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Hustler Turf 4200 Lawn Mower User Manual

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2. ON unis xoo1jenneN eam v aaa og6ps vo ___________ _____ faam on am a 804 apes N 1 0 uonounf AM YO INys YO INYS pee1 prouajos 5 piouejos YO Mys DIM NOILIIUDS3Q 5 9 728444 Rev 11 02 Spring nuts gt Rear pump linkage nut Figure 5 6 connecting link to the rear pump steering linkage Fig 5 3 The unit is now ready to operate T Bar rotational resistance adjustment On units with serial numbers prior to and including 11374 last five digits Purpose of this spring and connecting link assembly Fig 5 3 is primarily to provide the operator with a means of adjusting the rotational resistance of the T bar handle Before adjusting for rotational resistance lock the T bar in neutral and make sure the spring is vertical see previous step 7 The spring may be tightened to increase the rotational resistance or loosened to decrease it to suit the operator s comfort Adjustment may be made by turning the nut Fig 5 3 to vary the spring tension until the operator is satisfied with the resistance to rotation As a starting point turn the tension adjusting nut Fig 5 3 until the connect
3. AWARNING Seat belt mustbe fastened while operating this machine Failure to use seat belt will result in serious injury in the eventofa rollover 728444 Rev 11 02 USE SEAT BELT Avoid crushing A ADO not jump i machnetes amp B Block or chock the machine when parked on a slope or when trailering Never operate the mower deck with side deflector removed or in raised position except when the grass catcher attachment is being used Avoid skin 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 physician immediately Acid will also damage clothing 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 and explosion if exposed to flame Always remove the negative ground first and replace it last Do not overfill battery Electrolyte may overflow and damage paint wiring or structure When cleaning the battery use soap and water Be careful not to get soap and water into the battery Use soda mixed in water to clean corrosion off the terminals Hot surface Seat belt must be fastened while operating a machine equipped with ROPS Failure to use seat belt will result in serious injury in the event of a roll over When operating on terrain where ther
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6. Remove all grass dirt and trash from tractor If touchup is required order Hustler spray paint 13 oz can from your Hustler dealer Check thoroughly for any worn or damaged parts that need replacing and order them from your dealer Thoroughly lubricate machine according to lubrication instructions Block tractor up so weight is off tires NOTE Do not deflate tires Protect battery from freezing temperatures Perform separate engine preparation as listed in engine owner s manual Store tractor in a dry place 728444 Rev 11 02 7 1 New season preparation Before starting the tractor following post season storage the following servicing is required 1 Clean tractor removing trash and dirt accumulation Check that all worn or damaged parts were replaced 2 Check engine oil hydraulic oil and coolant levels 3 Fill fuel tank with fresh fuel WARNING At start of new season always check that fresh oil and coolant have been added to machine If oil and coolant are drained at season s end and not replaced engine damage will result 4 Run machine at half speed for 5 minutes checking operation of steering control levers and PTO shaft Stop machine and check for oil leaks loose fittings and so forth 5 Tighten any bolts that have loosened and make sure all hairpins clevis pins and cotter pins are in place 6 Install all safety shields and review safety precautions listed in this manual
7. Safety interlock system with seat switch connected to neutral lock and PTO switches Steering levers must be locked in neutral and PTO switch must be off before engine will start Controls Hand operated throttle ignition switch PTO clutch switch pump clutch lever parking brake lever attachment lift lever and auxiliary valve lever Ignition switch controls solenoid activated engine shut off and glow plugs models 4200 4400 4420 4600 only Choke lever models 4300 amp 4500 only Indicators Hour meter glow plug indicator light oil pressure warning light engine heat warning light and alternator warning light Audible signal for high engine temperature or low engine oil pressure Model 4200 4400 4420 4600 only 728444 Rev 11 02 INDEX PAGE Access to engine and hydraulic pumps 5 11 Auxiliary hydraulics eese 4 1 Belt replacement erre epe 5 16 Burnishing the electric clutch sess 5 11 Common specifications eunesseesnensensennnenseensen nennen 9 2 Controls A ia 3 1 Cooling SyStem rar nehme 5 15 Driving the tractor esses 3 5 Electrical diagrams et te it ide 5 4 Electrical system 5 10 End of season tractor care essere 7 1 Engine air filter e cei 5 13 Engin eanformation eri eee entes 8 1 Engine oil filter sse 5 13 Engine starting iso etre det
8. Attach an implement to the tractor PTO shaft per the implement s mounting instructions 2 Cycle the clutch on and off 50 times 15 seconds on and 15 seconds off with the engine operating at low idle approximately 1500 rpm Make certain that the PTO shaft comes to a complete stop between cycles Access to engine and hydraulic pumps WARNING Always wear adequate eye A protection when servicing the hydraulic system battery and cooling system Figure 5 10 i Screen Reservoir Figure 5 11 The engine hood at rear is hinged To raise it unfasten the two latches and tilt hood up and forward A hood support rod is stored clipped to the bottom side Insert this rod in the hole provided in the rear support on right side Fig 5 10 Access to the hydraulic reservoir and pumps is gained by pulling forward on the spring latch located at the front of the operator s seat platform and tilting the seat up and forward Hydraulic system IMPORTANT Never use hydraulic or automatic transmission fluid in this system use only motor oil as specified Always keep quick release couplers capped when separated and wipe them clean before connecting Remember dirt is the prime enemy of any hydraulic system A WARNING Hydraulic oil escaping under pressure can penetrate skin Before applying pressure to hydraulic system make sure all connections are tight and all hoses and lines are in good condition To find a leak under
9. Attachment Lift Lever 13 Seat Latch Auxiliary Control Lever Hour Meter start release key when engine fires and switch will automatically return to RUN position Models 4300 and 4500 A three position switch off run and start With key inserted rotate it clockwise to start Release key when engine fires and switch will automatically return to RUN position Throttle Figs 3 2 and 3 3 a mechanical link connected to the engine governor for controlling engine rpm On models 4200 4400 4420 4600 Fig 3 2 move lever up to increase engine rpm move down to decrease engine rpm On models 4300 and 4500 Fig 3 3 move lever down and forward to increase engine rpm pull up and back to decrease engine rpm Choke control Fig 3 2 a cable link to manual engine choke models 4300 and 4500 only Move up for cold starting move down for normal run Figure 3 3 4 Electric PTO clutch switch Fig 3 2 a two position 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 WARNING Never turn the PTO switch ON unless the PTO shaft is securely connected to a power driven attachment 5 Neutral locks Fig 3 4 front and rear locking devices
10. X Every 50 hrs NOTE After completing maintenance cycle 1000 Check oil level hydraulic XXIXIXI X X X X X X hours repeat evcle Lube PTO U joints 2 rep Check alternator belt tension xXIX IX X IX IX F Check pump belt tension amp condition Introduction Check steering lever tension xIx IxIx Ix1 IxIx1Ix1x x Change engine oil and filter WARNING Unless specifically required DO Lupe pump eich mount KENAA eed E EN EXER NOT have engine running when servicing or D Check governor oil level XIXIXIX X X di E 1 Check fuel amp hydraulic hoses making adjustments to tractor Engage neutra D Check alternator amp governor belt tension X X X X X lock levers and parking brake To prevent AD Lubricate throttle governor amp choke linkage x x x X x carbon monoxide poisoning be sure proper ventilation is available when engine must be operated in an enclosed area Read and observe safety warnings in front of manual Check grommets and ball joints on steering linkage XX AD Adjust idle mixture amp speed x x x Change fuel filter AD Replace spark plugs Clean hydraulic filler cap Clean radiator core Regular maintenance is the best prevention for costly Change hydraulic filter Z and oil downti
11. Fig 5 T Wear plate Adjustable wear plates attached to the front and rear neutral lock devices positions the control lever in neutral Loosen the mounting cap screws and move the plate holes are slotted for this purpose to compensate for wear or when tractor wants to creep when neutral locks are engaged When plate becomes worn to the point that adjustment is no longer possible it can be turned over to utilize the opposite side Replace plate when both sides are worn Fig 5 7 Parking brake adjustment Occasionally check the parking brakes by engaging the parking brake lever start engine and set throttle at slow idle Advance steering control lever approximately 1 forward brakes should hold tractor from movement When adjustment becomes necessary disengage the parking brake lever and rotate the knob located on end of lever clockwise Fig 5 8 Parking brake lever Figure 5 8 Electrical system A 12 volt negative ground system is used for ignition and accessories throughout The battery is located behind the hinged compartment cover on the left fender Fig 5 8 A BCI group 24F battery is recommended for all season use The batteries recommended for the different machines are 4300 4500 12V 350 CCA cold cranking amps 4200 12V 65AH 385 CCA cold cranking amps 4400 4420 12V 80AH 500 CCA cold cranking amps 4600 12V 80AH 500 CCA cold cranking amps A heavier reserve b
12. 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 NOTE For parts information on your tractor refer to the Hustler 4200 4300 4400 4420 4500 4600 Parts Manual Hustler P N 728436 Engine information The 4200 uses a Kubota D950 three cylinder water cooled engine Primary source of information is engine operator s manual which is included with 4200 owner s manual packet For additional copies order Hustler P N 031773 Kubota P N 19208 8916 1 Other information includes ORDER KUBOTA HUSTLER DESCRIPTION PART NUMBER PART NUMBER Illustrated Parts List Kubota D950 07909 59000 031781 Work Shop Manual Kubota D950 07909 70076 031799 For more information See your Hustler dealer The 4400 uses a Kubota V1200 B four cylinder water cooled engine Primary source of information is engine operator s manual which is included with 4400 owner s manual packet For additional copies order Hustler P N 031807 Kubota P N 19286 8916 1 Other information includes ORDER KUBOTA HUSTLER DESCRIPTION PART NUMBER PART NUMBER Illustrated Parts List Kubota V1200 BBS 1 07909 50460 031815 Work Shop Manual Kubota V1200 B 07909 70107 031823 The 4600 uses a Kubota V1505 B four cylinder water cooled engine Primary source of information is engine operator s man
13. engine manual for more specific details Models 4200 4400 4420 4600 1 Before starting tractor each day perform daily pre operation checking 2 Engage safety start interlock system buckle seat belt if tractor has seat belt Set parking brake 4 Set throttle at approximately 1 3 OPEN position 5 4200 amp 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 4420 amp 4600 Rotate key switch counterclockwise to PRE HEAT hold this position until glow plug light goes off This is necessary only when the temperature is below 50 F This operation is not necessary when restarting a warm engine Shown below are the standard preheating times for various temperatures This operation however is not required when the engine is warmed up Ambient Preheating time temperature Ordinary heat type Above 10 C GOH 10 C 50 F to Approx 6 seconds 5 C 23 F Pre heat position until glow plug light goes off Below 5 C 23 F Approx 12 seconds Pre heat position until glow plug light goes off the second time Limit of continuous use 20 seconds Failure to follow these recommendations can lead to premature failure of the starter motor and the fuel shut off solenoid NOTICE Ether or other starting fluids must neve
14. from neutral The farther forward lever is from neutral the faster tractor will travel forward The farther back lever is from neutral the faster tractor will go in reverse Operating suggestions 0 WARNING The Hustler steering control lever is very responsive Easy does it For smooth operation move lever slowly avoid sudden movement Skill and ease of operation come with practice and experience 3 6 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 Approach at a slow speed and angle one drive wheel at the obstruction Continue at an angle until the wheel clears and then pivot the opposite wheel around When turning on soft wet turf keep both wheels rolling either forward or backward Pivoting on one stopped wheel can damage turf This is especially important when mowing Maintain an even recommended tire pressure This affects the rolling radius of the wheels and tractor will want to veer off in the direction of the tire with least pressure Tractor performance is maximum when the throttle is set at full rpm This gives maximum power to the drive wheels when needed faster response for the hydraulic lift and auxiliary cylind
15. of dependable performance This model meets ANSI B71 4 safety specifications for commercial turf care equipment A separate Engine Manual is included with your owner s packet which contains additional engine information that will not be repeated in this manual You are urged to read it before attempting any operation or repair of the engine The Quick Reference Decal located on your tractor is designed to give the operator brief information needed in the daily operation of the machine This decal is not intended to be used in place of this manual but instead is to be used as an extension of this manual This decal should be kept legible at all times and replaced if it becomes damaged It is the owner s responsibility to make certain that the operator reads and understands this manual and the Quick Reference Decal before operating this machine Using this manual General operation adjustment and maintenance guidance is outlined for both the experienced and novice Hustler user Operating conditions vary considerably and cannot all be addressed individually Through experience however operators should find no difficulty in developing good operating skills suitable to most conditions Directions used in this manual for example RIGHT or LEFT refer to directions when seated on tractor facing forward unless otherwise stated Photographs and illustrations used were current at the time of printing but subsequent production changes may cause
16. or too light a grade Change oil and check for source of contamination For additional causes Fan belt slipping See engine manual Adjust belt tension Wiring defective See your dealer Alternator malfunctioning Numerous Steering control linkage needs adjustment See your dealer See engine manual Adjust linkage Pump or wheel motors faulty Low hydraulic oil level See your dealer Fill reservoir Cooling fins plugged Clean fins Hydraulic pump faulty Steering linkage needs adjustment Steering linkage needs adjustment See your dealer Adjust linkage Adjust linkage Wheel motor faulty See your dealer Hydraulic pump faulty See your dealer Unequal tire pressure Brake needs adjustment Inflate tires equally just parking brake Neutral lock levers need adjusting Too much weight on attachment just neutral lock levers Reduce amount of weight Hydraulic oil level low Add oil to system Hydraulic pump faulty See your dealer Valve control faulty See your dealer Leak in hydraulic system See your dealer Restriction in hose or fitting Check hoses PTO shaft will not turn Fuse blown Replace fuse Loose wires Check wiring STORAGE End of season tractor care When storing tractor at end of mowing season the following steps should be taken to ensure readiness for the next mowing season 1 2 3
17. system prior to any period of non use over three months DISCLAIMER OF WARRANTY The foregoing warranties are in lieu of all other warranties expressed or implied including but not limited to the implied warranties of merchantability and fitness for a particular purpose However if the Hustler Turf Equipment is purchased as a consumer product any implied warranty of merchantability or fitness for a particular purpose is limited to the duration of this limited warranty Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state LIMITATION OF REMEDIES In no case shall Hustler Turf Equipment be liable for any special incidental or consequential damages based upon breach of warranty breach of contract negligence strict liability in tort or any other legal theory Such damages include but are not limited to e Loss of profits e Loss of savings or revenue e Loss of use of Hustler Turf Equipment or any associated equipment e Cost of capital e Cost of any substitute equipment facilities services or downtime e The claims of third parties including customers and injury to property Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you TIME LIMIT Any action for b
18. your machine to vary slightly in detail Hustler Turf Equipment reserves the right to redesign and change the machine as deemed necessary without notification If a change has been made to your machine which is not reflected in this owner s manual or the parts manual see your Hustler dealer for current information and parts 728444 Rev 11 02 1 1 Warranty registration The Delivery and Warranty Registration card must be completed and signed to validate your warranty protection As the new equipment owner you are expected to see that the card is completed and forwarded to Hustler Turf Equipment at time of delivery Be sure to register the tractor plus each attachment that displays a model and serial identification number plate i e mower decks snow blower front blade etc IMPORTANT Any unauthorized modification alteration or use of non approved attachments voids the warranty and releases Hustler Turf Equipment from any liability arising from subsequent use of this equipment Model and serial number Tractor model and serial numbers are found on the serial identification plate located on the panel directly below and to the right of the operator s seat These numbers are required on the Warranty Registration card They will also assure you of the correct service parts when replacement becomes necessary Parts and service Use original Hustler equipment replacement parts only These parts are available through your local
19. 0 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 1 Fuel Diesel No 2 Hustler 4600 specifications Engine Make Kubota Model V1505 B 1 Type Four cylinder in line 4 cycle diesel liquid cooled Displacement 91 44 cu in 1498 cc Horsepower 37 5 hp 28 KW mfg rating 9 3000 RPM Maximum Torque 73 ft lbs 2200 RPM 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 1 Fuel Diesel No 2 Hustler 4300 amp 4500 specifications Engine Make Ford Industrial Model 4300 VSG 4111 6005 A S O 4363A 4500 VSG 4131 6005 A S O 4362A Type Four cylinder in line 4 cycle gasoline liquid cooled valve in head Displacement 4300 67 cu in 1100 cc 4500 78 65 cu in 1289 cc Horsepower 4300 34 25 KW mfg rating 3000 RPM 4500 42 5 32 KW mfg rating 3000 RPM Maximum Torque 4
20. 300 61 ft lbs 2600 3600 RPM 4500 72 5 ft Ibs 2600 3600 RPM Compression Ratio 4300 9 5 1 4500 9 3 1 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 1 with filter change Fuel Unleaded gasoline Common specifications Traction drive system Type Dual hydrostatic closed loop system Pumps Tandem hydrostatic pump Variable displacement axial piston type Each pump powers one drive wheel motor Pump Drive V belt drive from engine crankshaft with manual clutch Final Drive Direct drive high torque wheel motors One for each drive wheel Filter 10 micron pressure side replaceable spin on type Ground Speed 0 10 mph 0 16 1 kph forward 0 6 mph 0 9 7 kph reverse infinitely variable Steering One hand Tee lever steering provides independent control of each of two drive wheels Speed turning forward reverse and braking are all controlled through the dual hydrostatic transmissions Turning Radius True O degrees Turns within its own length Counter rotating independently powered drive wheels provide maximum in maneuverability Brakes Service Independent dynamic braking through hydrostatic transmissions Parking Positive automotive type drum and shoe Hand operated lock over center control l
21. 4200 4300 4400 4420 4500 4600 Hustler Trac tor Owner s Manual HUSTLER P O Box 7000 Hesston Kansas 67062 2097 728444 Rev 11 02 A WARNING A The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 728444 Rev 11 02 728444 Rev 11 02 TABLE OF CONTENTS 1 General Information uod ill Sect 1 2 Sabety PrecautiOns icc Een Sect 2 SES cul ERES Sect 3 4 JNCCOSSOMES de Er Sect 4 5 Maintenance and Adjustment see Sect 5 6 Troubleshooting antun Sect 6 ar PE Sect 7 Os Product Literature sense Be Sect 8 9 Technical Specifications intere didas tron te ie neenon Sect 9 I0 Index oi eoe Soo eb n es Sect 10 GENERAL INFORMATION 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 To the new owner The purpose of this manual is to assist owners and operators in maintaining and operating the Hustler tractor Please read it carefully information and instructions furnished can help you achieve years
22. Check monthly or every 200 hours whichever comes first Check coolant level Every 8 hours Z Perform initial hydraulic filter change after 50 hours at same time initial engine 5 break in adjustments are performed Visually inspect tractor for loose hardware A See Engine Manual Refer to Engine Owner s Manual for recommendations and and or damaged parts Daily other maintenance items Visually inspect tires Daily B 4200 4400 4420 4600 change after first 35 hours of operation Refer to Engine Check oil level engine Every 4 hrs Owner s Manual for recommendations and other maintenance items 9 y C 4200 4400 4420 4600 tractors only Check radiator screen Every 4 hrs D 4300 4500 tractors only Clean air filter intake screen Every 4 hrs E Use oil with a rating equivalent to CD or higher Check fuel level Every 8 hrs Inspect every 100 hours and replace if worn or cracking is noticed Otherwise XXE replace every 1000 hours or 2 years whichever comes first G Check air cleaner service indicator Every 8 hrs G Donot clean filter element Replace with a new one Lube rear wheel axle Every 8 hrs Check hydraulic and fuel line hoses for any cracks or leaks Visually inspect radiator core Every 40 hrs Trash amp Uo DE around aoe could cause a fire Keep engine Lube rear wheel bearings 2 Every 40 hrs compartment ang clean Lube PTO spline Every 50 hrs Tighten hub bolts on wheels Y
23. Hustler equipment dealer To obtain prompt efficient service always provide the following information when ordering parts 1 Correct part description and number as given in the parts manual supplied with your owner s packet 2 Correct model number 3 Correct serial number warranty repair and service must be handled through an authorized Hustler dealer Arrangements should be made through your local service center For location of nearest dealer or should you need further assistance contact Customer Service Department Hustler Turf Equipment P O Box 7000 Hesston KS 67062 Telephone 316 327 4911 FAX 316 327 2117 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 If the Purchaser discovers within this warranty period a defect in materials or workmanship e He must promptly notify Hustler Turf Equipment or an authorized dealer in writing of the defect In no event shall such notification be received by Hustler Turf Equipment or an authorized dealer later than thirteen 13 months from date of delivery Within a reasonable time after such notification Hustler Turf Equip
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25. T position to indicate that the diesel engine glow plugs are operating The light will go off when the engine is ready to start Safety start interlock system Check tractor safety start interlock system daily prior to operation This system is an important tractor feature It should be repaired immediately if it malfunctions The machine incorporates a separate seat switch which will stop the tractor engine when the operator is unseated for any reason while the tractor mower or other attachment is 728444 Rev 11 02 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 With the front neutral lock in the up position and or the clutch switch on slowly raise off of the seat The engine should stop within one second 5 With the front neutral lock in the down position and the clutch switch off slowly raise off of the seat The engine should continue to run 6 If the engine fails to stop when the clutch switch is on or front neutral lock lever is up and the operator is off the seat check the function of the seat switch If the seat switch is not operating properly is not opening and closing and if the cause can not be det
26. VEL REVERSE TRAVEL REVERSE TRAVEL RIGHT TURN RIGHT TURN N Neutral Position Direction of arrows indicate direction of tractor movement Figure 3 8 Steer g Lever Back Of Neutral e Lever Slightly Forward And Rear Neutral Lock Lever NOTE Only One Hand Required For Operation Lifted Figure 3 10 Figure 359 pumps and motors 4 After towing make certain the two valves are returned Moving tractor with stalled engine to their operating position Turn them clockwise and torque to 40 50 foot pounds Should it become necessary to transport the tractor because the engine stalls and cannot be restarted 1 The hydraulic pump is equipped with tow valves Driving the tractor Before towing the tractor turn the tow valves counterclockwise four complete revolutions using a 5 16 allen wrench This allows the hydraulic oil to flow freely in the system The valves are located per Fig 3 7 Y DANGER Never make sudden stops or reverse Only one hand is required to control speed and direction of the tractor in most conditions Fig 3 8 2 Move the tractor by hand or use a winch to pull it onto direction especially when going down a slope a transport vehicle The steering is designed for sensitive response 3 If towing is necessary tractor may be towed for Rapid movement of the steering lever in either distances up to 1 2 mile at speeds not greater than 3 direction could result in a reaction of the tracto
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28. an alteration and will not be considered for warranty in the event of engine damage Recommended service procedure 1 Check dust cap Dust or water should not be allowed to build up closer than one inch from the baffle The Vacuator Valve should eliminate dust and water from cup automatically empty only as necessary Check to see if the Vacuator M Valve is functioning and in good condition Replace if necessary Do not operate machine without the Vacuator Valve installed 728444 Rev 11 02 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 Do not attempt to use a damaged element which will allow abrasive particles to enter the engine 5 Reinstall the dust cup Make sure it seals all the way around the air cleaner body then tighten the clamping thumb screw 6 Check all fittings and clamps periodically for tightness and inspect hoses for holes or cracks 7 Periodically check the intake hose for signs of ingested dust Locate and repair the source of ingested dirt 8 Never operate a machine without an air filter installed When operating in extremely dirty co
29. an inexpensive maintenance check that can prevent costly non warrantable premature engine damage Overservicing Overservicing occurs when an air filter element is removed for cleaning or replacement before it is necessary Each time the filter is removed a small amount of dirt and dust could fall in the intake system This accumulated dirt can cause a dusted engine It only takes a few grams of ingested dirt over the normal service life of an engine to cause a dusted engine An air cleaner element should only be changed when the restriction indicator shows red Do not clean element replace with a new element only Cleaning used air filter elements through improper cleaning procedures can get dust on the inside of the filter causing dirt ingestion and engine failure 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 Donaldson warranty for air filters expires upon cleaning or servicing in any manner because the condition of the filter after servicing is completely out of their control Therefore on a dust ingested engine failure there will be no warranty consideration if the air filter element has been cleaned or serviced in any manner A partially dirty air filter element works better than a new element Therefore a dirty filter element is not bad for the engine unless it is excessivel
30. anty is backed by Ford Motor Co or Kubota respectively Special attention should be paid to applicable data which will not be duplicated here 728444 Rev 11 02 TROUBLESHOOTING PROBABLE CAUSES SUGGESTED REMEDIES 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 PROBABLE CAUSES SUGGESTED REMEDIES Starting motor does not crank Engine cranks but does not start Engine Runs with continuous misfiring Engine runs unevenly Engine runs improperly Loss of power or system will not operate in either direction Loss of power or system will not operate in either direction Overheating Temperature light glows Frequent refilling of radiator required Coolant appears rusty Audible alarm 728444 Rev 11 02 Safety interlock system not engaged Engage system Electric clutch switch in on position Put switch in off position Fuse blown Replace fuse Weak or dead battery Recharge or replace battery For additional causes No fuel or line plugged See engine manual Fill tank or replace line Pump engaged Disengage pump Numerous Numerous Restrict
31. attery may be required if extremely cold conditions make engine cranking difficult Follow battery manufacturer s maintenance safety 728444 Rev 11 02 Left fender Q Figure 5 9 storing and charging specifications Common circuit failures are usually caused by shorting corroded or dirty terminals loose connections defective wire insulation or broken wires Switches solenoids and ignition components may also fail causing a shorted or open circuit Before attempting any failure diagnosis of the electrical system use a test light or voltmeter to check the battery voltage If the battery voltage is satisfactory check the cleanliness and tightness of the terminals and ground connections A general understanding of electrical servicing and use of basic test equipment is necessary for troubleshooting and repair Major overhaul or repair of the starting motor or alternator should be performed by trained technicians only Although integral the tractor electrical system can be described as three separate circuits for explanation and troubleshooting 1 Run Circuit this circuit supplies needed continuity for normal operation of engine controls and electric clutch while the operator remains seated on the tractor For personal protection the engine will stop should the operator become unseated while operating the tractor when the neutral lock is disengaged or the electric clutch is switched ON When the ignitio
32. bar bracket Turn yoke on threaded cable end to lengthen or shorten effective length as needed Flotation springs Flotation springs connected between the tractor and front mounted attachments act as shock absorbers allowing the 728444 Rev 11 02 attachment to float when moving over uneven ground Proper flotation provides good balance and weight distribution with tractor for best drive wheel traction The tractor comes standard equipped with three of these springs which must be connected as specified in instructions supplied with the attachment being mounted PTO shaft This telescoping shaft assembly delivers live engine power to front mounted attachments through the electric clutch When not connected to an attachment the shaft must be secured to the hanger located under the tractor footrest WARNING Never turn the PTO switch ON unless the PTO shaft is securely connected to a power driven attachment The PTO electric clutch switch bracket on operator s platform has provisions for inserting a lock out pin so switch may not be unintentionally switched on when PTO shaft is not connected to attachment This shaft assembly has three grease fittings for periodic servicing when in use Refer to the maintenance schedule for frequency Auxiliary hydraulics The tractor s hydraulic system includes a control valve hoses and quick connect couplers for supplying hydraulics to attachment cylinders When not in use the co
33. d in the daily operation of the machine This decal is not intended to be used in place of this manual but instead is to be used as an extension of this manual This decal should be kept legible at all times and replaced if it becomes damaged It is the owner s responsibility to make certain that the operator reads and understands this manual and the Quick Reference Decal before operating this machine Local regulations may restrict the age of the operator The owner should also ensure that the operator mechanic know that they are responsible for their own safety as well as the safety of other persons within the vicinity Remember the operator is responsible for accidents or hazards occuring to other people or their property A Always stop tractor engine engage neutral lock levers engage parking brake and remove ignition key when leaving operator s seat Always remain seated while operating machine Always keep safety shields and covers in place except for servicing Always maintain a safe distance from people and pets when mowing Always operate machine in daylight or with adequate working lights Follow daily and weekly checklists making sure hoses are tightly secured and bolts are tightened Always observe traffic laws while driving machine gt gt gt gt gt gt 728444 Rev 11 02 2 1 from one location to another Always keep engine and machine clean removing accumulated dirt trash grass clippings and othe
34. d thoroughly familiarize himself with the owner s manual regarding operation and safety of the machine as well as all safety warnings on the machine itself WARRANTY REGISTRATION 1 The Warranty registration form MUST be completed and signed by the authorized dealer and original purchaser 2 For validation the completed Warranty registration form MUST be forwarded to Hustler Turf Equipment within ten 10 days following date of purchase 3 The date of purchase constitutes delivery 728444 Rev 11 02 SAFETY PRECAUTIONS This safety alert symbol is used to call attention to a message intended to provide a reasonable degree of PERSONAL SAFETY for operators and other persons during the normal operation and servicing of this equipment DANGER denotes immediate hazards which will result in severe personal injury or death WARNING denotes a hazard or unsafe practice which COULD result in severe personal injury or death All operators should read this manual or be instructed about safe operating and maintenance procedures This is the owner s responsibility Incorrect usage of this machine may result in severe injury Personnel operating and maintain ing it should be trained in the proper use and should read the manuals completely and thoroughly before attempting to set up operate adjust or service this machine The Quick Reference Decal located on your tractor is designed to give the operator brief information neede
35. e is a potential for a roll over it is important that a ROPS be installed on the equipment The ROPS will prevent serious injury in the event of roll over Seat belt must be fastened while operating a machine equipped with ROPS Failure to use seat belt will result in serious injury in the event of a roll over DANGER IM lt AWARNING AWARNING AWARNING SEN Avoid quick stops A Avoid sudden movements of steering lever A Move tractor very slowly when attachment is removed A When mowing reduce speed on slopes A An operator should not operate on a slope until he is thoroughly familiar with the equipment and read the Owner s Manual AWARNING r Whirling blades feet away Beware of thrown objects Keep hands and 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 Hydraulic fluid escaping under pressure can penetrate skin Hydraulic fluid may also cause infection in a minor cut or opening in the skin if exposed to hydraulic fluid see a doctor at once Before applying pressure to hydraulic system make sure all connections are tight and all hoses and lines are in good condition Relieve all pressure in the system before disconnecting or working on hydraulic lines To find a leak under p
36. e or any solid object as dust and dirt particles will be forced through the media causing continual passing of dirt into the engine Visually inspect the outside of the air cleaner canister periodically for external damage and replace if necessary Incorrect air cleaner element Use only the correct Donaldson air filter element Hustler part number 032029 which is designed to fit the canister properly Hustler air filter elements have the correct media composition filter area micron size and dimensions Always use genuine Hustler filters Many aftermarket filters have been found to be incompatible with Hustler s canisters and engines The air filter must remain intact to block passage of dirt and foreign particles from entering the engine Being inclined to disbelieve the need for more expensive air filter elements used on gasoline and diesel engines may cause some individuals to opt for a less expensive part The filter element must be sufficient size and construction to withstand stresses caused by rapid cycling of the air volume demanded by the engine without cracking or tearing under fatigue and pressure especially diesel engines Therefore Hustler Turf Equipment and the engine manufacturers have carefully selected a reliable filter designed to fit the needs of the engines The filter specified is a Donaldson filter Hustler part number 032029 Owners should be reminded that failure to use original equipment replacement parts is
37. e solution before adding it to the recovery tank It is not necessary to remove radiator cap for adding small amounts of coolant to system A The system should be drained flushed and refilled with fresh solution after every 500 hours of operation The lower radiator tank is equipped with a drain cock Remove the radiator cap and open this drain for emptying system If frequent refilling is necessary or if coolant appears rusty thoroughly check the system Refer to the engine manual for information on checking and cleaning system The engine cooling fan draws air through both the hydraulic oil cooling and engine cooling radiators These are protected by a screen shroud Keep the shroud clean at all times and make sure trash is not allowed to accumulate on or between the radiators nor allow the fins and cores to become plugged The rear screen is removed by lifting engine hood and inserting the support rod Loosen the strap clamps one on each side at top tilt the shroud back then move the bottom forward to clear the retaining clips and lift shroud off The oil cooler may be separated from its mounting by loosening the four rubber mounting pad wing nuts and sliding the cooler assembly back and off the mounts It should be noticed that it is not necessary to remove the hex lock nut wing nut or rubber spacer to remove or replace the cooler assembly for servicing or cleaning Fig 5 18 Never force anything into the radiator fins which ma
38. erlock system Designed to protect the operator and others from accidental injury this system prevents unintentional engine starting The engine starter will not engage until A Steering control lever front and rear neutral locks are set B PTO clutch switch is in the OFF position WARNING Excessive starter cranking after running out of fuel and not following proper fuel system bleeding will lead to premature failure of the starter motor and or the fuel shut off solenoid WARNING The safety interlock system should not be disconnected or bypassed NOTE The operator s seat is equipped with a separate safety switch If for any reason the operator should become unseated when the neutral lock is disengaged or the PTO switch in the ON position this switch will open and engine will stop 3 Disengage the hydraulic clutch lever to lessen drag on the starter motor particularly when oil is cold 4 Advance throttle to approximately 1 4 open slot 5 Insert key in ignition switch and rotate full clockwise to engage starting motor Release key when engine fires NOTE Continuous cranking for longer than 20 seconds may damage the starter motor After continuous cranking for 20 seconds wait two minutes before engaging starting motor again TOP VIEW HIGH PRESSURE RELIEF VALVES HIGH PRESSURE RELIEF VALVES Figure 3 7 728444 Rev 11 02 FRONT OF TRACTOR FACES THIS DIRECTION FORWARD TRAVEL ZERO TURN FORWARD TRA
39. ermined replace the seat switch If the problem can not be located contact the Hustler Service Department This safety interlock system should always function per steps 4 and 5 If it does not function properly it should be corrected immediately Do not operate machine without properly functioning seat safety switch IMPORTANT Never switch the PTO on unless it is securely connected to a suitable attachment Engine starting Your Hustler tractor incorporates a safety interlock system Designed to protect the operator and others from accidental injury this system prevents unintentional engine starting The engine starting motor will not engage until A Steering control lever front and rear neutral locks set B PTO clutch switch is in the OFF position WARNING The safety interlock system must not be disconnected or bypassed NOTE The operator s seat is equipped with a separate safety switch If for any reason the operator should become unseated when the neutral lock is disengaged or the PTO switch is in the ON position this switch will open and engine will stop Before engaging the starting motor disengage the hydraulic clutch lever to lessen drag on the starter motor particularly when oil is cold Always rotate the key switch to the ON position to make sure that each warning light is operating The following is general information taken from the respective engine owner s manual If difficulty is encountered refer to the
40. ers plus maximum PTO power Use the steering control lever to control ground speed rather than engine rpm WARNING Some front mounted attachments A are heavy enough to lift the rear tractor wheels off the ground when raised for turning backing or transporting Your Hustler can be equipped with rear stack weights to counter balance the tractor in these circumstances Consult your dealer for information WARNING If tractor is equipped with a ROPS always buckle seat belt before starting tractor A 728444 Rev 11 02 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 Flotation Front tool bar This is the point of connection between the tractor and mower decks or other front mounted attachments dozer blades snow thrower utility scoop etc The tractor hydraulic system raises and lowers the tool bar assembly through a series of lifting cables These cables can be adjusted to keep attachments level when in the raised position If adjustment is necessary loosen the lock nut remove the clevis pin to free the threaded cable yoke from tool
41. eter 3 3 Flotation springs esee enne 4 1 Eront tool te 4 1 Fuel system inicia iii 5 12 General engine maintenance esee 5 16 Hout meter uere eee des 5 2 Hustler 4200 specifications uuenseesesseesensersnense nennen 9 1 Hustler 4400 specifications 9 1 Hustler 4420 specifications eee 9 1 Hustler 4300 amp 4500 specifications 9 1 Hustler 4600 specifications essen 9 1 728444 Rev 11 02 10 1 PAGE Hydraulic pump eese 8 1 Hydraulic system tene 5 12 Instrumentation eese nennen 3 3 Lubrication oie ere te dete 5 2 Maintenance introduction 5 1 Model and serial number sese 1 1 Moving tractor with stalled 3 5 New season preparation essere 7 1 Operating suggestions 3 6 Parking brake adjustment ses 5 10 Parts and service eedem 1 1 PPO Shaft nom pep iss depu 4 1 Safety start interlock system sese 3 3 Steering lever tension ele ee ee cesses eeeeeeeeeeeeeeeeneeees 5 10 Steering linkage iere goes 5 2 OT 5 2 To the new owner seen 1 1 Torque values cement tte 5 2 Using this manual eene 1 1 Warranty Tegis
42. ever changing filter performing maintenance transporting or storing the tractor Models 4200 4400 4420 and 4600 This engine requires number 2 diesel fuel only The spin on type fuel filter is located on the left rear side of the engine Change filter after every 400 hours of operation or annually whichever Occurs first Diesel engines are subject to air blockage whenever the fuel tank runs empty the fuel filter has been removed any fuel lines have been disconnected or removed and replaced or when the tractor has been stored for a period of time Should such air blockage occur it will be necessary to bleed the system removing any trapped air between the fuel tank and filter then trapped air between the filter and injector pump as follows 1 Fill the tank with fresh fuel and make sure the shut off valve is open at tank 728444 Rev 11 02 A Fuel Filter 4300 amp 4500 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 5 14 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 If engine fails to start repeat steps 2 3 and 4 Models 4300 and 4500 This engine is designed to use unleaded gasoline wi
43. ever on left side of operator Adjustable tension Frame Constructed of 3 16 in 5 cm welded steel and 2 in x 2 in 5 cm x 5 cm steel torsion tubes with 1 8 in and 3 16 in 3 cm and 5 cm wall thickness Attachment drive PTO shaft splined 2 high speed U joints PTO shaft speed 3000 RPM Attachment clutch Electromagnetic Attachment lift Hydraulic cylinder with hand lever control Attachment tool bar Two point tool bar quick disconnect type Removing 2 pins and flotation springs releases any attachment Constructed of 1 4 in x 1 2 in 6 cm x 1 3 cm welded steel Auxiliary hyd raulics Auxiliary hydraulic valve with manual control lever and quick couplers Tires Standard rear tires 13 x 6 50 6 with rib tread Three drive tire options Regular 23 x 8 50 12 with turf tread Wide 23 x 10 50 12 with turf tread Wide 23 x 10 50 12 with bar tread Capacities Fuel tank 11 U S gal 41 6 1 Hydraulic oil system 3 5 U S gal 13 2 1 Cooling system 3 25 U S gal 12 3 I models 4300 amp 4500 2 50 U S gal 9 5 1 model 4200 2 75 U S gal 10 4 I model 4400 4420 4600 Dimensions Length 100 in 254 cm Width 50 in 128 cm Height 50 5 in 128 cm Weight 1500 Ibs 681 kg Seats Three seat options Regular padded backrest type with molded vinyl Heavy duty adjustable suspension seat with armrests and fore and aft adjustment Safety features
44. he engine is running check the instrument warning lights to determine problem area 12 Warning lights Fig 3 4 a cluster located on the footrest panel directly behind the neutral locks These lights will come on if an operating problem exists with the engine oil cooling or electrical alternator system e Oil pressure warning light this light comes on when the ignition switch is placed in ON position and stays lit until engine is running and a safe oil pressure is developed If light comes on during operation shut off the engine immediately and locate the problem e Temperature warning light this light will come on when the engine coolant temperature reaches an unsafe level during operation If light comes on shut down the machine as soon as possible Never risk continued operation when light remains on high temperatures can severely damage the engine e Alternator warning light this light will come on when the ignition switch is placed in the ON position and stays lit until the engine is running and alternator is supplying the electrical system If light remains on while engine is running it indicates that the battery is being discharged e Pre heat light models 4200 and 4400 this light comes on when ignition switch is placed in the PRE HEAT position to indicate that the diesel engine glow plugs are operating Pre heat light models 4420 and 4600 this light comes on when ignition switch is placed in the PRE HEA
45. hold the steering control lever in a neutral position as tractor will not move when the engine is running and drive pump is operating Rotating the front lock up and forward allows the control levers to be moved forward Lifting the rear lock with toe of operator s foot allows the control lever to be moved in reverse F Steering Control Lever Instrument Lights Rear Neutral Lock Lever Figure 3 4 6 Steering control lever Fig 3 4 this lever controls tractor speed and direction The lever is used to steer accelerate brake and change direction 7 Pump clutch lever Fig 3 5 this lever engages and disengages the hydraulic pump drive belt Push forward on lever to engage the hydraulic pump drive Pull back on lever to disengage IMPORTANT Always let the engine warm up to operating temperature and set the throttle at a moderate rpm before engaging the hydraulic pump clutch Engage the clutch slowly Sometimes more than one attempt is necessary particularly when the oil is cold and thickened Never snap the clutch to engage Allow the machine to run and warm the oil a short time before driving or using hydraulics Parking Brake Lever N Figure 3 5 8 Parking brake lever Fig 3 5 engage the parking brake by rotating the lever up and back until it over centers and locks Release by rotating the lever forward and down WARNING The parking brake is not designed to hold tractor on
46. ing link compresses the spring 0 06 0 10 1 1 2 2 turns Test neutral again by raising the neutral lock lever and moving the T lever around and returning it again to the neutral position and locking it Re adjust for neutral if necessary IMPORTANT The spring does not need to be very tight for this system to work properly On units with serial numbers after 11374 last five digits To adjust the rotational resistance of the T bar handle on these units lock the T bar in neutral The spring may be tightened to increase the rotational resistance to suit the operator s comfort Adjustment may be made by loosening the rear pump linkage nut Fig 5 6 and tightening the two spring nuts to compress the spring When the operator is satisfied with the resistance to rotation tighten the rear pump linkage nut Test neutral again by raising the neutral lock lever and moving the T lever around Wear Plate ont Neutral Tensio Other En o Cap Screw Figure 5 7 and returning it again to the neutral position and locking it Re adjust for neutral if necessary 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
47. ion in air cleaner See engine manual See engine manual Service air cleaner Hydraulic line blockage See your dealer Internal interference or leakage in wheel motor See your dealer Insufficient hydraulic oil supply Poor compression or timing Check level or reservoir Have dealer check hydraulic pump See your dealer or engine manual Steering linkage needs adjustment Adjust linkage Relief valves on pump Stuck open See your dealer For additional causes Leaks in system See engine manual Replace tighten hoses and connections Coolant level low Add coolant Fan belt slipping Adjust belt tension Radiator screen clogged Clean screen Radiator core clogged Clean radiator core Thermostat sticking or inoperative See engine manual Heat light malfunction See your dealer For additional causes See engine manual 6 1 Oil light glows Audible alarm Alternator light glows High oil consumption Engine knocks and other engine noises Tractor jerky when starting or Tractor operates in one direction only Hydraulic system operating hot Tractor creeps when Steering control lever in neutral Tractor circles or veers in one direction Tractor creeps when parking brake on Attachment auxiliary lifts respond slowly Low oil level Add oil Oil pressure gauge or line faulty See your dealer Oil diluted
48. 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 Exhaust gases contain carbon monoxide which is odorless and deadly poison Never attempt to make any adjustments or repairs to the tractor drive system or attachment while the tractor engine is running Repairs or maintenance requiring engine power should be performed by trained personnel only Never work under the machine or attachment unless it is safely supported with stands blocks or a hoist Do not touch hot parts of machine Never attempt to back machine onto transport trailer with attachment in raised position Never direct discharge of material from mower deck or snow thrower towards bystanders Always disengage the blades and wait for them to stop before crossing gravel drives walks or roads When operating on terrain where there is a potential for a roll over it is important that a ROPS be installed on the equipment The ROPS will prevent serious injury in the event of roll over Seat belt must be fastened while operating a machine equipped with ROPS Failure to use seat belt will result in serious injury in the event of a roll over Prevent fires by keeping engine compartment battery hyd
49. l 2 Install the filter element on base tighten 1 2 turn after initial gasket contact DO NOT OVERTIGHTEN 3 Start tractor engine engage the hydraulic pump clutch and let it run at approximately 2 3 throttle for a few minutes to work any trapped air out of the system before stroking the wheel motor control levers 4 Disengage the pump clutch lever stop the engine and check the filter and connections for leaks 5 Check hydraulic reservoir for specified oil level Add clean oil as necessary NOTE The hydraulic pump is equipped with tow valves For more information refer to Operation section Moving tractor with stalled engine Fuel system WARNING Observe usual fuel handling precautions do not smoke while refueling do not fill tank with engine running or while engine is hot allow engine to cool before storing machine inside a building keep fuel away from k T Ta Hydraulic Hilter Turn As Indicated Remove eos E P ed Figure 5 12 728444 Rev 11 02 Ven gt SCHW CN Figure 5 14 open flame or spark and store machine away from open flame or spark if there is fuel in the tank Read and observe safety precautions at front of this manual The 11 U S gallon 41 6 liter fuel tank is located in the tractor s right fender It is equipped with a gauge built into the filler cap There is a fuel shut off valve installed on the fuel tank Close this valve to prevent fuel loss or spill when
50. me or expensive premature repair The following Change radiator coolant m d inf 5 d Ch pkstesingehsckebzurges pages contain suggested maintenance information an schedules which the operator should follow on a routine basis x gt lt gt lt gt lt x gt lt gt lt gt lt 728444 Rev 11 02 5 1 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 A Clear away heavy build up of grease oil and dirt especially in the engine and hydraulic reservoir area minute dust particles are abrasive to close tolerance engine and hydraulic assemblies Some repairs require the assistance of a trained service mechanic and should not be attempted by unskilled personnel Consult your Hustler service center when assistance is needed WARNING Keep your machine clean remove any deposits of trash and clippings which can cause engine fires and hydraulic overheating as well as excessive belt wear Torque values Particular attention must be given to tightening the drive wheel lug and wheel motor nuts Failure to correctly torque these items may result in the loss of a wheel which can cause serious damage Torque values given below are in foot pound
51. ment will correct any defect in material or workmanship on the Hustler Turf Equipment with either new or used replacement parts Such repair including parts and labor shall be at the expense of Hustler Turf Equipment and Second Year At the conclusion of the one year limited warranty if the 1200 hour of use limit has not been reached described in paragraph a above there shall be an additional one year limited warranty on all defects in materials and workmanship in the covered drive train only see Covered Drive Train Description The second year of the warranty will be in effect until the 1200 hour of use limit is attained or the second year from the date of delivery is reached whichever comes first If the Purchaser discovers within this warranty period a defect in materials or workmanship in the covered drive train e He must promptly notify Hustler Turf Equipment or an authorized dealer in writing of the defect In no event shall such notification be received by Hustler Turf Equipment or an authorized dealer later than 120 days from date of delivery Within a reasonable time after such notification Hustler Turf Equipment will provide either new or used replacement parts and labor to correct any defect in material or workmanship in the covered drive train on the Hustler Turf Equipment Such repair including parts and labor shall be at the expense of Hustler Turf Equipment and c Rental Units 90 days Wi
52. n switch is turned to the RUN position battery voltage is supplied from the switch to the operator s seat switch When weight is applied to the seat the normally open seat switch closes and completes the circuit through the relay coil to ground Current flowing through the relay coil closes the normally open relay switch which completes the circuit to the neutral lock switch and fuel shut off solenoid So long as appropriate weight remains on the seat the engine will run when the electric clutch switch is ON and or the neutral lock is disengaged However when weight is removed from the seat the engine fuel shut off solenoid will close and the engine will stop 728444 Rev 11 02 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 When the neutral lock is engaged the switch is closed and current flows through one switch circuit to the starter for engine cranking Current from the ignition switch passes through the electric clutch switch when it remains in the OFF position to and through the other neutral lock
53. nd adjust to approximate neutral Fig 5 4 Re tighten nut and make the final adjustment with the turnbuckle If wheel s are rotating in reverse then loosen the lock nuts on the turnbuckle and rotate the turnbuckle to lengthen the linkage as referenced in Fig 5 1 until the wheel s come to a stop When both wheels remain in neutral then tighten the lock nuts to lock the turnbuckle Test again by raising the neutral lock lever and moving the T lever around and returning it again to the neutral position and locking it NOTE On units with serial numbers prior to and including 11374 last five digits if the tires are in neutral adjust the connecting link to make the spring vertical then tighten the nut holding the Figure 5 4 Nuts SS 3 59 06 Nuts Spring Spring Figure 5 5 Models 4200 amp 4400 Electrical Diagram oujoer3 Jepueg Jepues Sseid IO dwe Le 25 0 4 esny NOD 9 5 IN uodo ON 82 u9IMS ugno 2190813 leued JOyeolpu MOS YO MS 4 Jess amp _ 728444 Rev 11 02 5 4 Models 4200 amp 4400 ID Electrica uonounr M JePIOH esn Jj eur YOUMS 9190813 esn4euru 91 ana se YOUMS YANO o1 06 yms uoniu
54. nditions Hustler recommends Pre Cleaner Kit part number 462135 be used to extend the life of the element The Pre Cleaner mounts on top of the air filter canister and is designed to remove dirt and debris before it enters the air filter Cooling system Engine cooling is accomplished with circulated water and Ethylene Glycol mixture The radiator is equipped with a pressure cap and recovery tank System capacity for the 4300 and 4500 tractors is approximately 3 25 U S gallon 12 3 liter System capacity for the 4200 tractor is approximately 2 50 U S gallon 9 5 liter System capacity for the 4400 4420 4600 tractors is approximately 2 75 U S gallon 10 4 liter 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 Visually inspect the system daily prior to operating tractor Check coolant level in the recovery tank located under the engine hood on the right side behind fender Fig Recovery Tank ladiator Screen P a 728444 Rev 11 02 Figure 5 18 5 17 The tank is marked with cold engine and hot engine levels Level should not go above the hot level mark when engine is at normal operating temperature and coolant should be added to maintain level at or slightly above the cold level mark at all times When adding coolant pre mix th
55. onal resistance spring and linkage connecting the two pump levers located near the pump Prior to making either of these adjustments visually inspect the urethane grommets at the hydraulic pump end of the steering control levers or linkage straps and ball joints at front at least once a month or every 200 hours of operation whichever occurs first These grommets and ball joints must be replaced if lost or worn WARNING Failure to maintain these grommets and ball joints will affect steering Visually inspect steering shock absorbers every 500 hours for damage or wearing If excessive oil leakage is evident then replace that shock absorber The tractor steering has been factory adjusted to eliminate creeping when the neutral lock is engaged However should the tractor begin to creep the steering control lever linkage can be adjusted as follows Fig 5 1 and 5 2 Front end of steering linkage PP 7 GA 7 pad amp ps Turnbuckle ER Sn L 2 Ball joint Figure 5 1 Rear steering linkage adjustment Connecting link Linkage rod Loosen this bolt before making neutral adjustments amp to bring spring to vertical position when in neutral Neutralizer spring straps P dl Rear pump Front pump arm Figure 5 2 728444 Rev 11 02 Steering Lever Neutral Adjustment with Turnbuckle Fine adjustment to the steering is made with the turnbuckle on the front end of the steering cont
56. orten the linkage referenced in Fig 5 1 until the wheel s come to a stop Turnbuckle already at maximum adjustment On units with serial numbers prior to and including 11374 last five digits if the turnbuckle is adjusted to the maximum threads bottomed out or extended with more than 1 1 4 exposed when ignoring the jam nut on either side of the turnbuckle 3 NEUTRAL NO TURN Spring is perpendicular vertical to the plates Tension adjusting nut x LT 4 I EIN Plate on front Plate on rear pump arm pump arm Front of Tractor Connecting link Spring gt Tighten nut after steering is set to neutral Illustrative only not all parts are shown Figure 5 3 728444 Rev 11 02 5 3 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 On units with serial numbers after 11374 last five digits if the turnbuckle is adjusted to the maximum threads bottomed out or extended with more than 1 1 4 exposed when ignoring the jam nut on either side of the turnbuckle turn the turnbuckle back to the center of its adjustment 3 4 of threads showing when ignoring jam nut Then check the 3 59 06 dimension shown in Fig 5 5 Make certain this dimension is correct then loosen the front nut a
57. pressure use a piece of cardboard or wood never use your hands Lower all attachments and shut off engine before opening any hydraulic lines The 3 5 U S gallon 13 2 liter hydraulic oil reservoir is located under the tractor seat platform Fig 5 11 Check level of oil in hydraulic system after every 100 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 07 of Lubrizol additive Hustler P N 027912 This additive available from your Hustler dealer will increase the performance life of the hydraulic system components Filter is located to the left of reservoir and is accessible from underneath Fig 5 12 A standard oil filter wrench is used to change filter threads are right handed Use a 10 micron 700 psi filter element only IMPORTANT Fill the filter element with clean oil before installing to prevent drawing air into the system pumps 1 Fill the filter element with approximately 1 8 pints 0 82 liter clean system oil Smear a light coating of oil on upper surface of rubber sea
58. r 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 Always wear adequate eye protection when servicing the hydraulic system battery and cooling system or when grinding mower blades and removing accumulated debris Always wear adequate ear protection such as earplugs when operating this equipment as prolonged exposure to uncomfortable or loud noises can cause impairment or loss of hearing Do not wear radios or music headphones while operating the machinery Safe operation requires your full attention Always be aware of what is behind the machine before backing up Always inspect machine for damage after striking a foreign object If damage is found repair machine immediately Be sure to disengage deck clutch place steering control lever in neutral engage neutral lock levers stop tractor engine engage parking brake and remove ignition switch key before leaving operator s seat to inspect damage Always buckle seat belt if provided with one before starting tractor Never pull back suddenly on your control lever while the machine is in forward motion Never turn the PTO switch on unless the PTO shaft is securely connected
59. r mph at a time Exceeding these limits at one time will that can cause serious injury overheat the hydraulic system and may damage the 728444 Rev 11 02 3 5 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 A After starting engine release parking brake if set engage hydraulic pump clutch lever release the front neutral lock move it up and forward and steer as follows To go forward push steering control lever forward Fig 3 8 To go in reverse use ball of the left foot to lift rear neutral lock and pull lever back Fig 3 8 and 3 9 The lock should return to down lock position when lever is returned forward past neutral This prevents sudden reversing during normal forward operation and stopping To turn left rotate steering control lever counter clockwise while pushing steering control lever forward To turn right rotate steering control lever clockwise while pushing steering control lever forward The tractor will make a smooth wide turn Fig 3 10 To zero turn rotate steering lever the direction desired with the lever at or near the neutral position This will allow the drive wheels to counter rotate To stop or decrease speed move steering lever to neutral When going forward pull back gently on lever When going in reverse push forward gently on lever To increase speed increase steering lever s distance
60. r be used as a starting aid with this engine Warranty will be denied when engine damage results from such use 6 Rotate key switch full clockwise to START position release key immediately after engine starts NOTE If the engine does not start 10 seconds after the starter switch is set at Start wait for another 30 seconds and then start the engine starting sequence over again Do not allow the starter motor to run continuously for more than 20 seconds 7 Check to make sure the engine oil pressure and alternator warning lights are off If not stop engine immediately and check for the cause 8 Allow the engine to idle a few minutes before advancing the throttle or engaging the hydraulic pump This allows the hydraulic oil to warm up for easier system circulation 9 Stop the engine by disengaging drive clutch and throttle back to low idle for a couple of minutes move steering control levers to neutral engage neutral lock levers then rotate ignition key counterclockwise to the OFF position Remove the key from switch before leaving the tractor and set parking brake 10 If the machine is allowed to run out of fuel bleeding the fuel system will be required before restarting the engine Refer to the Maintenance amp Adjustment Fuel System section of this manual A Models 4300 and 4500 1 Before starting the tractor each day perform daily preoperation checking 2 Your Hustler tractor incorporates a safety int
61. raulic lines fuel line fuel tank and operator s station clean of accumulated trash grass clippings and other debris Always clean up spilled fuel and oil Specific safety warning decals are located on the are many other possibilities too numerous to mention Just remember to always exercise extreme caution when operating on any slope A Never allow persons to operate this machine without proper instruction or allow children to operate machine A Never put hands or feet under any part of the machine while it is running A Never drive the tractor at high speeds without a front end attachment mounted to the tool bars Keep the attachment as low to the ground as possible mower decks should rest on the gauge wheels equipment near the immediate areas of potential hazards These decals should not be removed or obliterated Replace them if they become non readable Replace all safety decals that are damaged lost or otherwise illegible Replace all decals after repainting If a part is replaced that has a decal on it obtain a replacement decal from your Hustler dealer and install the decal in the same location The following illustrations show the various safety decals that are located on the machine A brief explanation is shown to help the operator understand the meanings of these decals V Read Owner s Manual and Quick Reference Card before attempting to operate this machine 2 2 728444 Rev 11 02 i J AWARNING
62. reach of warranty must be commenced within twenty five 25 months following delivery of the goods in a non rental application Any action for breach of warranty must be commenced within 120 days following delivery of the goods in a rental application 728444 Rev 11 02 NO OTHER WARRANTIES Unless modified in writing signed by both parties and approved by the President of Hustler Turf Equipment this agreement is understood to be the complete and exclusive agreement between the parties superseding all prior agreements oral or written and all other communications between the parties relating to the subject matter of this agreement No employee of Hustler Turf Equipment or any other party is authorized to make any warranty in addition to those made in this agreement ALLOCATION OF RISKS This agreement allocates the risks of product failure between Hustler Turf Equipment and the purchaser This allocation is recognized by both parties and is reflected in the price of the goods OWNER S RESPONSIBILITY You must maintain your Hustler Turf Equipment product following the maintenance procedures described in your owner s manual Such routine maintenance whether performed by a dealer or by you is at your expense This machine like any other powered equipment is potentially dangerous unless properly operated Any operator must be cautious and keep safety in mind at all times Any operator prior to using the Hustler Turf Equipment shoul
63. ressure use a piece of cardboard or wood never use your hands To relieve all pressure in system turn engine off and lower attachment The Hustler tractor steering is designed for sensitive response Rapid movement of the steering lever in either direction could result in a reaction of the tractor that can cause serious injury Keep the neutral lock lever in the down position except while backing Avoid quick stops Keep attachment lift cylinder fully extended attachment wheels on ground when transporting and going down slopes Move tractor very slow when attachment is removed Reduce speed on slopes Keep covers in place while machine is in operation OPERATION Ignition Switch Electric Clutch Switch Throttle Lever 4200 4400 4420 amp 4600 Neutral Lock Levers Throttle Lever 4300 amp 4500 Steering Control Lever 3 Choke Lever 4300 amp 4500 only Pump Clutch Lever Figure 3 1 Throttle Ignition NM Mode Lever Switch 9744300 amp Models 4200 amp 4400 S 14500 amp 4600 Figure 3 2 Controls For general location of the controls described in this section refer to Figure 3 1 1 Ignition switch Fig 3 2 Models 4200 4400 4420 and 4600 A four position switch off pre heat run and start With key inserted rotate it counterclock wise for engine pre heat then rotate full clockwise for 728444 Rev 11 02 3 1 Parking Brake 12 Warning Lights
64. rol lever linkage Additional adjustment is available if necessary at the rear linkage straps near the pump Neutral is properly adjusted when the T Lever steering tube is locked in the neutral position and the drive wheels are in neutral not turning If the tractor creeps in neutral position the control linkage may be adjusted as follows 1 Raise and block the tractor up so the drive wheels are off of the floor WARNING Make certain machine is secure A when it is raised and placed on the jack stands The jack stands should not allow the machine to move when the engine is running and the drive wheels are rotating Use only certified jack stands 2 Position the T Lever steering tube in neutral position and lock the neutral lock lever Start the engine engage hydraulics and observe which way the wheels are rotating NOTE On units with serial numbers prior to and including 11374 last five digits before making the neutral adjustment loosen the nut securing the connecting link to the rear pump steering linkage Fig 5 2 This will be tightened again after neutral is adjusted NOTE On units with serial numbers after 11374 last five digits before making the neutral adjustment loosen the nut securing the connecting link to the front pump steering linkage Fig 5 4 This will be tightened again after neutral is adjusted If wheel s are rotating forward loosen the lock nuts on the turnbuckles and rotate the turnbuckle to sh
65. rongly recommended that the operator drive the machine off of the slope using extreme caution if any sign of loss of traction is detected Wait until the condition that caused the problem is resolved before attempting to operate on the slope again Terrain conditions can affect traction resulting in possible loss of control of the machine Some of the conditions to be aware of are 1 Wet terrain Depressions in the ground i e holes ruts washouts Soil type i e sand loose dirt gravel clay Grass type density and height Extremely dry conditions of grass Tire pressure The attachments mounted to the tractor will also affect the way it handles on a slope Attachments such as the grass collection system may affect the machine differently than another attachment would Be aware that each attachment s characteristics vary Another consideration to safe mowing on slopes is to be aware of what is located at the bottom of the slope Extreme caution should be used when there is a hazard located at the bottom of the slope Some examples are 1 Water i e lake river 2 Cliff 3 Roads highways 4 Buildings 5 Rocks These are just a few examples of situations when caution must be used when operating on a slope There gt gt gt gt 4 Clean flammable material from machine Never leave machine unattended with ignition key in switch especially with children present Never refuel tractor while engine
66. s Wheel lug nuts 65 75 ft Ibs Wheel motor nut 425 450 ft Ibs It is recommended that these be checked after the first 2 hours of operation initially and every 50 hours following removal for repair or replacement For engine torque values see engine owner s manual Tires It is important for level mowing that the tires have the same amount of air pressure The recommended pressures are Drive Wheels Tail Wheels nose Gem 14 18 psi If the machine has Hustler Range Wings or a Hi Lift BAC VAC then the tire pressure should be increased to Drive Wheels Tail Wheels Solid fill tires are not recommended for Hustler turf equipment On any machine with a failure due to solid filled tires the warranty claim will be denied Hour meter To recognize when your machine needs servicing check the hour meter and the maintenance schedule The hour meter shows the number of hours the engine has run and the maintenance schedule lists the service intervals Lubrication There are seven grease fittings on the tractor which require regular servicing Use a good grade SAE multi purpose grease and wipe accumulated dirt from fitting 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 Neutral adjustment in the neutral lock position 2 The rotati
67. s 5 yoo 9 728444 Rev 11 02 5 8 Models 4420 amp 4600 ID Electrica 14617 HO 14617 y 14617 110 sseuJeH M JUBIT 81 MOTI3A 81 MOTI3A OTI3A 0 ce e 14617 10H avds 3 uogounr sseuJeH SIM 14617 110 14817 jezzng Movig MOTIZA MOTI3A 8c 12 9 Sc aods o jezzng g vl y uonounr SJIAA ON YAMS 4907 YAS YANO 110813 0 NOD YAMS 4907 YOHMS YANO WOD YAMS 4907 YN 2u12e 3 0 JepjoH SN4 N e N anid ez uogounf SAA esn4 eurT u EN 3n18 e punoj5 noH gs Movi iz 183894 ea ds 3ONVH 02 32vig 3n18 e si o er am vi sao SLIHM 91 st vl AONVYO 4 ania 81 v punog 0 106r Enid Moo 61 yams o ZL uos LONIU 1467 Bnd jeu 44617 el 8 sme a sn UOHOUNP sseuJeH M
68. sston Kansas 67062 or call 1 620 327 4911 WHAT IS NOT COVERED BY THIS WARRANTY Hustler Turf Equipment does not warranty e Some product components or manufactured by Hustler Turf Equipment Repairs made by unauthorized persons Damage caused by use of the Hustler Turf Equipment for purposes other than those for which it was designed Damages caused by disasters such as fire flood wind and lightening Damages caused by neglect abuse abnormal use improper or unreasonable use accident negligence or misuse Repairs or replacement resulting from the use of unauthorized parts accessories or attachments Repairs or replacement as the result if any alterations or modifications in the determination of Hustler Turf Equipment which adversely affects the operation performance or durability of the equipment Hustler Turf Equipment which has the serial number removed or made illegible Depreciation or damage caused by normal wear lack of reasonable and proper maintenance failure to follow the product s owner s manual operating maintenance and adjustment instructions or other parts not 728444 Rev 11 02 operational instructions provided by Hustler Turf Equipment e Normal maintenance parts and service including but not limited to filters fuel lubricants tune up parts belts brake or steering adjustments Repairs necessary due to improper fuel contaminates in the fuel system or failure to properly prepare the fuel
69. steep slopes 9 Attachment lift lever Fig 3 6 This lever controls the hydraulic raising and lowering of tractor tool bars and front end attachments Pull lever back to raise the bars and push it forward to lower them Normally the attachment is lowered to rest directly on the ground or gauge wheels and allowed to follow or float over the ground contours referred to as flotation For best flotation push the lever forward until attachment reaches the ground and hold it for several seconds until all weight is removed from the tool bars and lifting cables are slack Auxiliary control lever Fig 3 6 this lever is for control of the hydraulic cylinder mounted on some optional attachments Use of lever varies with each 10 Attac hne ever Auxiliary Control lever Figure 3 6 728444 Rev 11 02 attachment and is described in more detail in the operating instructions provided with the attachment Instrumentation 11 Electronic hour meter Fig 3 5 registers 1 10 hour increments up to 9 999 9 total hours Connected to the ignition switch the meter records the accumulative time while the ignition key is switched to the ON position Audible alarm signal not shown will sound when the ignition switch is turned to the ON or START position It will silence when the engine starts This alarm will also sound to indicate a problem with low engine oil pressure or high water temperature If alarm sounds when t
70. switch circuit and on to the fuel shut off solenoid and coil In summary this is a safety control circuit which inhibits the supply of heavy current to the starter motor unless the electric clutch switch is in the OFF position and the neutral lock is engaged 3 Accessory and Instrument Circuit this circuit is used for the warning lights and audible signal connected to the engine oil alternator and water sensing units It also supplies power for the hour meter and electric clutch switch When the ignition switch is turned to the RUN position battery voltage is supplied to the engine alert system via ignition switch terminals Grounding to complete the circuit and signal the operator is through the oil pressure and water temperature sending units The alternator warning light is connected between the ignition switch and the alternator field circuit The ignition switch also supplies battery voltage through the on off toggle switch and in line 5 amp fuse to the electric clutch with frame ground wire The hour meter operates from a wire tap at electric clutch switch and a frame ground wire Burnishing the electric clutch WARNING To insure maximum performance and life it is necessary to burnish the clutch The electric clutch will need to be burnished properly if a new clutch is installed Burnishing the clutch develops maximum contact between the clutch armature and the rotor To burnish the clutch use the following procedure 1
71. ta P N 16616 8916 1 Other information includes ORDER KUBOTA HUSTLER DESCRIPTION PART NUMBER PART NUMBER Illustrated Parts List Kubota V1205 97898 70850 758920 Work Shop Manual Kubota V1205 97897 00871 758938 For more information See your Hustler dealer 728444 Rev 11 02 8 1 ORDER HUSTLER PART NUMBER SUNSTRAND DESCRIPTION PART NUMBER Series 40 Service amp Repair Manual BLN 10056A 717231 For more information Sundstrand Hydro Transmission Customer Services 2800 East 13th Street Ames Iowa 50010 Phone 515 239 6586 Wheel motors The two hydraulic drive wheel motors on tractor are manufactured by Ross Gear Division of TRW ORDER ROSS HUSTLER DESCRIPTION PART NUMBER PART NUMBER Torquemotor MG MF MB ME Series Service Procedures MG MF MB ME 100 705343 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 728444 Rev 11 02 TECHNICAL SPECIFICATIONS Hustler 4200 specifications Engine Make Kubota Model D950 B 26 Type Three cylinder in line 4 cycle diesel liquid cooled Displacement 56 6 cu in 927 cc Horsepower 21 5 hp 16 KW mfg rating 3000 RPM Maximum Torq
72. th a minimum octane rating of 87 See engine manual for exceptions The fuel filter is located on the left side of the carburetor Fig 5 15 Change filter every 400 hours or annually whichever occurs first When changing filter by sure to note direction of fuel flow marked on filter case When replacing the fuel filter check the fuel line hoses for any cracks or leaks Replace as needed Engine oil and filter Check engine oil daily and after every 4 hours of operation Tractor must be setting level when checking oil Refer to engine manual and maintenance schedule for oil recommendation and capacities Engine air filter A specially designed two stage dry filter with restriction indicator Fig 5 16 supplies clean combustion air to the engine This is a self cleaning element but it needs to be replaced whenever the restriction indicator shows red Check the indicator daily and replace element as needed or annually whichever occurs first Recommended service procedure Many engine failures can be attributed to improper air cleaner servicing Ingested dust and dirt will cause cylinder piston and bearing damage in a few hours Dusted engines will result from 1 Overservicing the air filter element 2 Improper installation Service Indicator Figure 5 16 3 Damaged filter seals or canister 4 Incorrect air filter element size 5 Use of poorly designed aftermarket air filter elements Air cleaner servicing is
73. thin 90 days of date of delivery Hustler Turf Equipment provides a limited warranty on all materials and workmanship for units used for rental purposes If the Purchaser discovers within this warranty period a defect in materials or workmanship e He must promptly notify Hustler Turf Equipment or an authorized dealer in writing of the defect In no event shall such notification be received by Hustler Turf Equipment or an authorized dealer later than 120 days from date of delivery Within a reasonable time after such notification Hustler Turf Equipment will repair any defect in material or workmanship on the Hustler Turf Equipment with either new or used replacement parts Such repair including parts and labor shall be at the expense of Hustler Turf Equipment and COVERED DRIVE TRAIN DESCRIPTION Covered drive train components include and are limited to hydraulic pumps and wheel motors However such definition shall not include fittings hoses or seals utilized on the Hustler Turf Equipment and shall be specifically excluded hereunder WHO MUST PERFORM THE WARRANTY SERVICE All warranty service will be performed by dealers authorized by Hustler Turf Equipment Service calls and or transportation expense of the product to and from the authorized dealer for warranty work will be paid by the owner of the product For warranty service you can contact an authorized dealer or write Hustler Turf Equipment 200 South Ridge Road He
74. to a power driven attachment Never operate a poorly maintained machine Never carry passengers Never attempt high speed maneuvering especially in crowded or congested areas A Always keep clear of the mower blades and attachments during their operation 4 Never make sudden starts stops turns or reverse direction especially when manuevering on slopes The steering is designed for sensitive response Rapid movement of the steering lever in either direction could result in a reaction of the tractor that can cause serious injury If any attachment or additional weight is mounted on the rear of the unit any sudden movement of the steering lever could cause the front of mower to come off of the ground resulting in possible loss of control Always stay alert for holes and hidden hazards Use extreme caution when operating on slopes Be extremely careful changing directions on a slope Slow down A A Do not operate where the machine could slip or tip Installa ROPS and seat belt on the tractor when operating on slopes 4 The Hustler mower is capable of operating horizontally traverse on moderately steep slopes When operating on slopes of 15 degrees or more be aware of any conditions that may cause the tractor drive tires to lose traction resulting in a possible loss of control of the machine An operator should not operate on a slope until he is thoroughly familiar with the equipment It is st
75. ual which is included with 4600 owner s manual packet For additional copies order Hustler P N 756882 Kubota P N 16616 8916 1 Other information includes ORDER KUBOTA HUSTLER DESCRIPTION PART NUMBER PART NUMBER Illustrated Parts List Kubota V1505 97898 70870 758896 Work Shop Manual Kubota V1505 97897 00880 758912 For more information See your Hustler dealer The 4300 amp 4500 use a Ford VSG 4111 amp VSG 4131 four cylinder water cooled engine Primary source of information is engine operator s manual which is included with owner s manual packet For additional copies order Hustler P N 031682 Ford P N FPPO 194 263 Other information includes ORDER FORD HUSTLER DESCRIPTION PART NUMBER PART NUMBER Illustrated Parts List Ford VGS 411 413 194 265 031724 Engine Service Manual Ford VGS 41 1 413 FPPO 194 264 031716 Ford Service Directory PPO 192 333 035105 For more information See your Hustler dealer Hydraulic pump Power to wheel motors attachments and auxiliary cylinders is supplied by a Sundstrand tandem Series 40 hydraulic pump For information on pump see literature listed below For more information See your Hustler dealer The 4420 uses a Kubota V1205 B four cylinder water cooled engine Primary source of information is engine operator s manual which is included with 4420 owner s manual packet For additional copies order Hustler P N 756882 Kubo
76. ue 41 ft 165 1800 RPM Compression Ratio 22 1 Operating RPM 3000 max load 3200 no load Starter 12 volt 8 KW gear drive Charging System 12 volt 25 amp belt driven alternator Injector Pump Bosch type mini pump Injector Nozzle DN 12 SD 12 Starting Assist Glow plug system is standard Ignition key operates system Crankcase Capacity 4 5 qts 4 3 1 Fuel Diesel No 2 Hustler 4400 specifications Engine Make Kubota Model V1200 B 27 Type Four cylinder in line 4 cycle diesel liquid cooled Displacement 75 49 cu in 1237 cc Horsepower 28 5 hp 21 3 KW mfg rating 3000 RPM Maximum Torque 54 7 ft lbs 1800 RPM Compression Ratio 22 1 Operating RPM 3000 max load 3200 no load Starter 12 volt 8 KW gear drive Charging System 12 volt 25 amp belt driven alternator Injector Pump Bosch K 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 1 Fuel Diesel No 2 Hustler 4420 specifications Engine Make Kubota Model V1205 B 1 Type Four cylinder in line 4 cycle diesel liquid cooled Displacement 73 15 cu in 1198 cc Horsepower 30 0 hp 22 4 KW mfg rating 3000 RPM 728444 Rev 11 02 9 1 Maximum Torque 57 0 ft lbs 2600 RPM Maximum torque Compression Ratio 22 1 Operating RPM 300
77. upler dust covers must be in place to prevent contamination Always replace them immediately if damaged or lost Once connected the operator has control of the attachments hydraulic cylinder by means of the control lever on operator s deck If stroking the lever produces the wrong cylinder movement up down right left etc reverse the attachment hoses at the quick connect couplers WARNING Never attempt to connect or disconnect the couplers with pump clutch engaged and system oil under pressure MAINTENANCE AND ADJUSTMENTS Maintenance Locator Chart PTO Shaft Radiator Cap U Joint Grease Zerks 2 7 Battery Location Oil Dipstick diesel units Oil Cooler PTO Spline Grease Zerk 8 Air Filter 8 Service Indicator Oil Fill Location Drive Tire Hydraulic System Filter Oil Filter gas units FuelFilter gas units Rear Tire Hydraulic Reservoir 10 Oil Dipstick gas units Fuel Filter diesel units Pump Clutch Mount Grease Zerk Fuel Gauge amp Filler Cap 11 Oil Filter Location diesel units Coolant Recovery Tank Tail Wheel Pivot INTERVALS HOURS Refer to break in services for initial change MAINTENANCE SCHEDULE More often under dusty or dirty conditions and during hot weather X Torque after first 50 hours also Y Torque after first 2 hours of operation SERVICE AT INTERVALS INDICATED XX
78. y bend or distort them For cleaning use compressed air or pressurized water only DANGER Never remove radiator cap when engine is hot Pressurized hot steam and water may be released causing serious burns or possible blindness Belt replacement 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 WARNING If the pump belt fails loss of control may occur when operating on a slope Inspect the belt pulley grooves and flanges for wear A new belt or one in good condition should never run against the bottom of the groove Replace the pulley when this is the case otherwise belt will lose power and slip excessively Never pry a belt to get it on a pulley as this will cut or damage the fibers of the belt covering Keep oil and grease away from belts and never use belt dressings Any of these will destroy the belt composition in a very short time General engine maintenance 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 Please refer to these manuals for engine servicing lubricating oil levels with quality and viscosity recommendations belt tensioning etc The engine warr
79. y 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 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 5 14 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 The mowing conditions will determine the frequency of air filter element changing Generally it s time to service the air filter element when the restriction indicator shows red or when the engine begins to lose power Improper installation of an air filter element Dust must not leak past the seals on each end of the air filter element The filter must be aligned within the canister and properly seated for an effective seal so that no dirt can enter the engine Be sure to tighten the filter retaining nut securely to insure a proper seal Damaged filter seals or canister Never bang or bump the filter element against the tir

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