chart

















Shields and covers removed for clarity
Item No.
Description
Check or
Maintain
1
Blades (3) — sharp and securely fastened
Daily
2
Tires — properly inflated
Daily
3
Gearbox — sufficient lubrication*
Daily **
4
Clean clippings from under side of mower hous- Daily
ing and under the deck covers. Clean more often
when grass is moist
5
Proper tension on gauge wheel arms
Every 150 hours
6
Gauge wheel bearings
Weekly or Every 50
hours.
7
Belt — proper tension, belt serviceable***
Every 100 hours
8
PTO shaft (3) — Lubricate using all purpose
lubricant. Do not force lubricant into grease
zerks.***
Every 100 hours
9
Spindle housings (3) — Lubricate using all pur- Annually or Every
pose lubricant. Do not force lubricant into grease 750 hours.
zerks.
* ISO VG 46
** Check daily and change every 6 months.
*** Any maintenance operation that requires the removal of safety covers must be performed by a trained service technician.
Figure 4-2
109631CE_0612
4-3
Introduction
Spindle housing, under mower. Lubricate spindle housings annually or
after every 750 hours of operation, whichever occurs first. Use no more than
29.6 – 59.1cc of multi-purpose lubricant. Do not force lubricant into grease
zerks. Bearings are sealed and do not require much lubrication.
Regular maintenance is the best prevention for costly downtime or
expensive, premature repair. The following pages contain suggested maintenance information and schedules which the operator should follow on a routine basis. For more detailed information refer to the correct parts manual for
your unit.
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, on top of the deck and
under the deck areas especially under the deck guards.
Daily inspect mower deck 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 it should be removed routinely.
The easiest way to do this is to pivot the deck to the full up position and
scrape the build-up from underneath. See Mower Deck Tilt Procedure section. However, if the deck is not pivoted to the full up position but is raised
instead, the rear locking pins must remain inserted to prevent the rear of the
deck from falling. Figure 4-5
Plug
Sight gauge
WARNING: Never work under the deck unless it is safely
supported with jack stands. Make certain deck is secure when
it is raised and placed on the jack stands.
Figure 4-3
Mower deck service procedure
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.
There are three methods that can be used to lift and secure the deck when
maintenance is required on the underneath side of the deck.
IMPORTANT: Pivoting the deck to the service or operating position
requires two people due to the weight of the deck. Stand to the side of the
deck when raising or lowering the deck. Never stand at the front of the
deck to raise or lower it.
Description of operation
The three mower blades are indirectly driven by the power unit engine:
Power flows through the mechanical clutch, PTO drive shaft, right angle
gearbox, and finally through a V-belt drive system. The V-belt drives three
pulleys; each pulley is on top of a spindle housing assembly. The pulleys
drive 1” spindle shafts which in turn drive the blades. A blade is affixed to
each spindle shaft by a 5/8” bolt.
The mower deck is connected to power unit by attaching the mower tool
bar arms to the power unit tool bar with clevis pins and hairpins.
Locking deck in service position (cab not installed)
IMPORTANT: If a cab is installed refer to Locking deck in service
position (cab installed) section. Procedure is different to prevent breakage of
the front window of the cab!
The mower deck is designed to be raised and pinned in an upright position to allow easier access to the underneath side of the mower deck.
1. Park the unit on a flat surface, raise mower deck to the highest position
(against the stops) and set the parking brake. Figure 4-4
Torque values
WARNING: Particular attention must be given to tightening
the blade spindle bolts. Failure to correctly torque these items
may result in the loss of a blade, which can cause serious damage or personal injury.
Deck raised to highest pinned position
Torque values are given below:
Nm
Spindle blade bolt (bottom) . . . . . . . . . . . . 160.01
Spindle pulley bolt (top) . . . . . . . . . . . . . . 101.68
For all other torques refer to the deck parts manuals for standard torque
chart.
Tires
It is important for level mowing that the tires have the same amount of air
pressure. The recommended pressure is:
Front gauge wheels . . . . . . . . . . . . . . . . . . . . . 55-83 KPa
Figure 4-4
Hustler®
Solid fill tires are not recommended for
turf equipment. On
any machine, with solid filled tires, the warranty claim will be denied.
2. Shut off engine and remove the ignition key. It is important that the following be done as soon as the engine is shut off to prevent the hydraulic
system from bleeding down too much.
3. Pull out on the locking pins attached to the rear height adjusting chains
and rotate pin so roll pin locks into slot. Make sure the pin assembly is
detached from the rear deck mount bracket. This allows the rear of the
mower deck to pivot freely. Figure 4-5 and Figure 4-6
4. Lift the front of the mower deck and pivot it until the holes in the deck
and carrier arms are in alignment. Remove the locking pin from the storage hole and insert it thru the holes in the deck and carrier arm. Figure 4-
Lubrication
IMPORTANT: Any maintenance operation that requires the removal of
safety covers must be performed by a trained service technician.
Check gearbox lubricant daily by looking at the sight gauge located on
side of gearbox. It should appear half full. Fill as necessary with ISO VG46
oil (Hustler® P/N 601621). Fill by removing vent plug located on top front of
gearbox. Add oil until the sight ball floats off of the bottom. Figure 4-3
109631CE_0612
4-4
Rear height adjusting chain
Locking pin Storage position
Locking pins
60” deck shown
Figure 4-5
7, Figure 4-8 and Figure 4-9
NOTE: Make sure the area around the carrier arm’s pivot point is clear
of debris before trying to pivot the deck. The deck will not pivot to the
full service position if there is grass buildup in this area. Figure 4-10
Figure 4-8
Locking pin Deck locked in
service position
72” deck shown
60” deck shown
Roll pin
in slot
Roll pin
in slot
Deck pinning shown when cab is
not attached to the power unit
Figure 4-9
Locking pin
Locking pin
Figure 4-6
WARNING: Until the deck is fully pivoted and locked in the
tilted position with the locking pin, the deck will fall.
Carrier arm
WARNING: The locking pin must be inserted thru both sides
of the carrier arm to prevent the deck from falling.
Keep this area clean
Keep pressure on the front of the deck to prevent it from falling
Figure 4-7
Figure 4-10
4-5
109631CE_0612
5. Lock the deck in the mowing position using the two locking pins at the
rear of the deck before operating the unit. Figure 4-5
6. With the operator in the seat, lower the deck to the ground.
7. Be sure to replace the service position locking pin in the storage position.
Figure 4-8
Side Discharge Deck in tilted position
Lowering deck from service position (cab installed)
1. Now it will be necessary to raise the deck due to the hydraulic system
bleeding. Start the engine with the park brake engaged and raise the
deck to it’s highest position. Shut off engine, set park brake and remove
the ignition key. It is important that the following be done as soon as the
engine is shut off to prevent the hydraulic system from bleeding down
too much.
2. It requires two people to lower the deck to the mowing position, one on
each side of the deck. Pressure must be applied to the front (up) side of
the deck to prevent it from falling. Figure 4-7
3. Remove the locking pin from the gauge wheel bracket and cab bracket.
Figure 4-13 and Figure 4-14
4. Slowly lower the front of the deck until it is in the mowing position. Do
not drop the front of the deck.
Rear
anti-scalp
roller
Figure 4-11
WARNING: Never engage the PTO control lever or operate
power unit with the deck in the tilted position.
WARNING: When lowering the deck, make sure the deck is
held securely and that the two people completing this task
have good footing. As the deck is rotated forward more
weight will be transferred forward which must be controlled.
Keep to the side of the deck and do not allow any part of the
body, feet, or legs under the deck as it is lowered
5. After the locking pin is inserted, lower the mower deck until the rear
anti-scalp roller (side discharge decks) or rear of the deck (rear discharge
decks) rests on the ground. Figure 4-11 and Figure 4-12
WARNING: Do not drive forward to release the deck from
the upright position as that may damage the equipment or
cause bodily injury.
5. Lock the deck in the mowing position using the two locking pins at the
rear of the deck before operating the unit. Figure 4-5
6. With the operator in the seat, lower the deck to the ground.
7. Be sure to replace the service position locking pin in the storage position.
Figure 4-8
Locking pin Deck locked position
Cab & Deck
mount brackets
Rear of deck resting on ground
Figure 4-12
Lowering deck from service position (cab not installed)
1. After the required maintenance is done it will be necessary to raise the
deck again due to the hydraulic system bleeding. Start the engine with
the park brake engaged and raise the deck to it’s highest position. Shut
off engine and remove the ignition key. It is important that the following
be done as soon as the engine is shut off to prevent the hydraulic system
from bleeding down too much.
2. It requires two people to lower the deck to the mowing position, one on
each side of the deck. Pressure must be applied to the front (up) side of
the deck to prevent it from falling. Figure 4-7
3. Remove the locking pin from the deck and carrier arm. Figure 4-9
4. Slowly lower the front of the deck until it is in the mowing position. Do
not drop the front of the deck.
60” Side Discharge Deck Shown
Figure 4-13
WARNING: When lowering the deck, make sure the deck is
held securely and that the two people completing this task
have good footing. As the deck is rotated forward more
weight will be transferred forward which must be controlled.
Keep to the side of the deck and do not allow any part of the
body, feet, or legs under the deck as it is lowered. Figure 4-7
Locking deck in service position (cab installed,)
Jo-Dale Perry Cab equipped machines only (brackets installed) - If
these decks are mounted on a 3700 power unit equipped with a Jo-Dale Perry
cab it will be necessary for the power unit and deck to have the mounting
brackets, supplied with the cab (kit number 550299), installed. Figure 4-13
and Figure 4-14
Do not attempt to raise the deck into the service position if the
brackets are not installed
1. Park the unit on a flat surface, raise mower deck to the highest position
(against the stops) and set the parking brake. Figure 4-4
WARNING: Do not drive forward to release the deck from
the upright position as that may damage the equipment or
cause bodily injury.
4-6
109631CE_0612
Lowering deck from service position (cab installed, brackets
already attached)
1. After the required maintenance is done it will be necessary to raise the
deck again due to the hydraulic system bleeding. Start the engine with
the park brake engaged and raise the deck to it’s highest position. Shut
off engine, set park brake and remove the ignition key. It is important
that the following be done as soon as the engine is shut off to prevent the
hydraulic system from bleeding down too much.
2. It requires two people to lower the deck to the mowing position, one on
each side of the deck. Pressure must be applied to the front (up) side of
the deck to prevent it from falling. Figure 4-7
3. Remove the locking pin from the gauge wheel bracket and cab bracket.
Figure 4-13 and Figure 4-14
4. Slowly lower the front of the deck until it is in the mowing position. Do
not drop the front of the deck.
72” deck pin position
Locking pin Deck locked position
WARNING: When lowering the deck, make sure the deck is
held securely and that the two people completing this task
have good footing. As the deck is rotated forward more
weight will be transferred forward which must be controlled.
Keep to the side of the deck and do not allow any part of the
body, feet, or legs under the deck as it is lowered
60” deck pin position
WARNING: Do not drive forward to release the deck from
the upright position as that may damage the equipment or
cause bodily injury.
5. Lock the deck in the mowing position using the two locking pins at the
rear of the deck before operating the unit. Figure 4-5
6. With the operator in the seat, lower the deck to the ground.
7. Be sure to replace the service position locking pin in the storage position.
Figure 4-8
72” Side Discharge Deck Shown
Servicing deck in maximum raised position (without tilting deck)
If it is not possible to pivot the deck up and pin in place then the following method will work.
1. Park the unit on a flat surface, raise mower deck to the highest position
(against the stops) and set the parking brake. Figure 4-4
2. Shut off engine and remove the ignition key. It is important that the following be done as soon as the engine is shut off to prevent the hydraulic
system from bleeding down too much.
3. Block the rear corners of the deck up using 12.7cm blocks. IMPORTANT: Do not pull out on the locking pins attached to the rear height
adjusting chains.
4. Block the front corners of the deck up using jack stands. Make sure the
weight of the deck is resting on the jack stands.
Figure 4-14
2. Shut off engine and remove the ignition key. It is important that the following be done as soon as the engine is shut off to prevent the hydraulic
system from bleeding down too much.
3. Pull out on the locking pins attached to the rear height adjusting chains
and rotate pin so roll pin locks into slot. Make sure the pin assembly is
detached from the rear deck mount bracket. This allows the rear of the
mower deck to pivot freely. Figure 4-5 and Figure 4-6
4. Lift the front of the mower deck and pivot it until the slots in the gauge
wheel bracket and cab bracket are in alignment. Remove the locking pin
from the storage hole and insert it thru the slots in the deck and cab
brackets. Figure 4-7, Figure 4-8, Figure 4-13 and Figure 4-14
NOTE: The 60” and 72” decks will not be pinned in the same set of
slots. The 60” deck uses the lower slot in the cab mount and the outer
slot on the gauge wheel bracket. The 72” deck uses the upper slot in the
cab mount and the inner slot in the gauge wheel bracket. Figure 4-14
NOTE: Make sure the area around the carrier arm’s pivot point is clear
of debris before trying to pivot the deck. The deck will not pivot to the
full service position if there is grass buildup in this area. Figure 4-10
WARNING: 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. Use only certified jack stands. Use only appropriate
jack stands, with a minimum weight rating of 907.2kg to
block the unit up. Use in pairs only. Follow the instructions
supplied with the vehicle stands. Unless the deck is in the
tilted position, the rear locking pins must remain inserted to
prevent the rear of the deck from falling.
WARNING: Until the deck is fully pivoted and locked in the
tilted position with the locking pin, the deck will fall.
WARNING: Never engage the PTO control lever or operate
power unit with the deck in the tilted position.
WARNING: The locking pin must be inserted thru both sides
of the gauge wheel bracket to prevent the deck from falling.
WARNING: Never engage the PTO control lever or operate
power unit with the deck in the tilted position.
5. After the required maintenance is done it will be necessary to raise the
deck again due to the hydraulic system bleeding. Start the engine and
raise the deck to it’s highest position. Shut off engine, set park brake and
remove the ignition key. It is important that the following be done as
soon as the engine is shut off to prevent the hydraulic system from bleeding down too much.
6. Remove the rear blocks and the front jack stands.
7. With the operator in the seat, lower the deck to the ground.
5. After the locking pin is inserted, lower the mower deck until the rear
anti-scalp roller (side discharge decks) or rear of the deck (rear discharge
decks) rests on the ground. Figure 4-11
109631CE_0612
4-7
Cleaning mower deck
Belt maintenance & adjustment
IMPORTANT: Any maintenance operation that requires the removal of
safety covers must be performed by a trained service technician.
The blades in the mower are driven by a V-belt. Belt tension is maintained by use of a spring loaded idler pulley. As belt stretches and wears in,
additional tension may become necessary. To increase belt tension, move the
spring chain one (or more) link(s) at the anchor bracket (Figure 4-18).
Installed spring length should be as shown in Figure 4-19. When the belt is
re-tensioned each chain link allows approximately 15.2mm of adjustment.
IMPORTANT: Do not over tension the spring to compensate for a badly
worn belt or pulley.
Belt should be visually inspected every 100 hours for wear and serviceability. To replace, relieve tension on idler pulley, remove old belt and install
new belt following pattern indicated on maintenance illustration (Fig. 4-1).
Following are some maintenance suggestions:
DANGER: Before cleaning under mower, make sure the
PTO Control Lever is in the “OFF” position. Raise the
mower deck to highest position and engage parking brake
lever. Turn off engine. Secure deck for servicing by using
the instructions outlined in the “Mower deck service positions” sections.
WARNING: When possible clean under mower, using a stick
or similar instrument making sure that no part of the body,
especially arms and hands are under mower. If the deck is not
pivoted to the full up position but is raised instead, the rear
locking pins must remain inserted to prevent the rear of the
deck from falling. Figure 4-5
Daily, inspect mower for grass clipping build-ups, wire and string tangles. Underside of mower housing will collect cut grass and dirt more rapidly on moist days. Check it frequently when grass is moist. Otherwise,
clean under housing once a day for maximum efficiency.
Blade maintenance
Check the mower blades daily, they are the key to power efficiency and
well groomed turf. Keep them sharp, a dull blade will tear rather than cut the
grass, leaving a brown ragged top on the grass within a few hours. A dull
blade also requires more power from the engine.
Replace any blade which is bent, cracked or broken.
WARNING: Never attempt to straighten a bent blade by
heating, or weld a cracked or broken blade as the blade may
break and cause serious injury. Replace worn or damaged
blades.
Resharpening
Do not sharpen to original pattern (below)
Pattern
It is easier to get a straight cutting edge following
the resharpening pattern shown above.
DANGER: Never work with blades while engine is running
or the PTO Control Lever is in the “ON” position. Always
put PTO Control Lever in “OFF” position, engage parking
brake and turn engine off. Wear gloves when handling
blades. Always check for blade damage if mower strikes
rock, branch or other foreign object during mowing!
WARNING: Always wear adequate eye protection when
grinding mower blades.
Mower blade removal
Use a 15/16" wrench to remove the 5/8" cap screw holding the blade to
the spindle shaft from underneath. NOTE: A blade holding tool (part number 381442) is available from Hustler® Turf Equipment. It is designed to prevent the blades from rotating when they are being removed or installed on
the spindle. Contact your Hustler® dealer for more information.
Sharpen the blades on a grinder following pattern as shown (Figure 415). Touch-up sharpening can be done with a file.
Check the blades for balance following grinding. A commercial balancing tool is available through most hardware supply stores, or balancing can
be done by placing the blade on an inverted line punch or 1/2" bolt. Blade
should not lean or tilt. Spin the blade slowly, blade should not wobble. If
blade is out of balance, true it up before reinstalling.
Lay the blade on a flat surface and check for distortion (Figure 4-16 and
Figure 4-17). Replace any distorted blade.
Do not re-use spindle bolts which have stripped, worn or undercut
threads. Torque spindle bolts to 160.01Nm when reinstalling blades.
IMPORTANT: When mounting blades, rotate them after installation to
ensure blade tips do not touch each other or sides of the mower.
Original Edge
Figure 4-15
Warped Blade (Replace)
Cutting
Plane
Straight Edge
Comparison of Warped and Straight Blades
Figure 4-16
Belt should be visually inspected every 100 hours for wear and serviceability. To replace, relieve tension on idler pulley, remove old belt and install
new belt following pattern indicated on maintenance illustration (Figure 41). Following are some maintenance suggestions:
1. Maintaining proper belt tension gives more economical performance and
longer belt life. Replacement belts may be seriously damaged if
machine is operated before belts are properly adjusted.
WARNING: Failure to correctly torque the bolt may result in
the loss of the blade which can cause serious injury.
Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves
and use extra caution when servicing them.
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109631CE_0612
If gauge wheels do not stay firmly in place when handle is in down
(closed) position:
1. Relieve tension on lock pin and linkage by removing handle, lock linkage and lock pin from gauge wheel arm assembly.
2. Remove cotter pin from lock pin and insert one or two spare washers
between lock linkage and lock pin.
3. Reassemble gauge wheel arm by reversing above directions.
NOTE: If more tension is needed, additional spring washers may be
purchased from your Hustler® Dealer.
Cutting Edge
Twisted Blade Edge (Replace)
Cutting Plane
Cutting Edge
Tire care
Visually inspect gauge wheel tires daily to ensure proper inflation.
Gauge wheel tire inflation directly affects mower cutting height. Proper
pressure is 55 – 83KPa.
Straight Blade Edge
End view of blades, comparing twisted and straightened blades.
Figure 4-17
End of season storage
Read and follow suggestions in power unit’s operator’s manual. As a
minimum:
1. Clean off dirt and debris.
2. Check lubricant level in gearbox.
3. Check for broken, worn parts and replace or repair as necessary.
4. Touch up scrapes with spray paint and lubricate exposed metal to prevent
rust and corrosion.
5. Make sure tires are elevated off ground or floor. Do not deflate tires.
6. Store mower in clean, dry area.
2. All V-belts stretch when new. Check belt tension after 1 to 3 hours of
running when belts are new.
3. For better belt life and service, keep belts properly adjusted at all times:
• A loose belt may not slip noticeably, but at the same time it may be
wearing belt and pulley groove excessively. (Sluggish performance is
typical symptom of this problem.)
• If belt slips, excessive heat generated will shorten belt life.
• More belts are ruined by lack of tension than by too much tension.
4. A slight raveling of belt covering does not mean failure. Raveling should
be cut off.
5. Never use belt dressings on V-belts.
6. Keep oil and grease away from belts.
7. When replacing belts, check pulley groove condition. A worn groove
(notch in shoulder) will cause rapid belt failure. Replace pulley if
groove is worn.
8. Never pry belt over edge of pulley, this may cause fibers of belt to break.
9. Sun and weather injure belts, unnecessary exposure to these elements
should be avoided.
Set screw
Handle
Spare spring washer
Spring
Lock
linkage
Chain
Anchor
bracket
Spring
washers
Lock pin
Cotter pin
Handle pin
Figure 4-20
Figure 4-18
Spring Extension
20.6cm - 23.1cm
These spring washers face
one direction
These spring washers face
the other direction
Figure 4-19
Gauge wheel tension adjustment
Gauge wheel arms are held in place against the gauge wheel arm mount
by lock linkage and lock pin. Tension on arms is controlled by spring washers. There are 15 washers on each arm: 14 are between the lock linkage and
lock pin and 1 is a spare, placed in front of the lock linkage as shown in Figure 4-20.
NOTE: Seven of the spring washers are turned one way and the other
seven are reversed. The concave part of the two sets of washers should face
each other. This is what provides the tension. Figure 4-21
109631CE_0612
Figure 4-21
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4-10
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TROUBLESHOOTING
lems are to be resolved satisfactorily. A good rule to follow in locating trouble is to never make more than one adjustment at a time, then locate trouble
by a process of elimination. Remember the cause is usually simple, rather
than mysterious or complicated. Separate troubleshooting guides are
included in engine and power unit owner’s manuals.
Operators handling the same equipment every day soon develop a sense of
impending trouble when abnormal operation occurs. Immediate attention to
these danger signals can prevent major failures, ensure dependable operation
and increase the life of equipment.
The majority of operating problems that occur with a system can be traced
to improper adjustments or delayed service. A consistently applied preventive maintenance program, as outlined in the maintenance section of this
manuel, will prevent many problems. The following chart is designed to help
you locate a problem by suggesting probable causes and recommended solution(s).
The suggested remedies should be applied with care. Make certain that the
source of a problem is not located someplace other than where the problem
exists. A thorough understanding of the system is a must if operating prob-
SYMPTOMS
PROBABLE CAUSES
SUGGESTED REMEDIES
Power unit is sluggish, veers in
one direction, etc.
Numerous
Refer to power unit owner’s manual
Uneven Grass Cut
Tire inflation varies (power unit or deck)
Check and adjust tire pressures.
Gauge wheels incorrectly adjusted
Check and correct gauge wheels
Blades vary in sharpness
Ensure all blades are properly sharpened
Blades improperly installed after sharpening
Ensure blades are properly installed
Rear height adjustment improperly adjusted
Check and correct rear height adjustment
Mower leaving skip between
blades
Blades dull or too short
Check blade sharpness and length
Deck is packed with grass or debris
Clean underneath side of deck
Deck belt shows excessive
wear
Deck belt too loose
Consult your Hustler® dealer
Smoke in mower deck (especially while cutting in heavy
grass)
Deck belt too loose
Consult your Hustler® dealer
Belt may have jumped off pulley
Consult your Hustler® dealer
Blades not turning
Deck belt broke or too loose
Consult your Hustler® dealer
PTO lever in “OFF” position or shaft improperly
connected.
Check PTO lever, PTO switch wiring and shaft connections
Deck is in raised position, PTO automatically disengaged
Lower deck and reengage PTO drive
Blades not tight
Tighten blades
Blades touching sides or each other
Check blade clearance
Spindle assemblies loose
Tighten bolts on assembly
Beginning of spindle bearing failure
Replace spindle bearings
Damaged deck housing
Remove dents, etc.
Engine or power unit noise
See engine and power unit manual
Belt loose
Consult your Hustler® dealer
Excessive noise
One blade cutting smoother
than other blades
PRODUCT LITERATURE
If you would like to have a copy of the Hustler® product manuals, contact your Hustler® dealer.
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INDEX
PAGE
PAGE
Anti-scalp rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Mower deck tilt procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Attaching mower deck to power unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Mowing suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Belt maintenance & adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Blade maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Parts and service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Cleaning mower deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Rear counter-balance weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Cutting height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Safe Operating Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Description of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Safety and Instruction Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
End of season storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Gauge wheel tension adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Tire care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Hustler Turf Equipment Authorized Representative . . . . . . . . . . . . . . . . 2-2
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
To the new owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Leveling mower deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Torque values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Using a ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Model and serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Using this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Mower blade removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Warranty registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
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