4200/4300/4400 4420/4500/4600 Hustler Tractor Owner’s Manual ••••••• Hustler Turf Equipment ••••• P.O. Box 7000 ••• Hesston, Kansas • 67062-2097 728444 Rev.
WARNING: The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. 728444 Rev.
TABLE OF CONTENTS 1. General Information.............................................................Sect. 1 2. Safety Precautions................................................................Sect. 2 3. Operation..............................................................................Sect. 3 4. Accessories...........................................................................Sect. 4 5. Maintenance and Adjustments .............................................Sect. 5 6. Troubleshooting ......
GENERAL INFORMATION Warranty registration This manual applies to the following equipment: 4200 Hustler tractor, number 924621 4300 Hustler tractor, number 924647 4400 Hustler tractor, number 924639 4500 Hustler tractor, number 924654 4200 Hustler tractor, BTO, number 924704 4300 Hustler tractor, BTO, number 924712 4400 Hustler tractor, BTO, number 924720 4420 Hustler tractor, BTO, number 925024 4500 Hustler tractor, BTO, number 924738 4600 Hustler tractor, BTO, number 925008 The Delivery and Warranty Regi
Hustler Turf Equipment TWO YEAR LIMITED WARRANTY FOR TRACTORS AND POWER UNITS WHAT IS COVERED BY THIS WARRANTY Hustler Turf Equipment, makes the following warranty to the original purchaser only: a. First Year: Hustler Turf Equipment Tractors and Power Units are warranted for one (1) year or 1200 hours of use, whichever comes first, from date of delivery on all materials and workmanship.
● ● operational instructions provided by Hustler Turf Equipment.
728444 Rev.
SAFETY PRECAUTIONS from one location to another. ▲ Always keep engine and machine clean, removing accumulated dirt, trash, grass clippings and other material from machine to reduce wear, prevent overheating and fire. ▲ Always keep engine and machine clean, removing accumulated dirt, trash and other material from machine. ▲ Always be alert for hazards such as rocks, metal objects and other debris which may be thrown or entangled by mower blades. Watch out for holes or deep depressions.
▲ ▲ ▲ ▲ ▲ Never leave machine unattended with ignition key in switch, especially with children present. ▲ Never refuel tractor while engine is running; never refuel near an open flame or near devices which can create a spark. Refuel outdoors preferably, or in well ventilated areas. ▲ Never attempt to start engine when there is a strong odor of gasoline fumes present. Locate and correct cause. ▲ Never run the engine in an enclosed area unless exhaust is vented to the outside.
P Block or chock the machine when parked on a slope or when trailering. Whirling blades! Keep hands and feet away. Beware of thrown objects. Never operate the mower deck with side deflector removed or in raised position, except when the grass catcher attachment is being used. Do not smoke while refueling. Do not 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.
OPERATION 2b 9 10 1 6 13 2a 4 12 3 5 8 1. 2a. 2b. 3. Ignition Switch Throttle Lever (4200, 4400 4420 & 4600) Throttle Lever (4300 & 4500) Choke Lever (4300 & 4500 only) 7 11 4. 5. 6. 7. Electric Clutch Switch Neutral Lock Levers Steering Control Lever Pump Clutch Lever 8. 9. 10. 11. Parking Brake 12. Warning Lights Attachment Lift Lever 13. Seat Latch Auxiliary Control Lever Hour Meter Figure 3-1 start; release key when engine fires, and switch will automatically return to RUN position.
4. Electric PTO clutch switch (Fig. 3-2) – a twoposition switch which controls the electric clutch on the PTO shaft. Down position is OFF and up position is ON. When clutch switch is on, the PTO shaft rotates and delivers live power to attachment requiring it. IMPORTANT: Never engage clutch with engine running at high rpm. Clutch, drive line or attachment could be damaged.
attachment and is described in more detail in the operating instructions provided with the attachment. operating. This is a safety feature designed to prevent runaway or accidental entanglement. To inspect system: 1. The operator must be on the seat when testing the seat switch. 2. Set parking brake and set the steering control lever in the neutral position and disengage pump clutch. (Fig. 3-7) 3. Start the engine and allow it to warm up to operating temperature. 4.
2. Engage safety start interlock system, buckle seat belt if tractor has seat belt. 3. Set parking brake. 4. Set throttle at approximately 1/3 OPEN position. 5. 4200 & 4400 — Rotate key switch counterclockwise to PRE-HEAT; hold this position for 15 seconds when temperature is above freezing, or for 30 seconds when temperature is below freezing. This operation is not necessary when restarting a warm engine.
FRONT OF TRACTOR FACES THIS DIRECTION N FORWARD TRAVEL N ZERO TURN FORWARD TRAVEL RIGHT TURN REVERSE TRAVEL RIGHT TURN REVERSE TRAVEL N = Neutral Position Direction of arrows indicate direction of tractor movement. Figure 3-8 Steering Lever Back Of Neutral Lever Slightly Forward And Turned To The Right Rear Neutral Lock Lever Lifted NOTE: Only One Hand Required For Operation. Right Turn Demonstrated Figure 3-10 Figure 3-9 pumps and motors. 4.
WARNING: Never drive the tractor at high speeds without a front end attachment mounted to the tool bars or with the attachment in a raised position. Inexperienced operators may have a tendency to oversteer and lose control. Slow-moving practice maneuvers are recommended to become familiar with these characteristics before attempting normal speed operation. Sharp depressions or raised obstacles (such as gutters or curbs) should not be directly approached at high speed in an attempt to “jump” them.
ACCESSORIES A large variety of attachments are specifically designed for your Hustler tractor to handle most ground maintenance chores. These mount directly on the tractor in various ways, and each is provided with individual Assembly Instructions, Parts Manual, and Owner’s Manual which includes operation and maintenance information. The following describes standard tractor equipment for accepting and powering these attachments (Fig. 4-1).
MAINTENANCE AND ADJUSTMENTS 19 Maintenance Locator Chart 6 11 16 2 12 13 5 20 3 22 2 14 4 21 9 1 10 20 15 17 18 8 7 19 1. 2. 3. 4. 5. 6. PTO Shaft U-Joint Grease Zerks (2) 7. Battery Location PTO Spline Grease Zerk 8. Air Filter & Service Indicator Hydraulic System Filter 9. Oil Filter (gas units) Hydraulic Reservoir 10. Oil Dipstick (gas units) Fuel Gauge & Filler Cap 11. Oil Filter Location (diesel units) 12. 13. 14. 15. 16.
Remain alert for unusual noises, they could be signaling a problem. Visually inspect the machine for any abnormal wear or damage. A good time to detect potential problems is while performing scheduled maintenance service. Correcting the problem as quickly as possible is the best insurance. before attaching grease gun. Refer to the diagram for location and frequency. Steering linkage There are two types of steering adjustments that are discussed in this section. 1.
Steering Lever Neutral Adjustment with Turnbuckle Fine adjustment to the steering is made with the turnbuckle on the front end of the steering control lever linkage. Additional adjustment is available if necessary at the rear linkage straps near the pump. turn the turnbuckle back to the center of its adjustment (3/4" of threads showing when ignoring jam nut). Then adjust to approximate neutral using the slots in the rear steering linkage before making the final adjustment with the turnbuckle.
Electrical Diagram • Models 4200 & 4400 5-4 728444 Rev.
Electrical Diagram • Models 4200 & 4400 728444 Rev.
Electrical Diagram • Models 4300 & 4500 5-6 728444 Rev.
Electrical Diagram • Models 4300 & 4500 728444 Rev.
Electrical Diagram • Models 4420 & 4600 5-8 728444 Rev.
Electrical Diagram • Models 4420 & 4600 728444 Rev.
Spring and returning it again to the neutral position and locking it. Re-adjust for neutral if necessary. Spring nuts Steering lever tension Lever action should be positive and smooth, allowing free movement forward and back with very little or no side play. It should remain where set, when released from your grasp, anywhere in the forward travel position. If lever is too loose: loosen the jam nut on steering lever pivot bolt, tighten the tension nut to remove slack and tighten the jam nut (Fig. 5-7).
Battery Location 2. Starting Circuit: this circuit supplies electrical power for engine starting, providing the interlock is engaged and electric clutch is switched OFF. The operator seat switch is bypassed in this mode. When the ignition switch is turned to the START position, battery voltage is available from the switch to the electric clutch switch. When the electric clutch switch is in the OFF position, current passes through the center switch tap to the normally open neutral lock switch.
Hood hours of tractor operation or monthly, whichever occurs first. Check more often of system appears to be leaking or otherwise malfunctioning. Fluid level should touch the bottom of screen under filler cap. Use only SAE 10W40 SG, SF/CC, CD service motor oil. Change hydraulic system filter element after first 50 hours of tractor operation, then replace filter and oil in reservoir every 1000 hours or annually, whichever occurs first. When changing hydraulic oil use one unit (approximately 7 oz.
Vent Screw Fuel Filter (4300 & 4500) Fuel Filter Assembly Figure 5-13 Figure 5-15 2. Loosen the vent screw (Fig. 5-13) located on top of the fuel filter and leave it open until air bubbles are no longer present, then close the vent screw. 3. Loosen the vent screw on the injector pump (Fig. 514). Operate the hand priming lever (located below the injector pump) 10 to 30 times. 4. Start the engine and run at low rpm for 15 to 30 seconds to expel air from pump, then close the air vent screw. 5.
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. That is why it is so important to monitor airflow restriction with a restriction indicator. A restriction indicator takes the guesswork out of air cleaner servicing and allows you to safely benefit from the filter’s optimum performance.
2. Service elements only when restriction indicator shows red. Check restriction indicator daily or more frequently if operating in dusty conditions. 3. Loosen wing nut and remove element. Clean the canister with a damp cloth. 4. Before installing a new element, inspect it by placing a bright light inside and rotate the element slowly, looking for any holes or tears in the paper. Also check gaskets for cuts or tears.
Belt replacement General engine maintenance Inspect the pump drive belts frequently for wear and serviceability. Replace a belt that shows signs of severe cuts, tears, separation, weather checking and cracking, or burns caused by slipping. Slight raveling of belt covering does not indicate failure, trim ravelings with a sharp knife. Detailed instructions and recommendations for break-in and regular maintenance are specified in the Maintenance Instructions section of the Ford or Kubota Owner’s manual.
TROUBLESHOOTING The majority of operating problems that occur with a system can be traced to improper adjustments or delayed service. A consistently applied preventive maintenance program, as outlined in the maintenance section of this manual, will prevent many problems. The following chart is designed to help you locate a problem by suggesting probable causes and the recommended solution(s).
STORAGE End of season tractor care New season preparation When storing tractor at end of mowing season, the following steps should be taken to ensure readiness for the next mowing season. 1. Remove all grass, dirt, and trash from tractor. 2. If touchup is required order Hustler spray paint (13 oz. can) from your Hustler dealer. 3. Check thoroughly for any worn or damaged parts that need replacing and order them from your dealer. 4. Thoroughly lubricate machine, according to lubrication instructions. 5.
PRODUCT LITERATURE This section contains sources of additional literature concerning your tractor. Literature should be ordered from your Hustler dealer, or direct from indicated source. The 4600 uses a Kubota V1505-B, four-cylinder, watercooled engine. Primary source of information is engine operator’s manual, which is included with 4600 owner’s manual packet. For additional copies order Hustler P/N 756882 (Kubota P/N 16616-8916-1).
For more information: TRW Ross Gear Division 800 Heath Street Lafayette, Indiana 47902 Phone: 317-423-5377 Telex: 279413 NOTE: During warranty period, check with Hustler dealer before attempting repairs on any tractor system. Unauthorized repair work can void warranty of tractor, engine, and other components. 8-2 728444 Rev.
TECHNICAL SPECIFICATIONS Hustler 4200 specifications Maximum Torque – 57.0 ft. lbs. @ 2600 RPM Maximum torque Compression Ratio – 22:1 Operating RPM – 3000 (max. load), 3200 (no load) Starter – 12-volt, 1.2 KW gear drive. Charging System – 12-volt, 30 amp, belt driven alternator. Injector Pump – Bosch MD type mini pump. Injector Nozzle – DN 12 SD 12 Starting Assist – Glow plug system is standard. Ignition key operates system. Crankcase Capacity – 6 qts. (5.7 l) Fuel – Diesel No.
Operating RPM – 3000 (max. load), 3200 (no load) Starter – 12-volt Ford, external solenoid. Charging System – 12-volt, negative ground, 55 amp, belt driven alternator. Crankcase Capacity – 3.5 U.S. qts. (3.25 l) with filter change. Fuel – Unleaded gasoline. Auxiliary hydraulics – Auxiliary hydraulic valve with manual control lever and quick-couplers. Common specifications Capacities Tires – Standard rear tires - 13 x 6.50-6 with rib tread. Three drive tire options: Regular – 23 x 8.
INDEX PAGE PAGE Access to engine and hydraulic pumps...........................5-11 Auxiliary hydraulics .........................................................4-1 Belt replacement .............................................................5-16 Burnishing the electric clutch .........................................5-11 Common specifications ....................................................9-2 Controls ............................................................................3-1 Cooling system .