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HUSTLER 4200 - page 1
4200/4300/4400 4420/4500/4600 Hustler T ractor Owner’ s Manual ••••••• Hustler Turf Equipment ••••• P.O. Box 7000 ••• Hesston, Kansas • 67062-2097 728444 Rev. 11/02 ...
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HUSTLER 4200 - page 2
The engine e xhaust from this product contains chemicals known to the State of Calif or nia to cause cancer , bir th def ects or other reproductiv e har m. W ARNING: 728444 Rev. 11/02 ...
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HUSTLER 4200 - page 3
728444 Rev. 11/02 T ABLE OF CONTENTS 1. General Information .............................................................Sect. 1 2. Safety Precautions ................................................................Sect. 2 3. Operation ..............................................................................Sect. 3 4. Accessories.............. ...
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728444 Rev. 11/02 1-1 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 ...
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HUSTLER 4200 - page 6
728444 Rev. 11/02 1-2 Hustler T urf Equipment TWO YEAR LIMITED W ARRANTY FOR TRA CTORS AND PO WER 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 c ...
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HUSTLER 4200 - page 7
728444 Rev. 11/02 operational instructions provided by Hustler Turf Equipment. ● 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 sys ...
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HUSTLER 4200 - page 8
728444 Rev. 11/02 ...
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HUSTLER 4200 - page 9
728444 Rev. 11/02 2-1 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 h ...
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HUSTLER 4200 - page 10
• Do not operate where the machine could slip or tip. • Install a ROPS and seat belt on the tractor when operating on slopes. ▲ 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 ...
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HUSTLER 4200 - page 11
Never operate the mower deck with side deflector removed or in raised position, except when the grass catcher attachment is being used. 728444 Rev. 11/02 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 ...
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HUSTLER 4200 - page 13
728444 Rev. 11/02 3-1 Contr ols 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 start; relea ...
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HUSTLER 4200 - page 14
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 o ...
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HUSTLER 4200 - page 15
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. • ...
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HUSTLER 4200 - page 16
2. Engage safety start interlock system, buckle seat belt if tractor has seat belt. 3. Set parking brake. 4. Set throttle at approximately 1/3 OPEN position. 5. 4200 & 4400 — Rotate key switch counterclockwise to PRE-HEAT; hold this position for 15 seconds when temperature is above freezing, or for 30 seconds when temperature is below freezin ...
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HUSTLER 4200 - page 17
Mo ving tractor with stalled engine 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. 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 f ...
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HUSTLER 4200 - page 18
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. 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 con ...
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HUSTLER 4200 - page 19
728444 Rev. 11/02 4-1 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. Th ...
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HUSTLER 4200 - page 20
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HUSTLER 4200 - page 21
728444 Rev. 11/02 5-1 •– Refer to break-in services for initial change. + – 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. XX – Check monthly or every 200 hours, whichever comes first. Z – Perform initial hydraulic filter change afte ...
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HUSTLER 4200 - page 22
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. WARNING: Keep your machine clean, remove any deposits of tr ...
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HUSTLER 4200 - page 23
Steering Lever Neutral Adjustment with Turnbuckle Fine adjustment to the steering is made with the turnbuckle on the front end of the steering control lever linkage. Additional adjustment is available if necessary at the rear linkage straps near the pump. Neutral is properly adjusted when the T-Lever steering tube is locked in the neutral position ...
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HUSTLER 4200 - page 24
728444 Rev. 11/02 5-4 Electrical Diagram • Models 4200 & 4400 ...
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728444 Rev. 11/02 5-5 Electrical Diagram • Models 4200 & 4400 ...
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728444 Rev. 11/02 5-6 Electrical Diagram • Models 4300 & 4500 ...
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728444 Rev. 11/02 5-7 Electrical Diagram • Models 4300 & 4500 ...
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728444 Rev. 11/02 5-8 Electrical Diagram • Models 4420 & 4600 ...
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HUSTLER 4200 - page 29
728444 Rev. 11/02 5-9 Electrical Diagram • Models 4420 & 4600 ...
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HUSTLER 4200 - page 30
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 ...
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HUSTLER 4200 - page 31
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 ...
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HUSTLER 4200 - page 32
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 t ...
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HUSTLER 4200 - page 33
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 fu ...
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HUSTLER 4200 - page 34
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 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 rep ...
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HUSTLER 4200 - page 35
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 ...
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HUSTLER 4200 - page 36
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 c ...
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HUSTLER 4200 - page 37
728444 Rev. 11/02 6-1 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 suggesti ...
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HUSTLER 4200 - page 38
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HUSTLER 4200 - page 39
728444 Rev. 11/02 7-1 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. Remove all grass, dirt, and trash from tractor. 2. If touchup is required order Hustler spray paint (13 oz. can) from your Hustler dealer. 3. Check thoroughly for any w ...
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HUSTLER 4200 - page 40
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HUSTLER 4200 - page 41
728444 Rev. 11/02 8-1 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 inf ormation The 4200 ...
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HUSTLER 4200 - page 42
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 8-2 ...
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HUSTLER 4200 - page 43
728444 Rev. 11/02 9-1 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 Torque – 41 ft. lbs. @ 1800 RPM Compression Ratio – 22:1 Operating RPM – 3000 (max. l ...
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HUSTLER 4200 - page 44
Operating RPM – 3000 (max. load), 3200 (no load) Starter – 12-volt Ford, external solenoid. Charging System – 12-volt, negative ground, 55 amp, belt driven alternator. Crankcase Capacity – 3.5 U.S. qts. (3.25 l) with filter change. Fuel – Unleaded gasoline. Common specifications T raction drive system Type – Dual hydrostatic, closed loo ...
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HUSTLER 4200 - page 45
728444 Rev. 11/02 10-1 INDEX PAGE Access to engine and hydraulic pumps...........................5-11 Auxiliary hydraulics .........................................................4-1 Belt replacement .............................................................5-16 Burnishing the electric clutch .........................................5-11 Common ...
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