Hustler 4500/4600 Parts Manual ······· Hustler Turf Equipment ····· P.O. Box 7000 ··· Hesston, Kansas 766238 Rev. 8/06 · 67062-2097 WARNING: The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. IMPORTANT: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate this engine on any forest-covered, brush-covered, or grass-covered unimproved land. Other states or federal areas may have similar laws. This spark ignition system complies with Canadian ICES-002. The Engine Owner's Manual provides information regarding the U.S. Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance and warranty. Keep Engine Owner's Manual with your unit. Should the Engine Owner's Manual become damaged or illegible, replace immediately. Replacements may be ordered per the information found in the Product Information section of the owner's manual. Table of Contents Chapter 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Chapter 2 Contents Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frame Assembly - 4500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frame Assembly - 4600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sub-Frame Assembly - 4500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sub-Frame Assembly - 4600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 4 6 8 10 Chapter 3 Contents Tool Bar Assembly - 4500. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tool Bar Assembly - 4600. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Chapter 4 Contents Fuel System - 4500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Fuel System - 4600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fender Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Chapter 5 Contents Exhaust System - 4500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust System - 4600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cleaner Assembly - 4500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cleaner Assembly - 4600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 4 6 8 Chapter 6 Contents Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tail Wheel Installation - 4500 & 4600 . . . . . . . . . . . . . . . . . . . . . . . 4 Tail Wheel Breakdown - 747782 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Chapter 7 Contents Steering Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Neutral Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Chapter 8 Contents Mechanical Throttle Assembly - 4500 . . . . . . . . . . . . . . . . . . . . . . . Electronic Throttle Assembly - 4500 . . . . . . . . . . . . . . . . . . . . . . . . Throttle Control Cable - 4600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Choke Control Cable Assembly - 4500 . . . . . . . . . . . . . . . . . . . . . . Carburetor Assembly - Mechanical Throttle . . . . . . . . . . . . . . . . . . Carburetor Connections- Electronic Throttle. . . . . . . . . . . . . . . . . . Chapter 9 Contents Front Engine Assembly - 4600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Engine Assembly - 4600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Engine Assembly - 4500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Engine Assembly - 4600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Engine Assembly (Mechanical Governor) - 4500. . . . . . . . . . Rear Engine Assembly (Electronic Governor)- 4500 . . . . . . . . . . . Chapter 10 Contents 766238 8/06 2 4 6 8 10 12 2 3 4 6 8 12 Cooling System - 4500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Cooling System - 4600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Chapter 11 Contents Oil Cooler Assembly - 4500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Oil Cooler Assembly - 4600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Chapter 12 Contents Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve & Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic & Fuel Line Routing - 4500. . . . . . . . . . . . . . . . . . . . . . . Hydraulic & Fuel Line Routing - 4600. . . . . . . . . . . . . . . . . . . . . . . Chapter 13 Contents Electrical System (Footrest) - 4500 . . . . . . . . . . . . . . . . . . . . . . . . Electrical System (Engine) - 4500 (Mechanical Governor). . . . . . . Electrical System (Engine) - 4500 (Electronic Governor) . . . . . . . . Electrical System (Footrest) - 4600 . . . . . . . . . . . . . . . . . . . . . . . . Electrical System (Engine) - 4600 . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Diagram - 4500 (Mechanical Governor) . . . . . . . . . . . . . Electrical Diagram - 4500 (Electronic Governor) . . . . . . . . . . . . . . Electrical Diagram - 4600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 6 8 10 2 6 10 14 20 24 26 28 Chapter 14 Contents Decal Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Chapter 15 Contents 4500 Engine & Hydraulic Set-Up Procedures-Mechanical Gov . . . 2 4600 Engine & Hydraulic Set-Up Procedures . . . . . . . . . . . . . . . . 6 Chapter 16 Contents Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Motor Breakdown - 007914 . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Motor Breakdown - 792341 . . . . . . . . . . . . . . . . . . . . . . . . . Electric Clutch Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 17 Contents Seat Kit 306878K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat Kit 306860K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat Kit 306894K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat Kit 311217K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hood Kit 318915K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Scoop Kit 466615 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Tire Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 4 6 8 2 3 4 5 6 8 10 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1 766238 8/06 Chapter 1 General Information This manual covers Tractor Models:4500 (924738) & 4600 (925008) Frequently Ordered Parts PART NO. 027912 076919 032029 065730 033779 DESCRIPTION LUBRIZOL 7 OZ. BOTTLE RADIATOR CAP HEAVY-DUTY AIR FILTER HYDRAULIC OIL FILTER PUMP DRIVE BELT Model 4500 708677 044693 044727 FUEL FILTER, (MOTORCRAFT P/N E3FZ-9155-F OR EQUIVALENT) ENGINE OIL FILTER, (FL 400A OR EFL125) SPARK PLUG, (MOTORCRAFT P/N AGSF-22C OR EQUIVALENT) FUEL FILTER (KUBOTA P/N 70000-43081) ENGINE OIL FILTER (KUBOTA P/N 16271-32090) FAN BELT (KUBOTA P/N 16282-97011) Model 4600 042341 758870 758888 Service Literature PART NO. DESCRIPTION 728444 OWNER'S MANUAL 717231 SUNDSTRAND SERVICE MANUAL (M-25 HYDRAULIC PUMP) 033654 ASSEMBLY INSTRUCTIONS FOR TORQLINKTM SERVICE PROCEEDURE, GO TO http://www.parker.com Model 4500 031682 031724 031716 035105 FORD OWNER'S MANUAL FORD IPL FORD SHOP MANUAL FORD SERVICE DIRECTORY KUBOTA V1205/1505 OWNER'S MANUAL KUBOTA V1505 IPL KUBOTA V1505 SHOP MANUAL Model 4600 756882 758896 758912 When ordering parts, you must use the part number as shown for each part, not the index number. Always give the tractor model and serial number, and engine model and serial number to your parts and service representative. Note: Items sold in bulk such as seals and hoses are sold by the foot. Using this manual Illustrations used were current at the time of printing, but subsequent production changes may cause your machine to vary slightly in detail. Excel Industries, Inc. 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 parts manual, see your Hustler dealer for current information and parts. 766238 8/06 1-1 Hardware Description Codes & Abbreviations The following codes are used throughout this parts manual. Refer to this list when ordering parts. ABBREVIATION CB CE CP CS CW FW HX LW MB MS NT SC SB SS DESCRIPTION Carriage Bolt Clevis Pin Cotter Pin Cap Screw Cup Washer Flat Washer Hex Head Lock Washer Machine Bushing Machine Screw Nut Self Tapping Cap Screw Shoulder Bolt Set Screw Standard Torques The following chart lists the standard torque values for the threaded fasteners found in this manual. Torque all cap screws, nuts and set screws to these values unless a different torque is noted. SIZE .250 .312 .375 .438 .500 .562 .625 .750 .875 FT.-LBS 8.2 17 30 48 73 105 145 260 420 NM 11.1 23 40 65 99 143 200 350 565 NOTE: SIZE M3 M4 M5 M6 M8 M10 M12 M16 M20 FT.-LBS 1 2.2 4.5 7.7 18.5 37 64 160 320 NM 1.3 3 6.1 10.4 25 50 87 215 435 Loctite 592 to be used on all pipe threads. Lubricate all grease zerks. 1-2 766238 8/06 Chapter 2 Contents Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Frame Assembly - 4500. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Frame Assembly - 4600. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Sub-Frame Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Sub-Frame Assembly - 4600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 766238 8/06 2-1 Footrest Assembly 22 21 1 8 5 3 4 2 1 1 23 6 7 10 3 20 11 12 13 11 13 16 17 20 15 17 7 18 9 19 2 12 Main Frame Assembly 14 2-2 766238 8/06 Footrest Assembly INDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 SERVICE PART NO. 306811 307066 075408 002261 082420 055947 017038 017079 467738 442525 034280 017004 076547 034272 467837 055939 025403 024927 006841 735035 203455 017251 011379 MFG. PART NO. 306811 307066 075408 002261 082420 055947 017038 017079 467738 442525 034280 017004 076547 034272 467837 055939 025403 024927 006841 735035 203455 017251 011379 QTY. 1 1 1 1 1 4 12 4 1 1 8 8 8 4 1 8 16 8 1 A/R 3 3 3 SEAT MOUNT LATCH PIN FW .402 X .689 X .032 ZN SPRING ROLL PIN .125D X .875 LG ZN CS .25-20 X .50 HX G5 ZN LW .250 MEDIUM SPRING ZN FW .250 X .560 X .040 SAE ZN FOOTREST REAR SEAT SUPPORT CS .312-18 X .750 HX G5 ZN LW .312 MEDIUM SPRING ZN FW .344 X .688 X .065 SAE ZN NT .312-18 HX G5 ZN GRAB HANDLE CS .25-20 X .750 HX G5 ZN FW .281 X .625 X .062 ZN NT .25-20 HX G5 ZN PLUG BUTTON .562 PLUG BUTTON 1.125 SPRING CLIP CP .156D X 1.00 LG HML ZN TENSION SPRING DESCRIPTION NOTES: 1. Item 5, roll pin, to be centered in item 2, latch pin. 2. 4600 only. 3. 4500 only. 766238 8/06 2-3 Frame Assembly - 4500 1 2 3 4 1 FOOTREST 7 8 9 3 5 6 16 17 12 15 14 13 8 11 9 24 23 10 8 20 19 18 See Detail A 20 19 21 22 24 2 2 23 2 23 Detail A 2-4 766238 8/06 Frame Assembly - 4500 INDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 SERVICE PART NO. 383141 077859 017137 248237 017046 067918 034280 017004 076547 036236 385344 034272 052860 017012 076422 081745 448035 013334 017038 023069 387928 064329 033035 033035 MFG. PART NO. 383141 077859 017137 248237 017046 067918 034280 017004 076547 036236 385344 034272 052860 017012 076422 081745 448035 013334 017038 023069 387928 064329 033035 033035 QTY. 1 2 4 1 2 2 2 6 6 4 2 2 4 4 4 1 1 3 5 5 1 2 2 2 MAIN FRAME CS .50-13 X 3.250 HX G5 ZN FW .560 X 1.370 X .109 SAE ZN REAR CROSS MEMBER LW .50 MEDIUM SPRING ZN NT .50-13 HX G8 ZN CS .312-18 X .750 HX G5 ZN LW .312 MEDIUM SPRING ZN FW .344 X .688 X .065 SAE ZN CS .312-18 X 1.00 HX G5 ZN FOOTREST SUPPORT ANGLE NT .312-18 HX G5 ZN CS .375-16 X 1.250 HX G5 ZN LW .375 MEDIUM SPRING ZN FW .406 X 1.00 X .060 ZN CS .312-24 X .750 HX G5 ZN HOSE BRACKET CS .25-20 X .870 HX G5 ZN LW .250 MEDIUM SPRING ZN FDW .281 X 1.250 X .047 ZN BOTTOM SCREEN CS .25-20 X .625 HX G5 ZN SEAL .12 X .75 X 6" SEAL .12 X .75 X 29.5" DESCRIPTION NOTES: 1. Torque to 45 Ft. Lbs. 2. Align items 23 & 24, seals, with edges of item 21, bottom screen. Cut seal for slots. 766238 8/06 2-5 Frame Ass ...