HUSTLER MDV, MDV LeveLift Operator's Manual

Hustler ® MDV™

Operator’s Manual

200 South Ridge Road

Hesston, Kansas

67062

606653 REV A

The Engine Owner’s Manual provides information regarding the U.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
illegible, replace immediately. Replacements may be ordered per the information found in the Product
Literature section of the operator’s manual.

Federal law and California State law prohibit the following acts or the causing thereof:

1. The removal or rendering inoperative by any person other than for purposes of maintenance,
repair, replacement, of any device or element of design incorporated into any equipment for the
purposes of emissions control prior to or after its sales or delivery to the ultimate purchaser or
while it is in use, or

2. The use of the equipment after such device or element of design has been removed or rendered
inoperative by any person.

NOTICE OF REQUIREMENT OF SPARK ARRESTER MUFFLER

This equipment may create sparks that can start fires around dry vegetation. California Public Resources Code
Section 4442.6 provides that it is unlawful to use or operate an internal combustion engine on any forest-covered,
brush-covered, or grass-covered land unless the engine is equipped with a spark arrester maintained in effective
working order. 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
Forest 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.

WARNING

The engine exhaust from this product

contains chemicals known to the state

of California to cause cancer, birth

defects or other reproductive harm.

REV A 606653

Table of Contents

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

To the New Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Using this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Warranty Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Model and Product Identification Number . . . . . . . . . . . . . . . . . . . . . . . 1-1

Parts and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Attachments and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Safe Operating Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Safety and Instructions Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Safe Operating Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Pre-Operation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Transporting or Towing the Hustler

Towing Other Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

OPS (Occupant Protective System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Cargo Bed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

®

MDV™ . . . . . . . . . . . . . . . . . . . . . . 3-8

Maintenance & Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Safe Servicing Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Service Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Fuel and Evaporative Emissions Control System. . . . . . . . . . . . . . . . . . 4-4

Engine Oil and Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

General Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

606653 toc-1 REV A

CVT Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Lifting Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Maintenance Location Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Product Literature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

REV A toc-2 606653

GENERAL INFORMATION

This manual applies to the following Hustler® Turf Equip-

ment product lines:

Hustler® MDV™

To the New Owner

The Hustler® MDV™ is for off-road use only. It is not designed

nor is it intended to be used on public roadways. Doing so could
be a violation of the law and may cause injury or death.

The Hustler

®

MDV™ was designed to be used as a work vehi-

cle and is intended for that purpose.

Hustler® MDV™ owners and operators must read this man-

ual carefully. It contains operation and maintenance informa­tion that will help you achieve years of dependable service.

The Engine Owner’s Manual, included in the owner’s

packet, contains engine information that will not be repeated
in this manual.

The owner’s responsibilities include, but are not limited to,

making certain that the operators and mechanics:

• read and understand the engine owner’s manual
before attempting to operate or repair the engine.

• read and understand the vehicle’s operator manual
and all decals before operating this machine.

• understand the increased risks associated with haul­ing heavy cargo over irregular surfaces.

• are qualified and physically able individuals, properly
trained in the operation and maintenance of this
equipment. Before they are allowed to operate or
maintain this machine, they must be familiar with its
safe operation, operator controls, and decals.

• know 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.

• who cannot read and understand English have this
material explained to them.

IMPORTANT: As the owner/operator you can prevent acci­dents. You are responsible for accidents or injuries occurring
to yourself, other people or property.

Never let children or untrained people operate or service
the equipment. Local regulations may restrict the age of the
operator. Only people age sixteen or older are allowed to
operate or be a passenger in this vehicle.

For more detailed maintenance and adjustment informa­tion refer to the proper General Service Manual for your
machine. Refer to the Product Literature section of this man­ual for information on how to obtain this manual.

Using this Manual

This manual contains general operation information as
well as basic adjustment and maintenance information.

Since operating conditions vary considerably, all conditions
cannot be addressed individually. Through training and expe­rience, operators should develop safe operating practices
suitable to most conditions.

Directions used in this manual, for example RIGHT or LEFT,
refer to directions when in the operator position and facing
forward, unless otherwise stated.

Though current at the time of printing, photographs and
illustrations shown may vary slightly from your vehicle due to
subsequent production changes. Hustler

®

Turf Equipment,
Inc. and its affiliates reserve 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 manual, contact your Hustler

®

Dealer for cur-

rent information.

Warranty Registration

To activate your warranty policy the vehicle must be regis­tered, by your Dealer, with the Manufacturer within ten (10)
days following the date of purchase. It is recommended that
you contact your Dealer to make sure the vehicle is regis­tered.

IMPORTANT: The vehicle and any attachment that dis­plays a model and serial identification number plate must be
registered with Excel Industries, Inc., manufacturer of Hus-

®

tler

Turf Equipment, Inc (“Manufacturer”).

IMPORTANT: Any unauthorized modification, alteration,
or use of non-approved attachments or accessories voids the
warranty and releases Manufacturer from any liability arising
from subsequent use of this equipment. Do not use or oper­ate any attachment o raccessory not approved by Manufac­turer.

IMPORTANT: Damage caused by unauthorized replace­ment parts is not covered by this warranty. Manufacturer
expressly excludes liability for defects or damage caused by
such 'unauthorized' articles or service.

Model and Product Identification Number

The product identification number plate, located on the
front left side of the frame under the cargo bed, contains the
vehicle’s model and product identification numbers.

These numbers are required when the unit is registered
with Manufacturer of Hustler
assure you of the correct service parts when replacement
becomes necessary.

Record these numbers in the spaces provide below.

MODEL NUMBER PIN / SERIAL NUMBER

Vehicle

Engine

®

turf equipment. They will also

606653 1-1 REV A

Parts and Service

Use original Hustler® replacement parts, or parts that are
equivalent in overall performance, that are available from
your local Hustler
always provide the following information when ordering
parts:

1. Correct part description.

®

Dealer. For prompt, efficient service,

2. Correct part number.

3. Correct model number.

4. Correct serial number.

All arrangements for warranty repair and service must be

handled through an authorized Hustler

®

Dealer.

REV A 1-2 606653

SAFETY PRECAUTIONS

DANGER
WARNING

Incorrect usage of this equipment may result in severe injury
or death. Personnel operating and maintaining it should be
trained in its proper use. They should read this manual com­pletely and thoroughly before attempting to set-up, operate,
adjust, or service this equipment.

Attachments and Accessories

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.

– denotes immediate hazards which WILL result in
severe personal injury or death.

– denotes a hazard or unsafe practice which COULD
result in severe personal injury or death.

This manual uses two other words to highlight information:

A. IMPORTANT – calls attention to special mechanical

information.

B. NOTE – emphasizes general information worthy of

special attention.

The owner’s responsibilities include, but are not limited to,

• making certain that the operators and mechanics read
and understand this manual and all decals before
operating this machine.

• making certain that before the operators and mechan­ics are allowed to operate or maintain this machine,
they must be familiar with its safe operation, operator
controls, and decals.

• ensuring that the operators and mechanics know 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.

Improper use, adjustment, or maintenance by the operator,
mechanic or owner can result in injury or death. Reduce the
potential for injuries by following these safety instructions.
Pay close attention to the safety alert symbol “” and the
instructions that follow it. Failure to comply with these

instructions may result in personal injury or death.

 Only use accessories and attachments approved by

the manufacturer.

 Do not use approved attachments and accessories

until you have read and understood the warnings
included with the attachment or accessory. Maintain
your attachment and accessory documentation with
this vehicle's manual.

 Attachments or accessories may affect the way the

vehicle handles.

 Non-approved attachments or accessories may dam-

age the vehicle, adversely affect it's performance and
could create unforeseen hazards which may lead to
severe personal injury or death

Safe Operating Practices

This work vehicle is capable of causing serious injury or
death. Always follow all safety instructions to avoid serious
injury or death.

 Never allow persons to operate this vehicle without

proper instruction and reading the operator’s manual
or allow children under age 16 to operate or be a passen-
ger in the vehicle. Allow only responsible adults who
are familiar with these instructions to operate this
vehicle.

 Never allow anyone to operate the vehicle who is

under the age of 16 or who has not obtained a valid
state-issued motor vehicle driver’s license.

Safe Operation

 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.

• Attachments or accessories may affect the way
the vehicle handles. Practice driving in a con­trolled area whenever a new attachment or
accessory is added to the vehicle.

• Do not modify the vehicle or use any unautho­rized attachment or accessory.

 Continually evaluate the environmental conditions

while operating. Environmental conditions can
adversely affect the way the vehicle handles.

 Drive slowly. Always drive at a speed that is appropri-

ate for your skills, your passenger’s skills, and the
operating conditions. Avoid unexpected or aggressive

606653 2-1 REV A

maneuvers that could cause discomfort or injury to you
or a passenger.

 When operating as part of a group, inform the others of

what you are going to do before doing it.

 Always operate vehicle in daylight or with adequate

working lights.

Personal Safety

 The driver and passengers should always wear appropri-

ate clothing when operating or riding in this vehicle.

• Do not wear sandals, tennis shoes, sneakers,
shorts or any type of loose fitting clothing as they
may get tangled in controls or moving parts.

• Long hair or jewelry may get tangled in moving
parts or controls.

 Always wear adequate ear protection, such as ear-

plugs. Prolonged exposure to loud noise can cause
impairment or loss of hearing.

• Do not wear radios or music headphones while
operating this vehicle. Safe operation requires
your full attention.

 Always wear safety goggles or safety glasses with side

shields when operating this vehicle.

 Use a helmet, gloves, and other protective gear as

appropriate or required for the operating conditions.

 Do not operate or ride in the vehicle if you are fatigued,

sick or while under the influence of alcohol or drugs, or
if you are pregnant.

Operation

 This vehicle is for off-road use only.

 Avoid operating on any paved surface. If it is unavoid-

able:

• drive slowly.

• only drive a short distance.

• avoid sudden turns or stops.

 Proper operation training will reduce the risk of acci-

dents. Operators will better understand how the vehi­cle will handle in different situations and different
types of terrain if they have been properly trained.

 Know your equipment and its limitations.

 Never try to get on or off a moving vehicle.

 Always engage the park brake, place the gear select

lever in neutral position, depress the brake pedal
(engage the brakes), and buckle the seat belt before
starting vehicle.

• Before starting the engine, make sure that
bystanders are at a safe distance away from the
vehicle.

• Check the seat belts regularly and replace if
frayed or damaged.

 Never leave a running vehicle unattended. Before leav-

ing the operator’s seat for any reason:

• Always stop on level ground.

• Engage the park brake.

• Put gear select lever in the neutral position.

• Return the cargo bed to the transport position.

• Stop the engine.

• Remove the ignition key.

• Wait for the engine and all moving parts to come

to a complete stop.

 Always remain seated while operating or riding in the

vehicle.

• Only start the engine from the operator’s posi­tion.

• Always drive with both hands on the steering
wheel.

• Never stick arms or legs outside of the vehicle’s
occupant protective structure. Arms and legs
could become trapped or crushed if caught while
driving or during an accident.

• Never operate the vehicle while standing.

 Always keep safety shields and covers in place, except

for servicing.

 Follow daily and weekly checklists, making sure hoses

are tightly secured and bolts are tightened.

• Never operate a poorly maintained vehicle.

 The exhaust system becomes very hot during and after

operation.

• Hot exhaust components can cause burns and
fires.

• Do not touch any part of a hot exhaust system.

• Keep combustible material away from the

exhaust system.

 Clean flammable material from vehicle. Prevent fires by

keeping the engine compartment, exhaust area, battery,
fuel line, fuel tank and operator’s area clean of accumu­lated trash and other debris. Always clean up spilled fuel
and oil.

 Prevent fires by keeping the engine and exhaust areas

clear of debris.

• Do not drive vehicle into or over flammable mate-

rials.

• Do not park the vehicle in tall grass.

• Allow the vehicle, especially the engine, to cool

before storing inside a building.

 Keep the operator’s compartment floor clean espe-

cially around the foot controls.



Do not travel with the hood or cargo bed raised. This
could impair visibility or cause loss of vehicle control.

REV A 2-2 606653

 Do not change the engine governor setting or over

speed the engine. Operating the engine at excessive
speed may increase the hazard of personal injury.

 Always be aware of what is behind the vehicle before

backing up. Always look down and behind before and
while backing up.

 Slow down before turning and maintain an even speed

through the turn.

 Braking suddenly may cause loss of vehicle control

and/or load shifting.

 Do not make sharp turns. Sharp turns increase the

chance of tipping or loss of control.

 Avoid rapid movement of the steering wheel as it

increases the chance of tipping or loss of control espe­cially when operating at high speeds.

 Never attempt high speed maneuvering, especially in

crowded or congested areas.

 Never carry more passengers than there are seats and

seat belts available.

• In addition to the driver, only one (1) passenger
should ride in the vehicle.

 Always wear the seat belt when operating or riding in

this vehicle.

• Do not operate unless the operator and passen­ger are properly positioned in their respective
seat and seat belt appropriately fastened with
only one person per seat belt.

• All passengers, including the operator, should be
able to sit with their back against the seat and a
firm grasp on the steering wheel or a designated
grab handle.

• Not using the seat belt could result in injury or
death during an accident or sudden change in
speed or direction.

 Never operate the vehicle with passengers in the cargo

bed or any position other than the designated seating
positions.

 Use care when approaching blind corners, shrubs,

trees, or other objects that may obscure your vision.

 Never attempt to drive over large obstacles such as

large rocks or fallen trees.

 Before operating in an unfamiliar area:

• Check for hidden obstacles or hazards.

• Reduce the vehicle speed.

• Use existing trails and avoid hazardous areas

such as steep, rocky slopes or swamps.

 Drive slowly and carefully when unsure or unprepared

for the surface.

Operating a Damaged Vehicle

 Operating a vehicle that has become damaged in some

way can result in an accident.

 An authorized Hustler® Dealer must inspect this vehi-

cle after any type of accident to make certain the vehi­cle is in an approved operating condition. All damaged
parts must be repaired or replaced.

Using a Ramp

 Exercise extreme caution when loading and unloading

this vehicle onto a truck or trailer with a ramp.

 Use only a single, full width ramp; do not use individual

ramps for each side of the unit. Having a full width
ramp provides a surface for the vehicle’s wheels to
contact if the vehicle starts to slide backwards. It also
reduces the risk of a wheel going off and the vehicle
tipping over.

 Do not exceed a 15 degree angle between the ramp

and the ground or between the ramp and the trailer or
truck.

 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. Drive slowly!

When operating on a slope be sure to choose the appropriate
traction control selection for the best traction.

 The Hustler® MDV™ is capable of operating horizon-

tally (traverse) on moderately steep slopes. When
operating horizontally on slopes, be aware of any con­ditions that may cause the vehicle tires to lose trac­tion resulting in a possible loss of control. An operator
should not operate on a slope until he is thoroughly
familiar with the vehicle.

Do not operate on slopes greater than 15 degrees.

 The OPS may reduce the chance of injury or death from

rollover. The seat belt must be fastened while operating
the vehicle. Failure to use a seat belt with OPS may result
in serious injury in the event of a roll over.

 Use extreme caution when operating on slopes.

• Practice on smaller slopes before attempting to
operate on larger slopes. Never operate this vehi­cle on slopes that are too steep for your abilities.

• The vehicle is more stable when it is driven
straight up or down a slope.

• Keep the front wheels straight when going over
the crest of a slope or when going over rough ter­rain.

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

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

• Turn slowly.

• Turn on the most level part of the slope.

606653 2-3 REV A

• If the vehicle begins to tip turn the front wheels
downhill and proceed to drive slowly down the
slope, if possible.

• When driving on soft terrain, it may be necessary
to turn the front wheels slightly uphill to keep the
vehicle traveling in a straight line.

 Watch for holes, ruts, bumps, rocks or other hidden

objects. Uneven terrain could overturn the vehicle. Tall
grass can hide obstacles.

 Remove obstacles such as rocks, tree limbs, etc.

 Keep all movement on slopes slow and gradual. Do not

make sudden changes in speed or direction.

 Avoid starting and stopping on a slope. If tires lose

traction, or if vehicle starts to tip, turn the front wheels
downhill and proceed to drive slowly down the slope.

 Avoid parking on a slope. If it is not possible to park on

a flat, level surface then, park the vehicle horizontally
across the slope, and engage the park brake.

• If you must park on a slope chock the wheels.

 Keep 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. This will reduce the risk of the
vehicle suddenly rolling over causing serious injury or
death.

 To avoid tipping backwards:

• Always back up steep slopes or out of boggy or
muddy ditches.

• Do not become overconfident in the vehicle’s
ability to climb slopes when the traction control
switch is in any position other than the normal
operating position.

 Do not operate on wet terrain. Slippery conditions

reduce traction which could cause sliding and loss of
control.

 Do not tow on slopes. The weight of the towed equip-

ment may cause loss of traction and loss of control.

 Reduce the cargo load and slow down when operating

on a slope or over rough terrain. Do not dump the
cargo bed while on a slope.

 Operate the cargo bed dump only with the vehicle sta-

tionary on level ground and the parking brake engaged.

 Make sure the vehicle is on a firm, level surface and

the parking brake is engaged before or tilting the cargo
bed.

 Pay attention to the size, weight, and placement of

attachments as they will affect vehicle stability.

 Never make sudden starts, stops, turns, or reversals of

direction, especially when maneuvering on slopes.
Rapid movement of the steering wheel could result in
a reaction of the vehicle that can cause serious injury.

 If vehicle loses power or stops when going up a hill:

• Engage the park brake to stabilize the vehicle.

• Keep the front wheels straight and slowly disen-

gage the park brake.

• Slowly, back straight down the slope using the
service brakes to control your speed.

• Do not allow the front wheels to turn sideways.

 Never start or stop suddenly when going up or down a

slope. This action may result in a reaction of the vehi­cle that can cause serious physical injury.

 It is strongly recommended that the operator drive the

vehicle off of the slope slowly, using extreme caution,
if any sign of loss of traction is detected. Wait until the
condition that caused the problem is resolved before
attempting to operate on the slope again.

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

• Wet terrain

• Depressions in the ground; i.e. holes, ruts, wash-

outs

• Mounds of dirt

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

• Grass type, density, and height

• Extremely dry conditions of grass

• Tire pressure

• Weight in cargo box

Any attachments mounted to the vehicle, cargo load,
and load placement will also affect the way it handles
on a slope. Be aware that each attachment’s charac­teristics vary.

Another consideration for safe slope operation 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:

• Water; i.e. lake, river

• Cliffs, retaining walls

• Roads, highways

• Buildings

• Rocks

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

Children

Tragic accidents can occur if the operator is not alert to the
presence of children. Children may be attracted to the vehicle
and related activity. Never assume that children will remain
where you last saw them.

REV A 2-4 606653

 Never leave the vehicle unattended with the ignition

key in the switch, especially with children present.

 Children or bystanders may be injured if they attempt

to move or to operate the vehicle while it is unat­tended. Always engage the park brake, place the gear
select lever in the neutral position, stop the engine,
and remove the ignition key when leaving the opera­tor’s seat.

 Be alert, stop the vehicle, and turn the vehicle off if

children enter the area.

 Before and while backing, look behind and down for

small children.

 Never carry children under the age of sixteen. They

may fall off and be seriously injured or interfere with
safe vehicle operation. The three point seat belt may
not provide adequate protection for anyone under the
age of sixteen.

 Children who have been given rides in the past may

suddenly appear in the vehicle area for another ride
and be run over or backed over by the vehicle.

 Never allow children under the age of sixteen to oper-

ate the vehicle.

 Use care when approaching blind corners, shrubs,

trees, the end of a fence or other objects that may
obscure vision.

Pulling or Hauling Loads

 Hauling cargo can alter vehicle handling and may

cause loss of control or brake instability, which can
result in serious injury or death.

 Drive slowly when towing. The vehicle should never

exceed a speed that allows for safe operating control
and adequate braking distance.

 Drive slowly. Allow a greater distance for braking.

 Pull only from the trailer hitch. Attaching to any other

point increases the risk of serious personal injury or
death.

 Only tow on level ground with the Gear Select Lever in

the LOW RANGE position.

 Do not stand between the vehicle and trailer unless the

park brake is engaged.

 Never allow riders on the towed equipment.

 Drive slowly when the cargo bed is loaded and do not

overload. Avoid sudden starts or stops, load could shift.

 Never exceed the approved load capacity.

 Always load the cargo bed with the load as far forward

and as low as possible.

 Cargo bed loads can shift during vehicle braking which

can affect vehicle stability. Make certain load is evenly
balanced and secured properly to prevent shifting.

 Do not load above height of cargo bed. Load could

shift forward injuring the driver or passenger.

 Make certain the load’s center-of-gravity is as low as

possible and avoid any load that is top-heavy.

 Make certain none of the load extends outside the

cargo bed. If this is unavoidable use extreme caution.
Stability and maneuverability may be adversely
affected, which could result in loss of control, property
damage, or personal injury.

 Heavy loads can cause braking and control problems.

Use extreme caution when applying brakes with a
loaded vehicle. Avoid terrain or situations that may
require backing downhill.

 Reduce the amount or weight of cargo and slow down

when operating on rough or hilly terrain.

 Operate the cargo bed dump only with the vehicle sta-

tionary on level ground and the parking brake engaged.

Do not dump the cargo bed while the vehicle is moving.

 Avoid crushing! Be careful not to put any part of your

body, such as hands or arms, between the bed and
vehicle.

 Do not place fingers or hands between the tailgate and

the cargo bed when closing; fingers or hands may be
pinched or severely injured.

Raising and Lowering the Cargo Bed

 Make sure the vehicle is on a firm, level surface and

the parking brake is engaged before tilting the cargo
bed.

 Do not put any part of body between cargo bed and

vehicle. To prevent injury, use only the handgrips pro­vided.

 Do not put any part of body between cargo bed and the

ground.

 Always lower the cargo bed to the transport position

before driving. If the vehicle is driven while the cargo
bed is raised the payload may cause the vehicle to tip.

Inclement Weather Conditions

 Never operate the vehicle when there is a risk for light-

ning.

 Never drive faster than the limit of visibility. Slow

down near the crest of a hill until there is a clear view
of the other side.

 Allow for additional stopping distance.

 Do not apply heavy braking force or accelerate when

skidding to prevent loss of control.

 Maintain low speeds on areas covered with clay, mud,

ice or snow to prevent uncontrolled skidding. Ensure
that the traction control switch is placed in the posi­tion appropriate for the conditions.

 If conditions are such that the vehicle may slide or

skid during operation then:

• Reduce vehicle speed.

• Do not suddenly apply the brakes or accelerate to

prevent loss of control.

606653 2-5 REV A

• Use the traction control selection and gear selec­tion for maximum traction and control.

 Before driving through water:

• Never cross any body of water where the depth is
unknown. Never operate the vehicle in water that
is deeper than the middle of the tire.

• Choose a course within the waterway where both
banks have a gradual incline.

• Check for rocks, holes or other obstacles that
may cause the vehicle to overturn, become stuck
or submerged.

 Operating around a frozen body of water:

• Never drive the vehicle onto a frozen body of
water. Severe injury or death can result if the
vehicle and/or operator and passenger falls
through the ice.

Service Precautions

 Unless specifically required, DO NOT have the engine

running when servicing or making adjustments to the
vehicle.

• Park the vehicle on level ground.

• Engage the park brake.

• Place the gear select lever in the neutral position.

• Stop the engine.

• Remove the ignition key.

• Chock the wheels.

• Disconnect the negative battery cable.

• 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, operate
the engine in a well ventilated area only. Loss of
consciousness or death can occur in a short
period of time.

• Read and observe all safety warnings in this man­ual.

 Always wear adequate eye protection when:

• servicing the battery.

• removing accumulated debris.

• servicing the coolant system.

 Remove all cargo and excess weight from the vehicle

before placing it on jack stands or raising the vehicle.

 Never work under the vehicle unless it is safely sup-

ported with jack stands.

• Make certain vehicle is secure when it is raised
and placed on the jack stands.

• The jack stands should not allow the vehicle 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 (907 kg) per jack stand to block the
unit up.

• Use in pairs only.

• Follow the instructions supplied with the jack

stands.

 Do not touch hot parts of the vehicle.

 Keep nuts and bolts tight, and keep equipment in good

working condition.

 Make certain that all mechanical parts such as the

speed control are adjusted properly. Replace any worn
or damaged parts. Refer to General Service Manual

123604.

 Use original Hustler

®

replacement parts, or parts that
are equivalent in overall performance, that are avail­able from your local Hustler

®

Dealer.

• The vehicle may not comply with the appropriate

safety standards if aftermarket parts, accesso­ries, or attachments are used.

Battery Service Precautions

 Battery posts, terminals, and related accessories con-

tain lead and lead compounds, chemicals known to the
State of California to cause cancer and reproductive
harm. Wash hands after handling.

 Charge batteries in a well-ventilated open area, away

from sparks and flames. Refer to the battery charger’s
manufacturer’s instructions for detailed information.
Unplug charger before connecting or disconnecting from
battery. Wear protective clothing and use insulated tools.

 If the battery is frozen, do not jump start the vehicle.

 Avoid skin and clothing contact with battery acid.

• 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 a 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
explosion if exposed to flame. Always disconnect
the negative (black) battery cable(s) before dis­connecting the positive (red) cable(s). Always
connect the positive (red) battery cable(s) before
connecting the negative (black) cable(s).

• Do not overfill the battery.

• Electrolyte may overflow and damage paint, wir-

ing or structure. When cleaning the battery, use

REV A 2-6 606653

soap and water. Be careful not to get soap and
water into the battery. Clean the battery termi­nals with a solution of four parts water and one
part baking soda when they become corroded.

 Shorts caused by battery terminals or metal tools

touching metal components can cause sparks. Sparks
can cause a battery gas explosion which will result in
personal injury.

• Prevent the battery terminals from touching any
metal parts when removing or installing the bat­tery.

• Do not allow metal tools to short between the
battery terminals and metal parts.

 Incorrect battery cable routing could cause damage to

the vehicle 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(s) before disconnecting the positive (red)
cable(s).

• Always connect the positive (red) battery cable(s)
before connecting the negative (black) cable(s).

Cooling System Precautions

 Always wear eye protection and gloves when servicing

the cooling system.

 Do not remove the radiator cap while the coolant is

hot.

• Allow coolant to cool then, slowly turn radiator
cap to the first stop to let the excess pressure
escape. Finish removing the cap.

• When re-tightening the radiator cap make sure it
is securely in place.

 If the coolant overheats:

• Park the vehicle on a level surface, place the gear
select lever in the NEUTRAL position, and engage
the park brake.

• Allow the engine to idle for several minutes. Do
not shut the engine off.

• The driver and passenger should step away from

the vehicle and maintain a safe distance from the
vehicle until the coolant has cooled off and
steam is no longer coming from the radiator.

• After the coolant has cooled, determine the
cause of the overheating and fix the problem. If
the cause cannot be determined, contact an
authorized Hustler

 If anti-freeze (coolant) is swallowed, seek immediate

medical assistance.

• Call the local Poison Control Center or the local
emergency number for immediate assistance.

• Do not make a person throw up unless told to do
so by poison control or a health care profes­sional.

®

Dealer for assistance.

 If anti-freeze (coolant) comes in contact with the skin

or clothing, wash it off immediately.

 Do not mix different types of anti-freeze. This can pro-

duce a harmful chemical reaction.

 Anti-freeze is extremely flammable and explosive

under certain conditions.

• Keep fire and children away from anti-freeze.

 Disposing of anti-freeze (coolant):

• When draining the cooling system, drain the cool­ant into a container. Do not allow the coolant to
drain onto the ground.

• Do not pour used coolant down a drain or into
any water source.

• Also, observe local environmental protection reg­ulations when disposing of anti-freeze (coolant).

Fuel Handling Precautions

 To avoid personal injury or property damage, use

extreme care when handling diesel fuel. Diesel fuel is
extremely flammable and the vapors are explosive.

• A fire or explosion from diesel fuel can burn you

and others and can damage property.

 Observe the usual diesel fuel handling precautions:

• Do not smoke while refueling. Extinguish all ciga­rettes, cigars, pipes and other sources of ignition.

• Do not remove fuel cap or fill tank with engine run­ning or while engine is hot. Clean up any diesel fuel

spills.

• If diesel fuel is spilled, do not attempt to start the
engine but move the vehicle away from the area
of spillage and avoid creating any source of igni­tion until diesel fuel vapors have dissipated.

• Keep diesel fuel away from open flame or spark
and store vehicle away from open flame or spark
or pilot light such as on a water heater or appli­ances.

• Refuel outdoors. Never refuel or drain the diesel
fuel from the vehicle indoors.

• Never attempt to start the engine when there is a
strong odor of diesel fuel fumes present. Locate
and correct the cause.

• Store diesel fuel in an approved container and
keep it out of the reach of children. Never buy
more than a 30-day supply of diesel fuel.

• Do not fill fuel containers inside a vehicle or on a
truck or trailer bed with interior carpets or plastic
truck bed liners. Always place diesel fuel contain­ers on the ground away from your vehicle before
filling.

•Do not carry fuel or other flammable liquids in the
vehicle or cargo bed.

• When practical, remove the vehicle from the truck
or trailer and refuel the vehicle with its wheels on

606653 2-7 REV A

the ground. If this is not possible, then refuel

WARNING

such on the truck or trailer using a portable con­tainer and not a fuel dispenser 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 fueling is com­plete. Do not use a nozzle lock-open device.

• Never use diesel fuel for cleaning parts.

• Read and observe safety precautions elsewhere

in this manual.

 Diesel fuel is harmful or fatal if swallowed.

 Avoid prolonged breathing of vapors.

• Long-term exposure to vapors can cause serious
injury and illness.

 Keep diesel fuel away from eyes and skin.

• Keep face away from nozzle and fuel tank or fuel
container opening.

• If diesel fuel is spilled on clothing, change cloth­ing immediately.

Safety and Instructions Decals

It is the owner’s responsibility to make certain that the
operators and mechanics read and understand all decals
before operating this vehicle.

Specific warning decals are located on the vehicle
near the immediate areas of potential hazards. Do
not remove or obliterate these decals. Replace
them if they become non-readable.

The following illustrations show the warning decals that
are located on the vehicle. A brief explanation is shown to
help the operator understand the decal’s meaning.

• Read Operator’s Manual and Safety Warning Decals before

attempting to operate this machine.

The decals are designed to give the operator and mechanic
brief daily operational and service information. Use these
decals as an extension of this manual. Do not remove or
obliterate the decals. Replace unreadable or missing decals.

• Do not smoke while refueling.

• Do not remove the fuel tank cap or fill tank with engine running or

while the engine is hot.

• Allow engine to cool before storing machine inside a building.

• Store away from open flame or spark if there is fuel in tank.

• Clean up any diesel fuel spills.

• Do not refuel while in enclosed trailer or other enclosed areas.

REV A 2-8 606653

DANGER: Battery Hazards!

• Avoid skin contact with battery acid

DANGER: Battery Hazards!

• 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. Use soda mixed in water to clean corrosion off the termi­nals.

• 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.

DANGER: Battery Hazards!

• 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 explosion if

exposed to flame. Always remove the negative ground first and replace it last.

Part Number 202200

WARNING:

Read operator’s man­ual and decals before
attempting to operate
this machine.

Clean flammable material from
vehicle. Prevent fires by keeping
the engine compartment,
exhaust area, battery, fuel line,
fuel tank and operator’s area
clean of accumulated trash and
other debris. Always clean up
spilled fuel and oil.

WAR NIN G:

Hot surface!

WAR NIN G:

Fire!

Avoid skin contact
with hot surface.

WARNING:

Slipping or Falling!

WARNING:

Pinch! Crushing body!

• Do not put any part of body

between cargo bed and vehi­cle.

• Do not put any part of body

between cargo bed and the
ground.

• Do not stand on

the vehicle.

Part Number 202206

606653 2-9 REV A

Part Number 202201

TO AVOID PERSONAL INJURY OR DEATH:

•

Read and understand the operator’s manual before operation.

•

Before allowing other people to use the vehicle, have them read the operator’s manual.

•

Do not operate the vehicle under the influence of drugs or alcohol.

•

This vehicle is for off road use only. Never operate on a public road as such operation could be a violation of the

law and may be hazardous.

•

Never allow anyone to operate the vehicle who is under the age of 16 or who has not obtained a valid

state-issued motor vehicle driver’s license.

•

Wear safety gear, including helmet and eye protection, as appropriate

•

Do not operate unless the operator and all passengers are properly positioned in their respective seat and seat
belts appropriately fastened with only one passenger per seat belt. Not using the seat belt could result in injury
or death during an accident or sudden change in speed or direction.

•

Never allow additional passengers and never carry small children on the lap of the operator or passenger.

•

Never operate the vehicle with passengers in the cargo bed or any position other than the designated
seating positions.

•

Before starting the engine, make sure that everyone is at a safe distance from the vehicle.

•

Slow down for turns, slopes, rough terrain or when hauling cargo. These conditions could increase the risk of
tipping or roll-over and warrant caution by the operator. For stable operation do not operate on slopes greater
than 15 degrees.

•

Never stick arms or legs outside of the vehicle Occupant Protective Structure. Arms and legs could become
trapped or crushed if caught while driving or during an accident.

•

Before getting off the vehicle, apply the parking brake, stop the engine and remove the key.

•

Keep covers in place and stay away from moving parts.

202201

Part Number 202202

REV A 2-10 606653

Part Number 202204

202204

CARGO BED LOAD CAPACITY: MAX 1,200 lb.

• Spread load evenly and secure to prevent movement.

• DO NOT load above height of bed. Load could shift forward injuring driver or passenger.

• Drive slowly. Avoid sudden starts or stops, load could shift.

• Driving with the bed raised is hazardous. Always lower and latch bed before driving.

NO RIDERS IN CARGO BED

or anywhere other than seats.

Avoid injury from explosion or fire.

DO NOT

carry fuel or other

flammable liquids.

TO AVOID PERSONAL INJURY OR DEATH:

1. Do not remove Occupant Protective
Systems for any application.

2. Do not modify or repair an Occupant
Protective System because welding,
grinding, drilling or cutting any portion
may weaken the structure.

Reduced clearance between cargo bed
and vehicle can cause hand injury.

202215

Part Number 202215

606653 2-11 REV A

Part Number 202216

TO AVOID PERSONAL INJURY:
Do not open coolant cap while
coolant is hot.

TO AVOID PERSONAL INJURY:

1. Use brake fluid(DOT-3) only. Other oil types will
ruin synthetic resin or rubber installed in brake
system components, and cause brake failure.

2. If brake fluid is spilled, wash o with water
immediately. Brake fluid quickly ruins synthetic
resin or rubber hoses.

202216

F

A

B

C

D

E

G

H

A. WARNING: Hot surface!
B. Avoid skin contact with hot surface.
C. WARNING: Rotating fan blade!
D. Keep hands, feet, and clothing clear of this area.

Keep shields or covers in place while vehicle is in operation.
E. Coolant overflow tank
F. Coolant (radiator) cap
G. Brake fluid reservoir
H. Radiator fans

REV A 2-12 606653

Part Number 202208

D

F

E

C

H

G

A

B

B

C

A

A. Read Operator’s Manual before attempting to

operate this machine.

B. Wear ear protection, eye protection and safety shoes

when operating this equipment.

C. Head light switch
D. Horn switch
E. Traction control switch

Ignition Switch Symbols

F. Front axle (not engaged)/Rear axle (unlocked

differential)

G. Front axle (unlocked differential)/Rear axle

(unlocked differential)

H. Front axle (unlocked differential)/Rear axle (locked

differential) — Operate in LOW range

A. OFF

606653 2-13 REV A

B. PREHEAT/RUN
C. START

REV A 2-14 606653

1. Hold this sheet of paper in front of you. Make sure that Line A is horizontal.

2. Align Line B with a vertical surface such as pole, tree or building.

3. Fold the paper along the slope guide lines (C, D or E).

4. Align the closest slope guide line with the ground slope. This will give you a close estimation of the ground slope.

Slope Guide Lines

Line B

D (10o)

C (5o)

E (15o)

Line A

Slope Guide

Use this diagram when determining the degree of slope to be mowed.

606653 2-15 REV A

REV A 2-16 606653

OPERATION

A

F

D

H

B

C

E

I

G

C

A

B

D

Safe Operating Practices

Refer to the Safety Precautions section of this manual for

operational and personal safety information.

Instrument Panel

A. Coolant light
B. Speedometer
C. Oil light
D. Glo–plug light
E. Seat belt light

F. Alternator light
G. Park brake light
H. Hour meter
I. Fuel gauge

position and stays lit until the engine is running and
the voltage exceeds the minimum operation require­ments.

If light comes on during operation, shut the engine off,
locate and correct the problem. If light remains on
while the engine is running, it indicates that the
battery is being discharged.

G. Park brake light (Figure 3-1) — this light comes on when

the ignition switch key is turned to the “PRE­HEAT/RUN” position and the park brake lever is in the
engaged position. It will remain lit until the park brake
lever is moved to the disengaged position.

H. Hour meter (Figure 3-1) — registers in 1/10 hour incre-

ments. It is connected to the ignition switch. It records
the accumulative time while the ignition key is
switched to the “PREHEAT/RUN” position.

I. Fuel gauge (Figure 3-1) — indicates the amount of fuel

in the fuel tank when the ignition switch key is in the
“PREHEAT/RUN” position.

Controls

Figure 3-1

A. Coolant light (Figure 3-1) — this light will come on when

the engine coolant temperature exceeds intended level
during operation. If light comes on, shut down the
machine as soon as reasonable. Never risk continued
operation when light remains on; high temperatures
can severely damage the engine.

B. Speedometer (Figure 3-1) — indicates the ground speed

the vehicle is traveling.

C. Oil light (Figure 3-1) — this light comes on when the

A. Ignition switch
B. Head light switch

C. Horn switch
D. Traction control switch

ignition switch is placed in the “PREHEAT/RUN” posi­tion and stays lit until the engine is running and a
specified oil pressure is developed. If the light comes
on during operation, shut the engine off immediately
and locate and correct the problem.

D. Glo–plug light (Figure 3-1) — this light comes on when

the ignition switch is turned to the “PREHEAT/RUN”
position and held. It shows that power is going to the
glo-plugs. Wait for the light to go off before starting
the engine.

E. Seat belt light (Figure 3-1) — this light comes on when

the ignition switch key is initially turned to “PRE­HEAT/RUN” position. It will remain for 30 seconds to
remind the operator and passenger to use the seat
belts for personal protection.

F. Alternator light (Figure 3-1) — this light comes on when

the ignition switch is placed in the “PREHEAT/RUN”

A. Ignition switch (Figure 3-2) — a three position switch:

“OFF”, “PREHEAT/RUN”, and “START”. With the key
inserted, rotate it clockwise to the “PREHEAT/RUN”
position. After pre-heat has occurred and glo-plug light
goes off, depress the brake pedal, rotate the key to the
“START” position; release the key when the engine
starts, and the switch will automatically return to the
“RUN” position. Do not hold in the “START” position
more than 10 seconds.

B. Head light switch (Figure 3-2) — turns the vehicle’s

headlights on and off when the ignition switch key is in
the “RUN” position.

C. Horn switch (Figure 3-2) — activates the vehicle’s horn

when the ignition switch key is in the “RUN” position
and the switch is depressed.

Figure 3-2

606653 3-1 REV A

D. Traction control switch (Figure 3-2 & Figure 3-3) —

2

3

1

E

F

G

1. Front axle (not engaged)/Rear axle (unlocked differential)

2. Front axle (unlocked differential)/Rear axle (unlocked dif-

ferential)

3. Front axle (unlocked differential)/Rear axle (locked differ-

ential)

Figure 3-3

This vehicle is equipped with a traction control system
that provides three different traction modes.

• Front axle (not engaged) / Rear axle (unlocked
differential)

• Front axle (unlocked differential) / Rear axle
(unlocked differential)

• Front axle (unlocked differential) / Rear axle
(locked differential)

Refer to the Traction Control Switch Operation section
for detailed information.

E. Park brake lever and release button

E. Park brake lever (Figure 3-4) — engages/disengages

the vehicle’s park brake. The park brake is engaged

Figure 3-4

when the lever is in the down position. To disengage
the park brake, pull against the park brake handle
slightly to reduce tension on the brake latch, depress

the brake lever release button on the end of the lever
and rotate the lever up to the fully released position.

IMPORTANT: If the vehicle is operated with the park
brake lever engaged, brake damage will occur.

F. Steering wheel G. Tilt steering lever

Figure 3-5

F. Steering wheel (Figure 3-5) — controls the direction of

the vehicle’s travel.

G. Tilt steering lever (Figure 3-5) — unlocks the steering

column to allow the up and down positioning of the
steering wheel for operator preference. Pull the lever
up to release the steering wheel. Push the lever down
to lock the steering wheel in position.

The tilt steering lever also has a notching system that
allows the lever to be placed in multiple locked
positions for operator preference.

To set the tilt position:

• Start with the tilt steering lever in the full down

(locked) position. Figure 3-6

• Rotate the tilt steering lever to the released posi­tion to release the steering wheel.

• Move the steering wheel to the preferred position
and lock it in place by rotating the lever to the full
down position. Figure 3-6

To set the lock position:

• Pull out on the tilt steering lever in the direction

shown (Figure 3-6) and rotate it up. It will rotate
without unlocking the steering wheel.

• Release the lever in the desired location and posi­tion it until it seats itself in one of the notches.
This is now the new lock position for the tilt
steering lever. Figure 3-6

• Now, you can rotate the lever up to unlock the
steering wheel and rotate the lever down and it

REV A 3-2 606653

will select the new location as the locked posi-

1

3

2

P

u

l

l

l

e

v

e

r

t

h

i

s

d

i

r

e

c

t

i

o

n

H

I

J

A

tion.

1. Released position

2. Initial lock position (full down)

3. Adjusted lock positions

H. Gear select lever (Figure 3-7) — moving this lever shifts

the vehicle’s transmission through its four different
settings.

Refer to the Gear Select Lever Operation section for
detailed information

I. Brake pedal J. Speed control pedal

Figure 3-6

I. Brake pedal (Figure 3-8) — press down on this pedal to

Figure 3-8

slow or stop the vehicle.

J. Speed control pedal (Figure 3-8) — this pedal controls

the travel speed of the vehicle. Pushing down on it
increases the vehicle’s speed.

Accessories

H. Gear select lever

Figure 3-7

A. 12V Electric outlet

Figure 3-9

A. 12V Electric outlet (Figure 3-9) — allows the use of a

12V external device such as an auxiliary light or cell
phone charger.

This outlet is powered when the key switch is in the
"PREHEAT/RUN" position.

606653 3-3 REV A

• When an accessory is not being used disconnect

B

WARNING

WARNING

it from the outlet.

• Do not connect any device that draws more than
120 watts.

• Do not use as a cigarette lighter.

• Do not use when wet.

• Close the cap when the outlet is not being used.

B. Glove box cover and latch knob

Figure 3-10

B. Glove box (Figure 3-10) — to gain access to the glove

box, rotate the latch knob clockwise and open the
cover. To close the cover, push up on it and rotate the
latch knob counterclockwise to latch it.

Pre-Operation Check

• parking brake

• instrument panel lights and gauges

• head lights

• Occupant Protective Systems

• joint boots

• tire pressure

• fuel level

• danger and warning decals

Operation

General Operation Information

To operate the vehicle without accident or injury, the opera­tor should understand how the vehicle will react in any situa­tion, especially during conditions that could cause the
vehicle to overturn. Vehicle speed, cargo load, towed vehicle,
and environmental conditions play a major part in most vehi­cle overturn incidents.

This operator’s manual sets forth some of the risks, but the
list is not all inclusive. It is the operator's responsibility to be
alert for any equipment or environmental condition that
could compromise low risk operation.

For more detailed safety information refer to the Safety Pre­cautions section of this manual.

This vehicle is designed to carry up to two people, includ­ing the driver, at one time. All occupants must ride in the des­ignated seating positions and use the seat belts properly.

Only individuals age 16 and older are authorized to ride or
operate this vehicle.

Inspect and verify that the vehicle is in proper
operating condition before operation. Failure to do
so increases the risk of an accident.

Always perform the pre-operation check before oper­ating to make sure the vehicle is in proper operating
condition.

To avoid serious injury, check and service the vehi­cle:

• on a level surface with engine off.

• with the parking brake engaged.

• with attachments lowered to the ground.

Before daily operation it is a good idea to get in the habit of
checking the following items to prevent mechanical/electri­cal issues.

– Do a walk around inspection of the vehicle.

– Check the following:

• engine oil level

• coolant level

• brake pedal

Engine Starting

Start the engine by following these steps. If you encounter

®

difficulty, contact your Hustler

1. Before starting the engine the operator should be
seated in the driver position. Secure the door properly
(if equipped).

2. Move the park brake lever to the down position (park
brake is engaged).

3. Place the gear select lever in the “NEUTRAL” position.

4. Insert the key in the ignition switch and rotate it to the

“PRE-HEAT/RUN” position. It will take approximately
two seconds before the glo-plug light will come on.
Wait for the glo-plug light to go off.

Preheating is necessary only when the temperature is
cool or cold. This operation is not necessary when
restarting a warm engine. Standard preheating times
for various temperatures are shown in the chart below.

Failure to follow these recommendations can lead to
premature failure of the starter motor and the fuel shut­off solenoid.

IMPORTANT: Ether, or other starting fluids, must never

be used as a starting aid with this engine. Warranty

Dealer.

REV A 3-4 606653

will be denied when engine damage results from such

WARNING

use.

Ambient Temperature

Above 60°F (15°C) No need

Above 10°F (–12°C) One cycle

Below -10°F (–23°C) Two cycles

Preheating time

Ordinary heat type

5. Depress the brake pedal and rotate the ignition switch

key fully clockwise to engage the starting motor.
Release the key when the engine starts.

IMPORTANT: The engine starter should not be oper­ated for periods longer than 10 seconds at a time. An
interval of at least two minutes should be allowed
between such cranking periods to protect the starter
from overheating and burn-out.

NOTE: All accessories can be used when the ignition
switch key is in the PRE-HEAT/RUN” position and the
engine is not running. Do not leave the key in this posi­tion as the battery will be depleted. Rotate the key back
to the “OFF” position when done.

6. As soon as the engine begins to run, check to make
certain the oil pressure light and the alternator warn­ing light are off. If not, stop engine immediately and
check for the cause.

Engine Warm Up

During engine warm up:

• Make sure the park brake is engaged.

• Make sure the gear select lever is in the

“NEUTRAL” position.

Allow the engine to idle a few minutes before applying a
load. This allows engine oil to circulate properly throughout
the engine.

IMPORTANT: This may prevent engine problems such as

seizure, parts breakage, and pre-mature wear.

Stopping the Engine

Use the following procedure to shut the engine off.

1. Throttle the engine back to low idle.

2. Place the gear select lever in the “NEUTRAL” position.

3. Engage the park brake lever to set the park brake.

4. Allow the engine to slow to low idle and then rotate the

ignition key counter-clockwise to the “OFF” position.
Remove the key from the switch before leaving the
vehicle.

Driving the Vehicle

1. Perform the Pre-Operation Check as outlined previ-

ously.

2. Adjust and fasten the seat belt.

3. Adjust the steering wheel for operator comfort, if nec-

essary.

4. Start the engine and allow it to warm up per the Start­ing the Engine and Engine Warm Up sections.

5. Turn the head lights on, if necessary.

6. Push down on the brake pedal to engage the brakes.

7. Disengage the park brake.

8. Release the brake pedal and apply pressure to the

speed control pedal.

When driving in reverse remember to:

• Turn around, look down, and behind you before pro-

ceeding.

• Depress the speed control pedal gradually.

• To stop, when traveling in reverse, remove your foot

from the speed control pedal and gradually apply pres­sure to the brake pedal. Do not engage the brake pedal
suddenly or with too much pressure.

IMPORTANT: The vehicle does not have engine braking.

When the throttle pedal is released and the engine speed
slows to idle, the vehicle’s transmission disengages. Use the
brakes to control the vehicle’s speed.

Steering the Vehicle

To allow for easier steering and control the Hustler® MDV™

is equipped with power steering.

The power steering is active when the key is in the “PRE­HEAT/RUN” position. The steering will function like a vehicle
without power steering when the ignition is turned off.

The power steering system makes steering control easier.
Exercise caution when traveling at high speeds.

When the vehicle is stationary avoid turning the steering
wheels as this will shorten tire life.

Stopping the Vehicle

To stop the vehicle:

1. Release pressure from the speed control pedal.

2. Apply gradual pressure to the brake pedal.

3. After the vehicle has come to a complete stop, move

the gear select lever to the “NEUTRAL” position, and
engage the park brake.

Parking the Vehicle

1. Stop the vehicle on a level surface. Avoid parking on a

slope. If parking on a slope is unavoidable, block or
chock the vehicle’s wheels to prevent rolling.

2. Set the gear select lever in the “NEUTRAL” position.

3. Engage the park brake.

4. Lower attachment to the ground (if equipped).

5. Shut the engine off.

6. Remove the key from the ignition switch.

606653 3-5 REV A

Slope Operation

For more slope safety information refer to the Slope Operation

section located in the Safety Precautions section of this manual.

Climbing Slopes

Do not attempt to climb slopes until you are thoroughly
familiar with the vehicle’s controls and handling on flat
ground.

Do not operate on slopes greater than 15 degrees.

The vehicle is more stable when it is driven straight up or
down a slope. Keep the front wheels straight when going
over the crest of a slope.

Never start or stop suddenly when going up a slope. Do not
accelerate suddenly as the front wheels may come off the
ground.

Do not drive up a slope where you cannot see what is in
front of you. If you cannot see over the crest of the hill, slow
down until you can.

If the slope is steep and/or if the ground is loose, it may be
necessary to shift the transmission to a different setting to
provide greater traction. Refer to the Traction Control Switch
Operation section for detailed information.

If vehicle loses power or stops when going up a hill:

• Engage the park brake to stabilize the vehicle.

• Keep the front wheels straight and slowly disen-

gage the park brake.

• Slowly back straight down the slope using the
brakes to control your speed.

• Do not allow the front wheels to turn sideways.

Descending Slopes

Before going down a slope, slow down or stop at the top.
Visually select the straightest and safest path and then pro­ceed down the slope. Driving straight down the hill will pro­vide the safest route as driving at an angle could result in the
vehicle flipping over. Proceed slowly and cautiously and
apply the brakes as necessary.

Never stop suddenly when going down a slope. This action
may result in a reaction of the vehicle that can cause serious
physical injury.

Exercise caution if the ground surface is loose as the tires
may lose traction. Braking effectiveness will be reduced in
this situation.

IMPORTANT: The vehicle does not have engine braking.

When the throttle pedal is released and the engine speed
slows to idle, the vehicle’s transmission disengages and
releases the engine to prevent it from stalling. Use the brakes
to control the vehicle’s speed.

Traversing Slopes

This vehicle is capable of operating horizontally (traverse)
on moderately steep slopes. When operating horizontally on
slopes, be aware of any conditions that may cause the vehi­cle tires to lose traction resulting in a possible loss of con­trol.

When driving on soft terrain, it may be necessary to turn
the front wheels slightly uphill to keep the vehicle traveling in
a straight line.

Watch for holes, ruts, bumps, rocks or other hidden
objects. Uneven terrain could overturn the vehicle. Tall grass
can hide obstacles.

If the vehicle begins to tip turn the front wheels downhill
and proceed to drive slowly down the slope, if possible.

Sliding and Skidding

Special care should be taken when operating on slippery or
loose surfaces. Slippery conditions reduce traction which
could cause sliding and loss of control.

A sliding vehicle creates a hazard when it suddenly starts
to slide or skid. Be careful when driving the vehicle if the con­ditions are right to cause slippery conditions. During a slide
or skid the vehicle’s tires may suddenly regain traction which
could result in further loss of control.

If you find yourself in a skid turn the front wheels in the
direction of the skid. Do not brake suddenly or forcefully as
this could further exasperate the situation.

Clay, mud, ice, or snow surfaces are particularly hazardous
to vehicle operation. Use caution and slow down when oper­ating in these conditions. Use the traction control selection
and gear selection for maximum traction and control.

Driving through Water

Avoid driving through water whenever possible. Never
cross any body of water where the depth is unknown. Never
operate the vehicle in water that is deeper than the center of
the tire.

IMPORTANT: Major vehicle damage can occur if the vehi­cle has been immersed in water that is higher than the center
of the tires. Take the vehicle promptly to an authorized Hus-

®

tler

Dealer for proper service. Do not start the engine!

Before driving through water:

• Check for rocks, holes or other obstacles that may
cause the vehicle to overturn, become stuck or sub­merged.

• Determine water depths and current.

• Choose a path where both banks have a gradual

incline and are not too slippery.

The wheel bearings may require maintenance or replace-

ment after prolonged water exposure.

After the brakes have been exposed to water apply enough

brake pressure to dry out the brake linings. Brakes that have

REV A 3-6 606653

been exposed to water for extended periods may wear out

WARNING

WARNING

WARNING

A

B

C

D

E

quicker. Check the brakes more frequently if this occurs.

Operating the vehicle in rapidly flowing water, such
as a river or stream, can cause the tires to lose trac­tion and allow it to be swept away in the current.

Wet brakes reduce braking capabilities which could
lead to an accident and personal injury.

Driving over Obstacles

When operating over obstacles:

• Always check for hidden obstacles or hazards before
proceeding. Be constantly alert for hazards such as
logs, rocks, and low hanging branches.

• Reduce the vehicle speed and exercise caution espe­cially when operating on unfamiliar terrain.

• Never attempt to drive over large obstacles such as
large rocks or fallen trees.

Gear Select Lever Operation

A. Gear select lever
B. LOW range
C. HIGH range

D. NEUTRAL
E. REVERSE

Driving over any obstacle can cause loss of control
or tipping.

Monitor during Operation

While driving, occasionally check to see if any of the fol-

lowing instrument panel lights are lit.

• Coolant light

• Oil light

• Alternator light

• Park brake light

If any of these lights come on during operation, perform

the following steps immediately:

1. Safely bring the vehicle to a complete stop.

2. Set the gear select lever in the “NEUTRAL” position.

3. Engage the park brake.

4. Shut the engine off.

5. Locate and fix the source of the problem.

6. If the problem can not be resolved, contact your local

Hustler

®

Dealer for assistance.

Figure 3-11

The gear select lever can only be shifted when:

• the vehicle is completely stopped.

• the speed control pedal is in the “NEUTRAL” (fully

released) position.

IMPORTANT: Bring the vehicle to a complete stop before
changing gears to avoid damage to the transmission and/or
the shifting linkage.

The type of job being performed will determine the proper

gear and engine speed.

Move the gear select lever to the “NEUTRAL” position and

engage the park brakes before leaving the vehicle.

If the gear select lever becomes hard to engage, do not

force it. To get it to move:

• engage the park brakes,

• slightly depress the speed control pedal and then

release it,

• then, move the gear select lever.

If the gear select lever becomes hard to disengage, do not

force it. To get it to move:

• fully engage (push down on) the brake pedal,

• then, move the gear select lever.

606653 3-7 REV A

Traction Control Switch Operation

2

3

1

A

1. Front axle (not engaged)/Rear axle (unlocked differential)

2. Front axle (unlocked differential)/Rear axle (unlocked dif-

ferential)

3. Front axle (unlocked differential)/Rear axle (locked differ­ential)

Figure 3-12

This vehicle is equipped with a traction control system that
provides three different traction modes. Select the mode that
works best for the conditions or terrain that the vehicle is
encountering at the time.

Engaging one of the front wheels in slippery or low traction
conditions helps improve traction. Move the traction control
switch to either the “2” or “3” position when more traction is
desired.

The traction control switch should only be switched from
one position to another when the vehicle is stopped.

1. Front axle (not engaged)/Rear axle (unlocked differen-

tial) – When the traction control switch is in this posi-

tion the rear drive wheels will operate independently of
each other. This position provides the least surface
damage, tire wear, and best turning in good traction
conditions.

During normal driving conditions use this position.

This position can be used when the gear select lever is
in either the LOW range or HIGH range position.

2. Front axle (unlocked differential) / Rear axle (unlocked

differential) – When the traction control switch is in

this position, one of the rear wheels and one of the
front wheels are engaged and providing the power. In
this position the rear axle propels the vehicle just like
in Position 1, but, if a rear wheel slips a front wheel will
engage.

Use this position when more traction is required.

This position can be used when the gear select lever is
in either the LOW range or HIGH range position.

3. Front axle (unlocked differential) / Rear axle (locked dif-

ferential) – When the traction control switch is in this

position, both rear wheels turn at the same speed. If
the rear wheels slip a front wheel will engage.

Use this position when more traction is required.

Only use this position when the gear select lever is in
the LOW range position. Using this position will
increase tire wear and reduce the turning radius.

Transporting or Towing the Hustler

®

MDV™

When transporting the Hustler® MDV™ using a truck or
trailer make sure to follow the guidelines listed below.
Always comply with Federal and/or Local regulations for
proper securement.

1. Drive the vehicle forward onto the transporting vehicle.

2. Engage the park brake and set the gear select lever in

the “NEUTRAL” position.

3. Chock or block the front and rear tires.

4. Secure the vehicle using the appropriate tie down

straps or chains. Only secure it at the locations shown
in Figure 3-13 and Figure 3-14.

A. Tie down strap

Figure 3-13

When towing the Hustler

®

MDV™ follow the guidelines

listed below:

1. Disengage the park brake.

2. The gear select lever must be placed in the “NEUTRAL”

position.

3. Only use the front hitch to tow the vehicle.

4. Never tow faster than 6 mph (10km/h).

REV A 3-8 606653

A. Tie down strap

A

WARNING

WARNING

A

A

WARNING

Figure 3-14

Towing Other Vehicles

Rear Trailer Hitch (if equipped)

To avoid serious injury:

• Always tow a load slowly enough to maintain

control and avoid tipping.

• To provide adequate braking ability and trac­tion, do not tow a load if the vehicle cargo
bed is loaded or attachment is installed.

• Attach a trailer to the trailer hitch only.

• Only tow on level ground in low range.

A. Rear trailer hitch

Figure 3-15

rear trailer hitch load information.

Front Trailer Hitch (if equipped)

ity in confined areas such as a barn.

front trailer hitch load information.

OPS (Occupant Protective System)

pant Protective System) as standard equipment. Figure 3-17

over. Do not remove any part of the OPS for any reason
except for replacement due to damage.

606653 3-9 REV A

• Do not attach chains or ropes to the OPS for
pulling purposes.

• When towing use safety chains.

Refer to the Maximum Cargo Load section of this manual for

Use the front trailer hitch for greater control maneuverabil-

Refer to the Maximum Cargo Load section of this manual for

The Hustler® MDV™ comes equipped with an OPS (Occu-

An OPS may reduce the chance of injury or death from roll-

A. Front trailer hitch

Figure 3-16

An OPS, which includes a seat belt, is effective in reducing
injuries during unit overturn accidents. Overturning the unit
without an OPS can result in serious injury or death.

• Do not attach chains or ropes to the occu­pant protective structure for pulling pur­poses.

• Always pull from the appropriate locations
listed elsewhere in this manual.

• Do not lift vehicle using the occupant protec­tive structure.

• In case of accident the occupant protective
structure should be replaced.

Always fasten the seat belt during operation.

Inspect the area prior to operation for proper overhead

clearance (tree limbs, guy wires, doorways, etc).

Do not contact any overhead object with the occupant pro-

tective structure.

A. Occupant Protective Structure

A

A

B

WARNING

Figure 3-17

Seat Belt Maintenance

The seat belts used on the Hustler® MDV™ are a three point

emergency locking retractable type. Figure 3-18

Inspect the seat belt system (all seat, seat belt parts, and
seat platform) daily prior to operation for signs of any dam­age. Replace any parts with signs of:

• cuts,

• fraying,

• extreme or unusual wear,

• significant discoloration due to UV exposure,

• dirt or stiffness,

• abrasion to the seat belt webbing,

• damage to the buckle, latch plate or hardware,

• any other problem.

Use soap and water to clean the seat belt. Do not use car­bon tetrachloride, naphtha, or other chemical cleaning
agents, as these will weaken the webbing. For the same rea­son, do not bleach or dye the webbing. Replace the seat belt
if worn or damaged.

Possible Damage to Occupant Protective Structure

If the unit has rolled over or the occupant protective struc­ture has been in some other type of accident (such as hitting
an overhead object during transport), replace the occupant
protective structure to retain the best protection.

Following an accident, check the occupant protective
structure, the operator’s seat, the seat belt, seat belt mount­ings and seat platform for possible damage. Before operat­ing the vehicle, replace all damaged parts.

OPS.

IMPORTANT: Do not attempt to weld or straighten the

A. Seat belt B. Seat belt latch

Figure 3-18

The occupant protective structure’s protective
capability may be impaired by structural damage,
overturn or alteration. Do not remove or alter any

of the occupant protective structure parts. Do not
attempt to weld, drill, grind, cut or straighten the
occupant protective structure. Failure to adhere to
these instructions could result in severe injury or
death.

If the occupant protective structure is replaced,
make sure to use the new hardware supplied with
the replacement OPS and apply the recommended
torque values to the attaching bolts.

OPS Inspection

Inspect the OPS after the first 20 hours of operation. Fol­lowing the initial inspection, check the OPS after every 500
hours of operation or every six months, whichever comes
first.

REV A 3-10 606653

1. Check the torque of the occupant protective structure

A

B

C

B

B

A

mounting bolts. Tighten the bolts to the correct
torques as shown below. Figure 3-19

2. Inspect the mounting parts for the seat belt. Tighten
the bolts to the correct torque as shown below.
Replace any parts that show wear or damage.
Figure 3-19 & Figure 3-20

3. Inspect the mounting parts for the seat belt latch.
Tighten the bolts to the correct torque as shown
below. Replace any parts that show wear or damage.
Figure 3-21

Torque values:

ft-lbs N•m

Occupant protective structure 

mounting hardware . . . . . . . . . . . . 73. . . . . . . . . 99

Seat belt mounting hardware . . . . . . 48. . . . . . . . . 65

Seat belt buckle hardware . . . . . . 204 in-lbs . . . . . 23

A. Occupant protective structure post
B. Occupant protective structure mounting hardware
C. Seat belt mounting hardware

Figure 3-19

A. Seat belt
B. Seat belt mounting hardware

Figure 3-20

606653 3-11 REV A

A. Seat belt latch

A

B

A

B. Seat belt latch mounting hardware

Figure 3-21

REV A 3-12 606653

Cargo Bed

C

T

R

T

R

C

C

A

B

The Hustler® MDV™ has been designed to carry or tow within specific load limits. Always read and understand the load warnings

shown in this manual and on the warning decals.

Maximum Cargo Load

NOTES:

A. Cargo Bed Capacity

B. Payload Capacity = cargo bed capacity + operator + passenger + options + accessories weight
C. Permissible Cargo Load = payload capacity – (operator + passenger + options + accessories) weight
D. Rolling weight: Trailer weight + Trailer load

IMPORTANT: Never carry loads exceeding cargo bed capacity and the payload capacity.

CARGO WEIGHT LIMITATIONS

Payload capacity 1650 lbs. (750 kg)

1200 lbs. (550 kg)

Cargo bed capacity (C)

Rear trailer hitch

Front trailer hitch

Cargo Bed Tailgate

Open the cargo bed tailgate by pulling inward on the latch
handles simultaneously. These latches are spring loaded and
will return to the latched position when released. Figure 3-22

Lower the tailgate to unload the cargo bed. Figure 3-23

Close the tailgate by lifting it into the closed position. The
latches will automatically engage when the tailgate is fully
closed.

Do not move the vehicle with the tailgate in the open posi­tion.

Max. rolling weight (R): 1650 lbs. (750 kg)
Max. tongue weight (T): 500 lbs. (225 kg)

Max. rolling weight (R): 500 lbs. (225 kg)
Max. tongue weight (T): 150 lbs. (70 kg)

A. Cargo bed
B. Tailgate

C. Latches

Figure 3-22

606653 3-13 REV A

Tailgate in open position

A

WARNING

A

A. Tailgate

Figure 3-23

Operating the Cargo Bed

Spread load evenly and secure to prevent movement.

Do not load above height of cargo bed. Load could
shift forward injuring the driver or passenger.

Drive slowly. Avoid sudden starts or stops, load
could shift.

Driving with the cargo bed out of the transport posi­tion can be hazardous. Always return the bed to the
transport position before driving.

Dump the cargo bed on level ground only.

There is a latch lever located on both sides of the cargo

bed. Only one will need to be used to unlatch the cargo bed.

When the cargo bed is loaded it may be necessary for two

people to tilt the cargo bed to the full raised position.

Make sure the cargo bed is latched and secured before
moving the vehicle. Never drive the vehicle with the cargo
bed in the tilted/raised position.

A. Latch lever

Figure 3-24

Tilt the cargo bed by lifting up on the latch lever to unlatch
the bed. Then, continue lifting, using the lever. until the cargo
bed is in the full raised position. Figure 3-24

REV A 3-14 606653

MAINTENANCE & ADJUSTMENTS

A

B

A

WARNING

Safe Servicing Practices

Refer to the Safety Precautions section of this manual for

more service safety information.

Service Introduction

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 order the correct Parts
Manual and General Service Manual for your unit. Refer to
the Product Literature section of this manual for more infor­mation.

Remain alert for unusual noises, which could signal 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, dirt and debris,
especially in the engine and drive train areas; minute dust
particles are abrasive to close-tolerance engine and drive
train assemblies.

Some repairs require the assistance of a trained service
mechanic and should not be attempted by unskilled person­nel. Consult your Hustler

®

Dealer when assistance is needed.

Hood

To open the hood, turn the latch clockwise, hold it, and
raise the hood. The latch is spring loaded so it will return to
the latch position automatically. The hood latch can be
locked using the keys supplied with the vehicle. Figure 4-1 &
Figure 4-2

To close the hood, lower it slowly into position and latch it.

Hood shown in the open position.

A. Hood

Figure 4-2

Seat

The seat is not adjustable.

To allow access under the seat it will be necessary to raise

the seat bottom.

To raise the seat bottom, lift the back of the seat bottom
and pull up. The seat will pivot to the open position.
Figure 4-2

Do not raise the seat bottom if the engine is run­ning unless it is necessary for servicing purposes.

606653 4-1 REV A

A. Hood B. Latch

Figure 4-1

Seat bottom shown in the open position.

A

WARNING

WARNING

For engine torque values, refer to the engine owner’s man-

ual.

Tires

• Do not attempt to replace a tire on a rim.

Only qualified persons with the proper equip­ment should mount tires on a rim.

• Support the vehicle using jack stands before
removing a wheel

• Always maintain the correct tire pressure. Do
not over inflate the tires. Tires should only be
inflated to the pressures shown in this man­ual.

Check tire pressure every day and inflate as necessary.

The recommended pressures are:

Front tires . . . . . . . . . . . . . . . . . . . . . . 18 psi (124 KPa)

Rear tires. . . . . . . . . . . . . . . . . . . . . . . 18 psi (124 KPa)

Lubrication

A. Seat bottom

Figure 4-3

Torque Values

• Particular attention must be given to tighten-

ing the wheel lug nuts. Failure to correctly
torque these items may result in the loss of a
wheel, which can cause serious damage or
personal injury.

• Never operate the vehicle with loose wheel
(lug) nuts.

Torque values are given below:

ft-lbs N•m

Wheel (lug) nuts . . . . . . . . . . . . . . . . . 73 . . . . . . . . 99

Lug nuts 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 General Service Manual for
a standard torque chart. See Product Literature section for
ordering information.

Use a SAE multi-purpose grease when greasing the lubrica-

tion points shown in the Maintenance Locator Chart.

Electrical System

IMPORTANT: Refer to the Safety Precautions section of this

manual for battery servicing safety information.

The electrical system is a 12 volt, negative ground. The rec-

ommended battery size is:

BCI group 24F with a 720 or better cranking AMP
rating

A maintenance-free battery is recommended. Otherwise,
follow battery manufacturer’s maintenance, safety, storing
and charging specifications.

Access to the Battery Compartment

The battery compartment is located on the left side of the
vehicle.

To gain access to the battery, locate the battery compart­ment door, rotate the door latch counterclockwise, and open
the door. Figure 4-4 & Figure 4-5

Battery Charging

Occasionally, it may be necessary to charge the battery.
Follow the battery charger manufacturer’s warnings and
directions when connecting a charger to the battery and
charging the battery.

REV A 4-2 606653

A. Battery compartment door

A

B

A

WARNING

A

B

B

B. Latch

Figure 4-4

IMPORTANT: If a fuse blows, determine what caused the

fuse to blow and resolve the problem before operating the

vehicle. If the cause can not be determined, contact your

Hustler

®

Dealer for assistance.

There are two fuse blocks located on the vehicle:

• Master fuse box

• Circuit fuse box

Master Fuse Box

The master fuse box is located under the cargo bed on the
left side of the vehicle. Access to the fuse box is through the
battery compartment. Figure 4-6

To open the master fuse box, unhook the two clamps and
remove the fuse box cover.

IMPORTANT: Never leave the fuse box cover removed

from the fuse box when operating the vehicle.

Refer to Figure 4-7 for the layout and description of the
fuses.

A. Battery

Figure 4-5

Fuses

A. Fuse box cover B. Clamps

Figure 4-6

Circuit Fuse Box

Disconnect the negative battery cable from the
battery before opening the fuse box cover.

The Hustler® MDV™ electrical system incorporates fuses to
protect it from potential damage. A blown fuse indicates that
there is an overload or short in the electrical system.

IMPORTANT: Replace a blown fuse with the same type

and size fuse.

606653 4-3 REV A

The circuit fuse box is located under the front hood and

mounted on the firewall. Figure 4-8

Open the circuit fuse box by lifting the two yellow clips,

then squeezing the tabs on the fuse box cover. Figure 4-8

IMPORTANT: Never leave the fuse box cover removed

from the fuse box when operating the vehicle.

The following diagram (Figure 4-9) shows the layout and

description of the fuses.

Figure 4-7

A

C

B

REF.

FUSE SIZE

(AMPS)

DESCRIPTION

A 100 Main power circuit fuse (all vehicle except

glo plugs function)

B 100 Glo plugs (engine pre-heat)

C 150 Starter power / battery charging

NOTE: These are AMI style fuses.

A

B

B

C

6

5

4

3

2

1

9

8

7

10

REF.

FUSE SIZE

(AMPS)

DESCRIPTION

1 30 Power steering

2 20 Radiator fan

3 20 Radiator fan / temperature switch

4 20 Horn / headlight / front differential

5 20 Auxiliary power (dash)

6 20 Power point

7 10 Alternator exciter

8 10 Transmission speed sensor / rear differential

actuator

9 20 Auxiliary power (under the hood)

10 20 Spare fuse

11

12

NOTE: These are blade type fuses.
NOTE: Fuse block orientation may differ from one shown.

A. Fuse box cover
B. Yellow clips

In-line Fuse

electrical system. It is located next to the dash under the
front hood. Figure 4-8

and pre-heat module which are on during engine cranking.
Figure 4-8

REV A 4-4 606653

This vehicle has a 10 AMP in–line fuse integrated into the

This fuse protects the start interlock, fuel solenoid, gauges,

C. In–line fuse housing

Figure 4-8

Figure 4-9

Fuel and Evaporative Emissions Control System

IMPORTANT: Refer to the Safety Precautions section of this

manual for fuel handling safety information.

The fuel and evaporative emissions control system for this
vehicle is EPA compliant. Use only Hustler
replacement parts.

Your evaporative emission control system may include
parts such as:

• fuel tank

• fuel lines

®

approved

• fuel line fittings

WARNING

A

B

A

B

WARNING

• fuel cap

• filters

• vapor hoses

• clamps, control valves

• control solenoids

• electronic controls

• vacuum control diaphragms

• purge valves

• liquid/vapor separator

• other associated components

Modifying or Tampering with the evaporative emissions con-

trol system or the fuel system is prohibited. Federal law and

California State law prohibit the following acts or the causing
thereof:

1. The removal or rendering inoperative by any person
other than for purposes of maintenance, repair,
replacement, of any device or element of design incor­porated into any equipment for the purposes of emis­sions control prior to or after its sales or delivery to the
ultimate purchaser or while it is in use, or

2. The use of the equipment after such device or element
of design has been removed or rendered inoperative by
any person.

A. Fuel gauge B. Fuel level bars

Figure 4-10

NOTE: Refer to the Engine Owner’s Manual for additional

fuel specification requirements.

IMPORTANT: Thread the fuel cap onto the filler neck and

tighten.

Use of replacement parts not equivalent to the
original parts may result in system failure and
pose a safety hazard.

IMPORTANT: If the fuel tank is drained, air will enter the
fuel system, which will require priming the fuel system. To
prevent this, fill the fuel tank whenever the fuel gauge dis­plays at least two bars above empty. Figure 4-10

Filling the Fuel Tank

The fuel tank is located on the right side of the vehicle.

Figure 4-11

To fill the fuel tank:

IMPORTANT: To prevent spilling fuel, do not top off or
overfill the tank. When filling the tank the fuel should
not be any higher than 1".

• Park the vehicle on level ground before filling the fuel
tank.

• Clean the area around the fuel cap and wait for the
engine to cool before removing the cap. Remove the
fuel cap slowly. Figure 4-11

• This engine requires No. 2 diesel fuel for most operating
conditions.

A. Fuel tank B. Fuel cap

Figure 4-11

Engine Oil and Filter

Allow the engine to cool before changing the
engine oil. If the engine has been running, use cau­tion when changing the engine oil as it will be very
hot. You should wear the appropriate protective
gear to avoid being burned or exposed to engine
oil.

Check engine oil daily and after every 4 hours of operation.
Machine must be sitting level when checking oil. Refer to
engine manual and maintenance schedule for oil recommen­dation and capacities.

606653 4-5 REV A

Engine oil dipstick – accessed through the battery compart-

A

A

B

ment. Figure 4-12

Engine oil fill cap – located under the cargo bed.

Figure 4-13

Engine oil filter – located under the cargo bed. NOTE: This
is a remote filter and is not located directly on the engine.
Figure 4-13 & Figure 4-14

Change the engine oil and filter after the first 50 hours of
operation and every 100 hours after that. If vehicle is being
operated in extremely dirty conditions, then it is recom­mended oil be changed more frequently. IMPORTANT: After
the new oil and filter have been installed, clean up any oil which
may have spilled.

Draining the Engine Oil:

1. Park the vehicle on a level surface.

• Place the gear select lever in the “NEUTRAL” position.

• Engage the park brake lever to set the park brakes.

• Rotate the ignition key counter-clockwise to the “OFF”

position.

• Remove the key from the switch before leaving the
vehicle.

2. Unlatch and tilt the cargo bed to the full raised posi­tion to allow access to the engine.

3. Locate the oil drain plug on the engine oil pan.

4. Position a suitable oil drain container under the

machine below the oil drain.

5. Remove the engine oil drain plug. Allow 10 minutes for
the engine oil to adequately drain.

6. Remove the filter oil ring and re-install.

7. After the oil is drained, re-install the engine oil drain

plug and tighten.

8. Locate the engine oil fill cap on top of the engine and
add the proper oil.

9. After changing the oil, clean up any spilled oil.

IMPORTANT: All oil drips or spills must be cleaned off of

the engine and engine exhaust system before operating
the machine.

Engine Air Filter

Perform engine air filter maintenance per the Maintenance

Schedule shown elsewhere in this manual.

A specially designed dry filter is standard equipment on
these vehicles and supplies clean combustion air to the
engine. Figure 4-15

These vehicles are equipped with a safety filter. The filter
element slides over the safety filter. Figure 4-16

The safety element does not require servicing unless it
becomes contaminated with dirt or moisture.

A. Engine oil dipstick

Figure 4-12

A. Engine oil fill cap B. Engine oil filter

Figure 4-13

Recommended Service Procedure

1. Open the evacuator valve, once a week or more fre-

quently if operating in dirty conditions, to clean out
large dust particles and dirt. Figure 4-15

2. Release clamps and remove element. Clean the air
cleaner canister with a damp cloth. Figure 4-15

3. Before installing a new element, inspect it by placing a
bright light inside and rotating 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.

4. Reinstall the dust cap. Make sure it seals all the way
around the air cleaner canister, then tighten the
clamps. Figure 4-15

5. Check all fittings and clamps periodically for tightness
and inspect hoses for holes or cracks.

REV A 4-6 606653

A

A

B

C

D

E

A. Safety filter

A

C

A

B

D

E

A. Engine oil filter

Figure 4-16

Figure 4-14

A. Air cleaner canister
B. Dust cap
C. Clamp

D. Evacuator
E. Air restriction indicator

A. Pre-cleaner
B. Air cleaner canister
C. Air in-take hose

Figure 4-17

D. Reset button
E. Air restriction indicator

Do not clean the element, but replace with a new element

Figure 4-15

6. Periodically check the intake hose for signs of

ingested dust. Locate and repair the source of
ingested dirt. Figure 4-17

7. Never operate the machine without an air filter
installed.

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.

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

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
damaged or “dusted” engine. It only takes a few grams of
ingested dirt over the normal service life of an engine to
cause a dusted engine.

606653 4-7 REV A

cleaning or servicing in any manner because the condition of
the filter after servicing is completely out of the filter manufac­turer’s 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 is simple. The

media in the filter must be porous to allow air to pass

WARNING

B

A

C

D

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 too

clogged to allow air to pass.

The operating conditions will determine the frequency of

air filter element changing.

When the engine is cold there should be a small amount of

coolant on the bottom of the overflow tank. If coolant level is
low add the appropriate solution.

Do not remove the radiator cap while the coolant is
hot.

Allow coolant to cool then, slowly turn radiator cap
to the first stop to let the excess pressure escape.
Finish removing the cap.

When re-tightening the radiator cap make sure it is
securely in place.

Air Restriction Indicator

These units have an air restriction indicator installed in the

air cleaner. Figure 4-15 & Figure 4-17

Replace the element whenever the restriction indicator
reaches the change filter red line. Check the indicator daily
and replace element as needed or annually whichever occurs
first.

Reset the indicator by pushing in on the yellow button after
each element change. Figure 4-17

Engine Cooling System

IMPORTANT: Refer to the Safety Precautions section of this

manual for coolant safety information.

The engine coolant recovery system controls the engine
coolant level. This system consists of the overflow tank, radi­ator filler neck, radiator cap, and hose.

New vehicles or vehicles that have just had the coolant
system flushed may need to have a small amount of coolant
added after a short period of operation. This is due to the
system purging itself of trapped air. When this occurs add
coolant to the overflow tank until the proper coolant level is
attained.

Engine cooling is accomplished with circulated water and
Ethylene Glycol mixture. A 50-50 mixture is recommended for
all season operation. This mixture provides freeze protection
to -32 degrees F (-35 degrees C). Should temperatures fall
below this level, additional Ethylene Glycol must be added to
the mixture.

The radiator is located under the hood and cargo tray at
the front of the vehicle. Figure 4-18

The radiator cap and overflow tank are located on the right
front of the firewall under the hood. Figure 4-18

Visually inspect the system daily prior to operating the
vehicle. With the vehicle parked on a level surface check the
coolant level in the overflow tank.

When adding coolant, pre-mix the solution before adding it
to the overflow tank. It is not necessary to remove the radia­tor cap for adding small amounts of coolant to the system.

Do not overfill. Figure 4-18

A. Radiator cap

B. Overflow tank

C. Cargo tray
D. Full “COLD” bracket

Figure 4-18

There may be a leak in the system if it is necessary to add
coolant frequently of if the overflow tank runs completely
dry. If this occurs have the coolant system inspected by an
authorized Hustler

®

Dealer.

Radiator Coolant Level

Follow these steps when adding coolant to the radiator
after the cooling system has been drained.

1. Park the vehicle, engage the park brake, and shut the
engine off. Remove the key from the ignition switch.

2. Raise the hood.

3. Allow coolant to cool then, slowly turn radiator cap to the

first stop to let the excess pressure escape. Finish
removing the cap.

4. Check the coolant level in the radiator hose.

5. Slowly add coolant as necessary.

6. Re-install the radiator cap. Make sure to use a Hustler

approved pressure cap when replacing a cap.

®

REV A 4-8 606653

Radiator and Cooling Fans

WARNING

WARNING

WARNING

Always check and clean the radiator fins at the intervals

outlined in the Maintenance Schedule.

Unauthorized attachments or accessories that have been
installed in front of the radiator or behind the cooling fans
may obstruct or deflect the air flow through the radiator. This
can cause overheating and engine damage.

NOTE: Using a high pressure washer to clean the vehicle
could damage radiator fins which can impair the radiator’s
effectiveness.

Radiator Overheating

If the coolant in the radiator overheats follow these steps:

1. Park the vehicle outside in an open area.

2. Place the gear select lever in the “NEUTRAL” position.

3. Engage the park brake.

4. Allow the engine to idle for 5 minutes.

5. Do not open the hood or access the radiator area until

the coolant has cooled down. Make sure there is no
steam coming from the radiator area before proceed­ing.

6. After the coolant has cooled, consult the Troubleshoot­ing section of this manual to assist in determining the

cause of the overheating.

7. Fix the problem before continuing operation. If the
problem can not be found, contact your Hustler
Dealer. Do not operate the vehicle until the issue is
resolved.

®

• burns caused by slipping.

If the CVT belt fails, loss of traction control will
occur especially when operating on a slope. If you

lose traction control while operating the vehicle:

• Steer the vehicle to a flat surface, if possible,

while using the brakes to control speed.

• Stop the vehicle, engage the park brake,
place the gear select lever in the NEUTRAL
position, shut the engine off, and remove the
key from the ignition switch,

• Inspect the vehicle and involve your Hustler
Dealer to resolve the problem before continu­ing to operate.

Brakes

Checking the Brake Fluid Level

Routinely inspect the brake system. Inspect the brake fluid

level per the Maintenance Schedule section.

Use DOT3 brake fluid only in the Hustler

tem.

Other types of brake fluid or oil will ruin synthetic
resin or rubber brake components which can
cause brake failure.

®

MDV™ brake sys-

®

General Engine Maintenance

Detailed instructions and recommendations for break-in
and regular maintenance are specified in the Engine Owner’s
Manual. Please refer to this manual for engine servicing,
lubricating oil levels with quality and viscosity recommenda­tions, bolt torques, etc. The engine warranty is backed by the
engine manufacturer. Special attention should be paid to
applicable data which will not be duplicated here.

CVT Belt

Inspect the CVT belt and drive pulley grooves annually for
wear or damage. Replace the belt after every 500 hours of
use or every 3 years, whichever comes first. Replace the
drive pulleys if any sign of wear or damage occurs.

Replace the belt if it shows signs of:

• severe cuts

• tears

• separation

• weather checking

• cracking

Never operate the vehicle if the brake fluid is below
the “MIN” mark in the reservoir.

• Avoid contamination of the brake fluid. Thor-

oughly clean area around the filler cap before
removing. Do not open the brake fluid reser­voir cap unless absolutely necessary.

• Use extreme care when filling the reservoir. If
brake fluid is spilled wash it off with water
immediately.

To check the brake fluid level:

1. Stop the vehicle on a level surface.

2. Set the gear select lever in the “NEUTRAL” position.

3. Engage the park brake.

4. Shut the engine off.

5. Remove the key from the ignition switch.

6. Open the hood.

7. Locate the brake fluid reservoir. It is on the left side in

front of the dash.

8. Check the brake fluid level in the reservoir. It should be
above the “MIN” marks.

606653 4-9 REV A

9. If it is below the “MIN” mark, add approved brake fluid

B

C

A

D

B

C

A

E

WARNING

until it is between the “MIN” mark and the top of the
reservoir. Figure 4-15.

10. Apply the brakes for a few seconds and check for fluid
leakage around the fittings.

D. Park brake lever and release button

Figure 4-20

A. Reservoir

C. Top of reservoir

B. “MIN” mark

Figure 4-19

Checking the Park Brake

To check the park brake:

1. Pull the park brake handle down to engage the park

brakes. Figure 4-20

2. Turn the ignition switch to the “PREHEAT/RUN” posi­tion. The park brake light on the instrument panel
should light up. Figure 4-21

3. Disengage the park brakes by pulling against the park
brake handle slightly to reduce tension on the brake
latch, then, depress the brake lever release button on
the end of the lever and rotate the lever up to the fully
released position. The park brake light on the instru­ment panel should go off. Figure 4-20 & Figure 4-21

4. If the park brake light does not come on and go off as
above, contact your Hustler
the vehicle.

®

Dealer before operating

E. Park brake light

Figure 4-21

Lifting Points

Never work under the vehicle unless it is safely
supported with jack stands.

• Make certain the vehicle is secure when it is
raised and placed on the jack stands.

• The jack stands should not allow the vehicle
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 (907 kg) per
jack stand to block the unit up.

• Use in pairs only.

• Follow the instructions supplied with the

jack stands.

To avoid possible vehicle damage lift and block the vehicle

up only at the locations shown in Figure 4-22 & Figure 4-23.

REV A 4-10 606653

IMPORTANT: When lifting or blocking the front of the vehi-

A A

B

B

B

A

A

cle make sure the jack or jack stands are placed directly
under the vehicle’s frame.

A. Jack stands B. Lift point

Figure 4-23

A. Jack stands B. Lift point

Figure 4-22

606653 4-11 REV A

MAINTENANCE SCHEDULE

NOTES:

1. Initial engine oil change is after 50 hours of operation. Thereafter, change oil after every 100 hours operation. Change more often under dusty or
dirty conditions and during hot weather periods.

2. Torque lug nuts initially and after first 2 hours of operation.

3. Change engine oil filter per the engine manufacturer’s recommendations. Refer to engine owner’s manual for recommendations and other main-

tenance items.

4. Service more often under dusty or dirty conditions. Use caution when servicing to prevent dust contamination in the engine. Do not clean filter
element. Replace with a new air cleaner element.

5. Check fuel system for any cracks or leaks including, but not limited to, fuel line hoses, fuel valve, vent line hoses, vent valve, vapor valve, and
grommets. Replace as needed.

6. Inspect Occupant Protection System hardware after the first 20 hours of operation and then after every 500 hours of operation or yearly which­ever comes first.

7. Refer to engine owner’s manual for engine service information.

8. More often under dusty or dirty conditions and during hot weather.

9. Inspect muffler for damage and make sure clamp is tight.

10. Check more often if operating under extreme conditions or if experiencing belt slippage.

HOUR METER READINGS AFTER

ITEMS

50 100 150 200 250 300 350 400 450 500 550 600 650 700

Engine start system Check Prior to each use

Visually inspect unit for loose hardware
and/or damaged parts

Fuel level Check Prior to each use

Engine compartment Clean Prior to each use

Air cleaner service indicator Check Prior to each use 8

Muffler

Visually inspect tires Check Prior to each use or every 4 hours

Radiator Clean Prior to each use or every 4 hours 8

Engine air cleaner element Replace As needed 4, 7

Battery connections Check

Tire pressure with a gauge Check

Engine exterior Clean

Lug nut torque Check

Engine oil and filter Change

Grease Apply

Battery condition Check

Alternator belt Adjust

Toe-in Adjust

Spark arrestor Clean

Fuel filter

Fuel line

Parking brake Check

Brake pedal Check

Radiator hose, pipe & clamp

Tire wear Check

Transmission fluid Change

Front differential oil Change

Check Prior to each use

Check Prior to each use

Replace





















Check

Replace

Check

Replace









Check

Replace













700

HOURS

every 500 hrs

every 50 hrs

every 50 hrs

every 50 hrs

every 50 hrs

every 100 hrs

every 100 hrs

every 100 hrs

every 100 hrs

every 100 hrs

every 100 hrs

every 100 hrs

every 500 hrs

every 100 hrs

every 2 years

every 100 hrs

every 200 hrs

every 200 hrs

every 2 years

every 200 hrs

every 400 hrs

every 400 hrs

NOTES:

9

7

2

1, 3

5

5

REV A 4-12 606653

ITEMS

50 100 150 200 250 300 350 400 450 500 550 600 650 700

Rear differential oil Change

Occupant Protection System Check

CVT belt

Engine valve clearance Adjust

Fuel injection nozzle injection pressure Check

Injection pump Check

Brake master cylinder (inner parts) Replace

Brake fluid Change

Rear brake cylinder seal Replace

Front brake seal Replace

Cooling system Flush

Coolant Change

Fuel system Bleed Service as required 5

Fuses Replace Service as required

Light bulbs Replace Service as required

Check Annually

Change Every 500 hours or 3 years whichever comes first





700

HOURS

every 400 hrs

every 500 hrs

every 800 hrs

every 1500 hrs

every 3000 hrs

every 2 years

every 2 years

every 2 years

every 2 years

every 2 years

every 2 years

NOTES:

HOUR METER READINGS AFTER

6

10

606653 4-13 REV A

Maintenance Location Diagrams

VIEW A

1

VIEW UNDER THE SEAT BOTTOM

VIEW A

1. Drive Shaft U-joint - Front (grease point)

2. Drive Shaft U-joint - Rear (grease point)

3. Engine Oil Fill

4. Engine Oil Filter

5. Engine Oil Drain Plug

6. Brake Fluid Reservoir

7. Coolant Recovery Tank

8. Radiator Cap

9. Air Restriction Indicator

10. Engine Air Cleaner

11. Evacuator

12. Battery

13. Engine Oil Dipstick

14. Fuel Tank

15. Fuel Cap

16. Tires

REV A 4-14 606653

VIEW B

3

4

2

5

VIEW UNDER THE CARGO BED

VIEW B

1. Drive Shaft U-joint - Front (grease point)

2. Drive Shaft U-joint - Rear (grease point)

3. Engine Oil Fill

4. Engine Oil Filter

5. Engine Oil Drain Plug

6. Brake Fluid Reservoir

7. Coolant Recovery Tank

8. Radiator Cap

9. Air Restriction Indicator

10. Engine Air Cleaner

11. Evacuator

12. Battery

13. Engine Oil Dipstick

14. Fuel Tank

15. Fuel Cap

16. Tires

606653 4-15 REV A

8

7

6

10

11

12

13

9

16

16

15

14

VIEW UNDER THE HOOD

VIEW BEHIND THE BATTERY COMPARTMENT DOOR

1. Drive Shaft U-joint - Front (grease point)

2. Drive Shaft U-joint - Rear (grease point)

3. Engine Oil Fill

4. Engine Oil Filter

5. Engine Oil Drain Plug

6. Brake Fluid Reservoir

7. Coolant Recovery Tank

8. Radiator Cap

9. Air Restriction Indicator

10. Engine Air Cleaner

11. Evacuator

12. Battery

13. Engine Oil Dipstick

14. Fuel Tank

15. Fuel Cap

16. Tires

REV A 4-16 606653

Maintenance Record

Use this form to keep track of the maintenance performed.

Date: Maintenance/Service Performed:

Dealer:

Hour Meter Reading:

Date: Maintenance/Service Performed:

Dealer:

Hour Meter Reading:

Date: Maintenance/Service Performed:

Dealer:

Date: Maintenance/Service Performed:

Dealer:

Hour Meter Reading:

Date: Maintenance/Service Performed:

Dealer:

Hour Meter Reading:

Date: Maintenance/Service Performed:

Dealer:

Hour Meter Reading:

Date: Maintenance/Service Performed:

Dealer:

Hour Meter Reading:

Date: Maintenance/Service Performed:

Dealer:

Hour Meter Reading:

Hour Meter Reading:

Date: Maintenance/Service Performed:

Dealer:

Hour Meter Reading:

Date: Maintenance/Service Performed:

Dealer:

Hour Meter Reading:

606653 4-17 REV A

REV A 4-18 606653

TROUBLESHOOTING

The majority of operating problems that occur with a system can be traced to improper adjustments or delayed service. A
consistently applied preventative maintenance program, as outlined in the Maintenance section of this manual, will prevent many
problems. The following chart is designed to help you locate a problem by suggesting probable causes and the recommended
solutions.

SYMPTOMS PROBABLE CAUSES

Brake switch not activated

Starting motor does not
crank

The engine will not start,
starts hard or fails to
keep running

Engine:
Continuous misfiring or
engine runs unevenly or
erratically

Loss of engine power

Engine overheating:
Temperature light glows

Frequent refilling of radia­tor required

Coolant appears rusty

Weak or dead battery Recharge or replace

Electrical connections are
corroded or loose

For additional causes See engine manual

No fuel or line plugged Fill tank or replace line (See

Incorrect fuel in the fuel
system

Dirt in the fuel filter Replace the fuel filter

Dirt, water or stale fuel in
the fuel system

In winter, oil viscosity
increases, and engine revo­lution is slow.

Numerous See engine manual

Numerous See engine manual

Restrictions in air cleaner Service air cleaner

For additional causes See engine manual

Leaks in system Replace/tighten coolant

Coolant level low Add coolant

Radiator core is dirty or
clogged

Thermostat sticking or
inoperative

Temperature light malfunc­tion

SUGGESTED

REMEDIES

Depress brake pedal

Pressure switch not work­ing

Check the electrical connec­tions

Fuel System section for
more details)

Drain the tank and replace
the fuel with the proper type

Contact your dealer

Use oils of different viscosi­ties, depending on ambient
temperatures.

hoses and connections

Clean radiator core

See engine manual

Contact your dealer

SYMPTOMS PROBABLE CAUSES

Low oil level Add oil

Low engine oil pressure

High oil consumption Numerous Contact your dealer

Abnormal vibration

Vehicle operation is not
smooth

Vehicle does not move
when the engine is run­ning

Brakes not working cor­rectly

Brake noise Numerous Contact your dealer

Oil diluted or too light Change oil and check for

Failed oil pump Contact your dealer

Engine mounting bolts are
loose

Numerous Contact your dealer

CVT belt slipping Replace

Park brake is engage Disengage the park brake

Gear select lever is in the
NEUTRAL position

Brake fluid level is low Add brake fluid

Air in the brake system Contact your dealer

Brake pads are worn Contact your dealer

SUGGESTED

REMEDIES

source of contamination

Tighten the engine mount­ing bolts

Move the gear select lever
to a different position

606653 5-1 REV A

REV A 5-2 606653

STORAGE

WARNING

WARNING

WARNING

When storing the vehicle for an extended period of time,
the vehicle, engine, and battery should have the following
items serviced before storage.

General Preparation for Storage

1. Remove all grass, dirt, and trash from the vehicle.

IMPORTANT: Wash the vehicle with a mild detergent

and water. Do not pressure wash the vehicle. Avoid
excessive use of water, especially near the instrument
panel, control panel, and engine.

2. Touch up all scrapes with touch-up paint.

3. Replace air filter element.

4. Check thoroughly for any worn or damaged parts that

need replacing and order them from your Hustler
Dealer.

5. Thoroughly lubricate the vehicle, according to the
Maintenance section.

6. Unload the cargo bed and latch in the transport posi­tion.

7. Block the vehicle up so the weight is off the tires.
Check tire pressure and inflate to the proper operating
pressure.

NOTE: Do not deflate tires.

8. Perform separate engine and battery preparation as

listed below.

9. Store the vehicle in a clean, dry place. Cover the vehi­cle after the muffler and engine have cooled.

NOTE: If the vehicle must be stored outdoors, cover it
with a waterproof tarpaulin. Keep the tires out of direct
sunlight and extreme heat.

®

Preparation of Engine for Storage

If the vehicle is to be unused for an extended period of time
(30 days or more), the engine will need to be prepared for
storage. Use the following procedures before storing the
vehicle.

IMPORTANT: Refer to the Fuel Handling Precautions sec-
tion of this manual for important safety information before
proceeding.

1. Add a Hustler
fuel system. Refer to the instructions shown on the
fuel stabilizer bottle for proper usage. For detailed
information consult with your Hustler

®

approved diesel fuel stabilizer to the

®

Dealer.

2. Fill the fuel tank with fresh fuel.

To prevent carbon monoxide poisoning, operate the
engine in a well ventilated area only.

3. Run the engine for a minimum of 10 minutes.

Allow the engine to cool before changing the
engine oil. Use caution when changing the engine
oil as it will be very hot. You should wear the
appropriate protective gear to avoid being burned
or exposed to engine oil.

4. Drain the oil from the crankcase while the engine is
still warm.

5. Replace the engine oil filter.

6. Refill with fresh oil of the proper viscosity.

7. Check the oil filler cap and fuel cap to make certain

they are securely in place.

8. Refer to the engine owner’s manual for more informa­tion.

Preparation of Battery for Storage

When the vehicle is to be unused for long periods, it is best
to disconnect the battery and remove it from the vehicle. At
this time perform the following battery maintenance:

1. Remove the battery.

2. Clean the battery, terminals, and cable connectors.

3. Charge the battery, if necessary.

4. Store the battery in a cool, dry place (do not expose to

freezing temperatures).

5. Always keep the battery fully charged. This is espe­cially important to prevent battery damage when the
temperature is below 32°F (0°C).

Preparation Following Storage

606653 6-1 REV A

To prevent carbon monoxide poisoning, operate
the engine in a well ventilated area only.

Before starting the vehicle after storage, the following ser-

vice is required:

1. Clean vehicle, removing trash and dirt accumulation.

WARNING

2. Check engine oil, brake fluid, transmission fluid, and
coolant levels.

3. Install fully charged battery and attach the battery
cables.

4. Fill fuel tank with fresh fuel.

5. With the park brakes engaged and the gear select lever

in the NEUTRAL position, run the engine at half speed
for 5 minutes. Make sure all warning lights and gauges
are working properly and the readings are normal.

6. Stop the engine and check for oil leaks, loose fittings
and so forth.

Always check that fresh oil and coolant have been
added to vehicle. If oil and coolant are drained and
not replaced, engine damage will result.

7. Tighten any bolts that have loosened and make sure
all hardware is in place.

8. Install all safety shields and review safety precautions
listed in this manual.

9. Check and inflate tires to 18 psi (124 KPa).

10. Check the brakes for proper adjustment. Adjust the

brakes as necessary. Refer to General Service Manual
123604 for more information.

11. Refer to the engine owner’s manual for more informa­tion.

REV A 6-2 606653

PRODUCT LITERATURE

If you would like to view or print a copy of the product manuals (Operator’s Manual, Parts Manual, or General Service Manual) for

these vehicles go online to www.hustlerturf.com.

Contact your local Hustler

®

Dealer if you require another engine manual.

606653 6-3 REV A

REV A 6-4 606653

INDEX

PAGE PAGE

Access to the Battery Compartment ...........................4-2

Accessories ...............................................................3-3

Air Restriction Indicator .............................................4-8

Attachments and Accessories ....................................2-1

Battery Charging ........................................................4-2

Battery Service Precautions .......................................2-6

Brakes .......................................................................4-9

Cargo Bed ................................................................3-13

Cargo Bed Tailgate ..................................................3-13

Checking the Brake Fluid Level ...................................4-9

Checking the Park Brake ..........................................4-10

Children .....................................................................2-4

Circuit Fuse Box ........................................................4-3

Climbing Slopes .........................................................3-6

Controls .....................................................................3-1

Cooling System Precautions ......................................2-7

CVT Belt ....................................................................4-9

Inclement Weather Conditions ................................... 2-5

In-line Fuse ............................................................... 4-4

Instrument Panel ...................................................... 3-1

Lifting Points .......................................................... 4-10

Lubrication ............................................................... 4-2

Maintenance Record ............................................... 4-17

Master Fuse Box ....................................................... 4-3

Maximum Cargo Load ............................................. 3-13

Model and Product Identification Number ................. 1-1

Monitor during Operation .......................................... 3-7

Operating a Damaged Vehicle .................................... 2-3

Operating the Cargo Bed ......................................... 3-14

Operation ............................................................2-2, 3-4

OPS (Occupant Protective System) ........................... 3-9

OPS Inspection ....................................................... 3-10

Parking the Vehicle ................................................... 3-5

Parts and Service ...................................................... 1-2

Descending Slopes ....................................................3-6

Draining the Engine Oil ...............................................4-6

Driving over Obstacles ...............................................3-7

Driving the Vehicle .....................................................3-5

Driving through Water ................................................3-6

Electrical System .......................................................4-2

Engine Air Filter .........................................................4-5

Engine Cooling System ..............................................4-8

Engine Oil and Filter ...................................................4-5

Engine Starting ..........................................................3-4

Engine Warm Up ........................................................3-5

Filling the Fuel Tank ..................................................4-5

Front Trailer Hitch ......................................................3-9

Fuel and Evaporative Emissions Control System ........4-4

Fuel Handling Precautions .........................................2-7

Fuses ........................................................................4-3

Gear Select Lever Operation .......................................3-7

Personal Safety ........................................................ 2-2

Possible Damage to Occupant Protective Structure .3-10

Pre-Operation Check ................................................. 3-4

Preparation Following Storage .................................. 6-1

Preparation of Battery for Storage ............................. 6-1

Preparation of Engine for Storage ............................. 6-1

Pulling or Hauling Loads ........................................... 2-5

Radiator and Cooling Fan .......................................... 4-9

Radiator Coolant Level .............................................. 4-8

Radiator Overheating ................................................ 4-9

Raising and Lowering the Cargo Bed ......................... 2-5

Rear Trailer Hitch ...................................................... 3-9

Safe Operating Practices .....................................2-1, 3-1

Safe Operation .......................................................... 2-1

Safe Servicing Practices ........................................... 4-1

Safety and Instructions Decals .................................. 2-8

Seat .......................................................................... 4-1

General Engine Maintenance ......................................4-9

General Operation Information ...................................3-4

General Preparation for Storage .................................6-1

Hood .........................................................................4-1

606653 i-1 REV A

Seat Belt Maintenance ............................................ 3-10

Service Introduction .................................................. 4-1

Service Precautions .................................................. 2-5

Sliding and Skidding ................................................. 3-6

INDEX

PAGE PAGE

Slope Guide ............................................................ 2-15

Slope Operation ..................................................2-3, 3-6

Steering the Vehicle .................................................. 3-5

Stopping the Engine .................................................. 3-5

Stopping the Vehicle ................................................. 3-5

Tires ......................................................................... 4-2

To the New Owner ..................................................... 1-1

Torque Values ........................................................... 4-2

Towing Other Vehicles ............................................... 3-9

Traction Control Switch Operation ............................. 3-8

Transporting or Towing the MDV ............................... 3-8

Traversing Slopes ..................................................... 3-6

Using a Ramp ............................................................ 2-3

Using this Manual ..................................................... 1-1

Warranty Registration ............................................... 1-1

REV A i-2 606653