4500
Table of contents
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924738/4500 Consists of:
Part No. Description Qty
543033 Station 1 Hydraulic 1
543041 Station 2 Engine 1
543058 Station 3 Frame 1
543058 Station 3 Frame 1
543066 Station 4 Footrest 1
543074 Station 5 Fender & Tank 1
543108 Station 6 Test & Adjust 1
Hustler 4500/4600
Parts Manual
925008/4600 Consists of:
Part No. Description Qty
543330 Station 1 Hydraulic 1
543348 Station 2 Engine 1
543355 Station 3 Frame 1
543363 Station 4 Footrest 1
543371 Station 5 Fender & Tank 1
543389 Station 6 Test & Adjust 1
766238 Rev. June 2007
WARNING:
The engine exhaust from this product
cont ains chemi cal s kno wn to the State
of Calif orn ia to cau se ca ncer, birt h
defects or other reproductive harm.
IMPORTANT: This engine is not eq uipped with a spark arrester muffler. It is a violation of California P ublic R esource Cod e
Section 4442 to use or operate t his eng i ne on any forest-co vered, brush-co vered, or grass-co vered unimproved land. Other
states or fed eral areas may have simi lar laws .
This spark ig nition system compli es with Canad i an ICE S-002.
The Eng ine Owner’s Manua l provides information regarding the U.S. Environmenta l Pro tectio n Agency (EPA) and the
Ca lifornia E mission Control Regulation of emiss ion systems, ma intenance and warranty.
Keep E ngine Ow ner’s Manual with your unit. S hould the E ngine Ow ner’ s Ma nual become damaged or illegible, replace immediately. Replacement s may be orde r ed per the informa ti on found in the Pro duct Information section of the
owner’s manua l.
924738 June 2007 cl-2
Chapter 1
Chapter 2
Chapter 3
Chapter 4
Chapter 5
Table of Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Footrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Frame Assembly - 4500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Frame Assembly - 4600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Sub-Frame Assembly - 4500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Sub-Frame Assembly - 4600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Tool Bar Assembly - 4500. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Tool Bar Assembly - 4600. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Fuel System - 4500. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Fuel System - 4600. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Fender Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Exhaust System - 4500. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Exhaust System - 4600. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Air Cleaner Assembly - 4500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Air Cleaner Assembly - 4600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Chapter 6
Chapter 7
Chapter 8
Chapter 9
Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Tail Wheel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Tail Wheel Breakdown - 747782. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Steering Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Neutral Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Mechanical Throttle Assembly - 4500. . . . . . . . . . . . . . . . . . . . . . . 8-2
Electronic Throttle Assembly - 4500 . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Throttle Control Cable - 4600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Choke Control Cable Assembly - 4500. . . . . . . . . . . . . . . . . . . . . . 8-7
Carburetor Assembly - Mechanical Throttle . . . . . . . . . . . . . . . . . . 8-8
Carburetor Connections- Electronic Throttle. . . . . . . . . . . . . . . . . . 8-10
Front Engine Assembly - 4600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Front Engine Assembly - 4500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Rear Engine Assembly - 4600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Rear Engine Assembly (Mechanical Governor) - 4500. . . . . . . . . . 9-8
Rear Engine Assembly (Electronic Governor)- 4500 . . . . . . . . . . . 9-12
766238 6/07 c-1
Chapter 10
Chapter 11
Chapter 12
Chapter 13
Cooling System - 4500. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Cooling System - 4600. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Oil Cooler Assembly - 4500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Oil Cooler Assembly - 4600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
Valve & Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
Hydraulic & Fuel Line Routing - 4500. . . . . . . . . . . . . . . . . . . . . . . 12-8
Hydraulic & Fuel Line Routing - 4600. . . . . . . . . . . . . . . . . . . . . . . 12-10
Electrical System (Footrest) - 4500 . . . . . . . . . . . . . . . . . . . . . . . . 13-2
Electrical System (Engine) - 4500 (Mechanical Governor). . . . . . . 13-6
Electrical System (Engine) - 4500 (Electronic Governor). . . . . . . . 13-10
Electrical System (Footrest) - 4600 . . . . . . . . . . . . . . . . . . . . . . . . 13-12
Electrical System (Engine) - 4600 . . . . . . . . . . . . . . . . . . . . . . . . . 13-16
Electrical Diagram - 4500 (Mechanical Governor) . . . . . . . . . . . . . 13-20
Electrical Diagram - 4500 (Electronic Governor) . . . . . . . . . . . . . . 13-22
Electrical Diagram - 4600. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-24
Chapter 14
Decal Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2
Chapter 15
4500 Engine & Hydraulic Set-Up Procedures-Mechanical Gov . . . 15-2
4600 Engine & Hydraulic Set-Up Procedures . . . . . . . . . . . . . . . . 15-5
Chapter 16
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-2
Wheel Motor Breakdown - 007914. . . . . . . . . . . . . . . . . . . . . . . . . 16-4
Wheel Motor Breakdown - 792341. . . . . . . . . . . . . . . . . . . . . . . . . 16-6
Electric Clutch Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-8
Chapter 17
Seat Kit 306878K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-2
Seat Kit 306860K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3
Seat Kit 306894K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-4
Seat Kit 311217K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-5
Hood Kit 318915K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-6
Air Scoop Kit 466615 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-8
Front Tire Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-10
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1
c-2 766238 6/07
Chapter 1
General Information
This manual covers Tractor Models: 4500 (924738) & 4600 (925008)
Frequently Ordered Parts
PART NO. DESCRIPTION
027912 LUBRIZOL 7 OZ. BOTTLE
076919 RADIATOR CAP
032029 HEAVY-DUTY AIR FILTER
065730 HYDRAULIC OIL FILTER
033779 PUMP DRIVE BELT
Model 4500
708677 FUEL FILTER, (MOTORCRAFT P/N E3FZ-9155-F OR EQUIVALENT)
044693 ENGINE OIL FILTER, (FL 400A OR EFL125)
044727 SPARK PLUG, (MOTORCRAFT P/N AGSF-22C OR EQUIVALENT)
Model 4600
042341 FUEL FILTER (KUBOTA P/N 70000-43081)
758870 ENGINE OIL FILTER (KUBOTA P/N 16271-32090)
758888 FAN BELT (KUBOTA P/N 16282-97011)
Service Literature
PART NO. DESCRIPTION
728444 OWNER’S MANUAL
717231 SUNDSTRAND SERVICE MANUAL (M-25 HYDRAULIC PUMP)
033654 ASSEMBLY INSTRUCTIONS
FOR TORQLINK™ SERVICE PROCEDURE, GO TO
Model 4500
031682 FORD OWNER’S MANUAL
031724 FORD IPL
031716 FORD SHOP MANUAL
035105 FORD SERVICE DIRECTORY
http://www.parker.com
Model 4600
756882 KUBOTA V1205/1505 OWNER’S MANUAL
758896 KUBOTA V1505 IPL
758912 KUBOTA V1505 SHOP MANUAL
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.
766238 6/07 1-1
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 nece ssary, 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.
Hardware Description Codes & Abbreviations
The following codes are used throughout this parts manual. Refer to this list when ordering parts.
ABBREVIATION DESCRIPTION
CB Carriage Bolt
CE Clevis Pin
CP Cotter Pin
CS Cap Screw
CW Cup Washer
FW Flat Washer
HX Hex Head
LW Lock Washer
MB Machine Bushing
MS Machine Screw
NT Nut
SC Self Tapping Cap Screw
SB Shoulder Bolt
SS Set Screw
Standard Torques
The following chart lists the standard torque va lues 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 FT.-LBS NM SIZE FT.-LBS NM
.250 8.2 11.1 M3 1 1.3
.312 17 23 M4 2.2 3
.375 30 40 M5 4.5 6.1
.438 48 65 M6 7.7 10.4
.500 73 99 M8 18.5 25
.562 105 143 M10 37 50
.625 145 200 M12 64 87
.750 260 350 M16 160 215
.875 420 565 M20 320 435
NOTE:
Loctite 592 to be used on all pipe threads.
Lubricate all grease zerks.
1-2 766238 6/07
Chapter 2 Contents
Footrest Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Frame Assembly - 4500. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Frame Assembly - 4600. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Sub-Frame Assembly - 4500. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Sub-Frame Assembly - 4600. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
766238 6/07 2-1
Footrest Assembly
22
15
17
16
21
23
20
1
8
7
6
1
5
3
4
1
2
10
3
20
11
13
19
11
13
12
2
18
17
7
9
12
Main Frame
Assembly
2-2 766238 6/07
14
Footrest Assembly
INDEX
NO.
10 442525 442525 1 REAR SEAT SUPPORT
11 034280 034280 8 CS .312-18 X .750 HX G5 ZN
12 017004 017004 8 LW .312 MEDIUM SPRING ZN
13 076547 076547 8 FW .344 X .688 X .065 SAE ZN
14 034272 034272 4 NT .312-18 HX G5 ZN
15 467837 467837 1 GRAB HANDLE
16 055939 055939 8 CS .25-20 X .750 HX G5 ZN
17 025403 025403 16 FW .281 X .625 X .062 ZN
18 024927 024927 8 NT .25-20 HX G5 ZN
19 006841 006841 1 PLUG BUTTON .562
20 735035 735035 A/R PLUG BUTTON 1.125
21 203455 203455 3 SPRING CLIP
22 017251 017251 3 CP .156D X 1.00 LG HML ZN
23 011379 011379 3 TENSION SPRING
SERVICE
PART NO.
1 306811 306811 1 SEAT MOUNT
2 307066 307066 1 LATCH PIN
3 075408 075408 1 FW .402 X .689 X .032 ZN
4 002261 002261 1 SPRING
5 082420 082420 1 ROLL PIN .125D X .875 LG ZN
6 055947 055947 4 CS .25-20 X .50 HX G5 ZN
7 017038 017038 12 LW .250 MEDIUM SPRING ZN
8 017079 017079 4 FW .250 X .560 X .040 SAE ZN
9 467738 467738 1 FOOTREST
MFG. PART
NO.
QTY. DESCRIPTION
NOTES:
1. Item 5, roll pin, to be centered in item 2, latch pin.
2. 4600 only.
3. 4500 only.
766238 6/07 2-3
Frame Assembly - 4500
1
2
3
4
1
FOOTREST
9
8
7
3
5
6
13
12
8
11
14
15
16
17
24
10
9
23
8
20
19
18
See Detail A
2
24
2
23
2
23
23
20
19
21
22
Detail A
2-4 766238 6/07
Frame Assembly - 4500
INDEX
NO.
10 036236 036236 4 CS .312-18 X 1.00 HX G5 ZN
11 385344 385344 2 FOOTREST SUPPORT ANGLE
12 034272 034272 2 NT .312-18 HX G5 ZN
13 052860 052860 4 CS .375-16 X 1.250 HX G5 ZN
14 017012 017012 4 LW .375 MEDIUM SPRING ZN
15 076422 076422 4 FW .406 X 1.00 X .060 ZN
16 081745 081745 1 CS .312-24 X .750 HX G5 ZN
17 448035 448035 1 HOSE BRACKET
18 013334 013334 3 CS .25-20 X .870 HX G5 ZN
19 017038 017038 5 LW .250 MEDIUM SPRING ZN
20 023069 023069 5 FDW .281 X 1.250 X .047 ZN
21 387928 387928 1 BOTTOM SCREEN
22 064329 064329 2 CS .25-20 X .625 HX G5 ZN
23 033035 033035 2 SEAL .12 X .75 X 6”
24 033035 033035 2 SEAL .12 X .75 X 29.5”
SERVICE
PART NO.
1 383141 383141 1 MAIN FRAME
2 077859 077859 2 CS .50-13 X 3.250 HX G5 ZN
3 017137 017137 4 FW .560 X 1.370 X .109 SAE ZN
4 248237 248237 1 REAR CROSS MEMBER
5 017046 017046 2 LW .50 MEDIUM SPRING ZN
6 067918 067918 2 NT .50-13 HX G8 ZN
7 034280 034280 2 CS .312-18 X .750 HX G5 ZN
8 017004 017004 6 LW .312 MEDIUM SPRING ZN
9 076547 076547 6 FW .344 X .688 X .065 SAE ZN
MFG. PART
NO.
QTY. 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 6/07 2-5
Frame Assembly - 4600
1
2
3
FOOTREST
4
9
8
7
3
5
6
13
12
8
11
14
15
21
1
21
10
9
2
22
8
20
18
17
16
2-6 766238 6/07
18
17
19
23
Frame Assembly - 4600
INDEX
NO.
10 036236 036236 4 CS .312-18 X 1.00 HX G5 ZN
11 385344 385344 2 FOOTREST SUPPORT ANGLE
12 034272 034272 2 NT .312-18 HX G5 ZN
13 052860 052860 4 CS .375-16 X 1.250 HX G5 ZN
14 017012 017012 4 LW .375 MEDIUM SPRING ZN
15 076422 076422 4 FW .406 X 1.00 X .060 ZN
16 013334 013334 3 CS .25-20 X .870 HX G5 ZN
17 017038 017038 5 LW .250 MEDIUM SPRING ZN
18 023069 023069 5 FDW .281 X 1.250 X .047 ZN
19 496828 496828 1 BOTTOM CLOSEOUT
20 737536 737536 1 SEAL .43 X .75 X 26.75”
21 033035 033035 2 SEAL .12 X .75 X 6.0”
22 033035 033035 2 SEAL .12 X .75 X 28.0”
23 064329 064329 2 CS .25-20 X .625 HX G5 ZN
SERVICE
PART NO.
1 383141 383141 1 MAIN FRAME
2 077859 077859 2 CS .50-13 X 3.250 HX G5 ZN
3 017137 017137 4 FW .560 X 1.370 X .109 SAE ZN
4 248237 248237 1 REAR CROSS MEMBER
5 017046 017046 2 LW .50 MEDIUM SPRING ZN
6 067918 067918 2 NT .50-13 HX G8 ZN
7 034280 034280 2 CS .312-18 X .750 HX G5 ZN
8 017004 017004 6 LW .312 MEDIUM SPRING ZN
9 076547 076547 6 FW .344 X .688 X .065 SAE ZN
MFG. PART
NO.
QTY. DESCRIPTION
1. Torque to 45 Ft. Lbs.
2. Align with edges, cut seal for slots.
NOTES:
766238 6/07 2-7
Sub-Frame Assembly - 4500
Radiator Assembly
11
8
9
10
9
5
4
3
7
2
8
1
5
1
4
1
3
9
13
14
15
12
10
22
9
30
13
14
25
24
26
23
28
27
13
16
14
29
5
1
17
4
3
1
4
6
1
20
21
1
18
1
1
19
2-8 766238 6/07
Sub-Frame Assembly - 4500
INDEX
NO.
10 385914 385914 4 MOUNTING SPACER
11 042630 042630 2 CS .50-13 X 6.50 HX G5 ZN
12 055947 055947 1 CS .25-20 X .500 HX G5 ZN
13 017038 017038 3 LW .250 MEDIUM SPRING ZN
14 025403 025403 3 FW .281 X .625 X .062 ZN
15 081158 081158 1 FORD STARTER RELAY ASSEMBLY
16 080358 080358 1 GROMMET .50 X 1.00 X .750 X .120
17 016410 016410 2 CS .375-16 X 2.00 HX G5 ZN
18 073858 073858 2 FW .406 X .750 X .250 ZN
19 712893 712893 2 FW .406 X 1.250 X .120 HRD ZN
20 017012 017012 2 LW .375 MEDIUM SPRING ZN
21 054502 054502 2 NT .375-16 HX G5 ZN
22 384107 384107 4 RADIATOR PAD
23 034272 034272 4 NT .312-18 HX G5 ZN
24 422576 N/A 2 RADIATOR BRACE
25 013334 N/A 2 CS .25-20 X .870 HX G5 ZN
26 036236 036236 4 CS .312-18 X 1.00 HX G5 ZN
27 049346 049346 4 FW .375 X .870 X .078 ZN
28 017004 017004 4 LW .312 MEDIUM SPRING ZN
29 056077 056077 2 CS .25-20 X 1.00 HX G5 ZN
30 024927 024927 2 NT .25-20 HX G5 ZN
SERVICE
PART NO.
1 447425 447425 1 SUB-FRAME
2 460600 460600 1 TOP PUMP MOUNT
3 067918 067918 6 NT .50-13 HX G8 ZN
4 017046 017046 8 LW .50 MEDIUM SPRING ZN
5 017137 017137 6 FW .560 X 1.370 X .109 SAE ZN
6 016527 016527 2 CS .50-13 X 1.00 HX G5 ZN
7 061812 061812 2 CS .50-13 X 3.50 HX G5 ZN
8 076992 076992 4 FW .530 X 1.750 X .125 ZN
9 076927 076927 4 ENGINE SIDE MOUNT
MFG. PART
NO.
QTY. DESCRIPTION
NOTES:
1. These fasteners are used to mount the hydraulic pump.
766238 6/07 2-9
Sub-Frame Assembly - 4600
7
2
8
9
12
1
5
1
4
1
3
10
19
Radiator Assembly
27
25
26
10
9
5
4
8
9
11
9
31
24
29
4
6
23
2
20
18
2
20
22
26
28
27
30
21
1
13
5
4
1
3
1
17
1
14
1
1
15
16
22
23
3
2-10 766238 6/07
Sub-Frame Assembly - 4600
INDEX
NO.
10 385914 385914 4 MOUNTING SPACER
11 080358 080358 1 GROMMET .500 X 1.00 X .750 X .120
12 042630 042630 2 CS .50-13 X 6.50 HX G5 ZN
13 016410 016410 2 CS .375-16 X 2.00 HX G5 ZN
14 073858 073858 2 FW .406 X .750 X .250 ZN
15 712893 712893 2 FW .406 X 1.250 X .120 HRD ZN
16 017012 017012 2 LW .375 MEDIUM SPRING ZN
17 054502 054502 2 NT .375-16 HX G5 ZN
18 497370 N/A 1 BOTTOM RADIATOR MOUNT
19 737536 N/A 1 SEAL STRIP .430 X .750 X 17.0”
20 497339 N/A 2 LOWER RADIATOR PAD
21 079210 079210 1 FW .344 X 1.00 X .060 ZN
22 017004 017004 5 LW .312 MEDIUM SPRING ZN
23 034272 034272 5 NT .312-18 HX G5 ZN
24 422576 422576 2 RADIATOR BRACE
25 013334 013334 2 CS .25-20 X .870 HX G5 ZN
26 017038 017038 4 LW .250 MEDIUM SPRING ZN
27 025403 025403 4 FW .281 X .625 X .062 ZN
28 036236 036236 4 CS .312-18 X 1.00 HX G5 ZN
29 049346 049346 4 FW .375 X .870 X .060 ZN
30 056077 056077 2 CS .25-20 X 1.00 HX G5 ZN
31 024927 024927 2 NT .25-20 HX G5 ZN
SERVICE
PART NO.
1 496117 496117 1 SUB-FRAME
2 460600 460600 1 TOP PUMP MOUNT
3 067918 067918 6 NT .50-13 HX G8 ZN
4 017046 017046 8 LW .50 MEDIUM SPRING ZN
5 017137 017137 6 FW .560 X 1.370 X .109 SAE ZN
6 016527 016527 2 CS .50-13 X 1.00 HX G5 ZN
7 061812 061812 2 CS .50-13 X 3.50 HX G5 ZN
8 076992 076992 4 FW .530 X 1.750 X .125 ZN
9 076927 076927 4 ENGINE SIDE MOUNT
MFG. PART
NO.
QTY. DESCRIPTION
NOTES:
1. These fasteners are used to mount the hydraulic pump.
2. Use 3M™ Scotch-Grip™ 1300 adhesive (082511) to glue item 20, lower
radiator pad, to item 18, bottom radiator mount.
766238 6/07 2-11
2-12 766238 6/07
Chapter 3 Contents
Tool Bar Assembly - 4500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Tool Bar Assembly - 4600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
766238 6/07 3-1
T ool Bar Assembly - 4500
1
Ground Wires
3
1
12
7
10
9
8
11
2
5
1
15
22
24
25
26
2
6
8
14
13
11
4
17
32
18
17
16
2
19
15
1
22
23
20
21
39
29
30
33
35
34
36
37
27
38
23
24
25
31
28
3-2 766238 6/07
T ool Bar Assembly - 4500
INDEX
NO.
10 705178 705178 2 CS .375-16 X 1.750 HX G5 ZN
11 076422 076422 4 FW .406 X 1.00 X .060 ZN
12 450874 450874 2 PULLEY SPACER
13 017012 017012 2 LW .375 MEDIUM SPRING ZN
14 016873 016873 2 NT .375-16 HXCLK ZN
15 007971 007971 4 DECK LIFT PULLEY
16 077859 077859 1 CS .50-13 X 3.250 HX G5 ZN
17 767962 767962 2 FW .531 X 1.063 X .090 SAE HD ZN
18 735175 735175 1 NT .50-13 FLEX-LOC ZN
19 429704 429704 1 CABLE GUIDE
20 421545 421545 1 GUIDE PIN
21 011387 011387 2 CP .125D X 1.250 LG HML ZN
22 030494 030494 1 CABLE ASSEMBLY, 48” LONG
23 007989 007989 1 CABLE ASSEMBLY, 34.50” LONG
24 024836 024836 2 NT .50-13 HX JAM G5 ZN
25 352815 352815 2 ADJUSTABLE YOKE END
26 422113 422113 1 TOOL BAR
27 068056 068056 2 CE .50 X 1.50 X .150 X 1.320 ZN
28 423681 423681 1 BOTTOM TOOL BAR
29 020016 020016 2 CE .50 X 2.00 X .150 X 1.820 ZN
30 017301 017301 2 HP .125 X 2.375 ZN
31 029413 029413 2 CE .750 X 2.750 X .150 X 2.590 ZN
32 017269 017269 2 CP .156 X 1.50 LG ZN
33 019471 019471 1 CE .380 X 1.750 .150 X 1.60 ZN
34 705137 705137 1 FW .391 X 1.250 X .060 ZN
35 002212 002212 1 SPRING
36 462531 462531 1 CABLE DEFLECTOR
37 704718 704718 1 FW .406 X .688 X .060 ZN
38 017244 017244 1 CP .125D X 1.00 LG HML ZN
39 030635 506576 1 HYDRAULIC CYLINDER
SERVICE
PART NO.
1 055939 055939 2 CS .25-20 X .750 HX G5 ZN
2 025403 025403 2 FW .281 X .625 X .062 ZN
3 029868 029868 1 LW .250 INT-EXT ZN
4 017038 017038 2 LW .250 MEDIUM SPRING ZN
5 024927 024927 2 NT .25-20 HX G5 ZN
6 043570 043570 1 SINGLE HOSE CLIP
7 000174 000174 2 CE .375 X 1.250 .156 X 1.090 ZN
8 017251 017251 6 CP .156D X 1.00 LG HML ZN
9 711127 711127 2 NYLON ROLLER GUIDE
MFG. PART
NO.
QTY. DESCRIPTION
NOTES:
1. Coat sides & ID of pulley bushing and ID & OD of spacers with anti-
seize lubricant 705715.
2. Do not overtighten, both pulleys to spin freely. Use Loctite 242 on end of
bolt.
766238 6/07 3-3
T ool Bar Assembly - 4600
1
2
Ground Wires
3
1
11
6
9
1
8
Glow Plug Timer
(Part of Engine)
7
14
10
7
18
13
12
10
31
17
16
15
14
1
16
4
5
1
14
21
23
25
24
21
22
19
20
38
28
29
32
34
33
35
26
36
37
22
23
24
30
27
3-4 766238 6/07
T ool Bar Assembly - 4600
INDEX
NO.
10 076422 076422 4 FW .406 X 1.00 X .060 ZN
11 450874 450874 2 PULLEY SPACER
12 017012 017012 2 LW .375 MEDIUM SPRING ZN
13 016873 016873 2 NT .375-16 HXCLK ZN
14 007971 007971 4 DECK LIFT PULLEY
15 077859 077859 1 CS .50-13 X 3.250 HX G5 ZN
16 767962 767962 2 FW .531 X 1.063 X .090 SAE HD ZN
17 735175 735175 1 NT .50-13 FLEX-LOC ZN
18 429704 429704 1 CABLE GUIDE
19 421545 421545 1 GUIDE PIN
20 011387 011387 2 CP .125D X 1.250 LG HML ZN
21 030494 030494 1 CABLE ASSEMBLY, 48” LONG
22 007989 007989 1 CABLE ASSEMBLY, 34.50” LONG
23 024836 024836 2 NT .50-13 HX JAM G5 ZN
24 352815 352815 2 ADJUSTABLE YOKE END
25 422113 422113 1 TOOL BAR
26 068056 068056 2 CE .50 X 1.50 X .150 X 1.320 ZN
27 423681 423681 1 BOTTOM TOOL BAR
28 020016 020016 2 CE .50 X 2.00 X .150 X 1.820 ZN
29 017301 017301 2 HP .125 X 2.375 ZN
30 029413 029413 2 CE .750 X 2.750 X .150 X 2.590 ZN
31 017269 017269 2 CP .156 X 1.50 LG ZN
32 019471 019471 1 CE .380 X 1.750 .150 X 1.60 ZN
33 705137 705137 1 FW .391 X 1.25 X .060 ZN
34 002212 002212 1 SPRING
35 462531 462531 1 CABLE DEFLECTOR
36 704718 704718 1 FW .406 X .688 X .060 ZN
37 017244 017244 1 CP .125D X 1.00 LG HML ZN
38 030635 506576 1 HYDRAULIC CYLINDER
SERVICE
PART NO.
1 056077 056077 1 CS .25-20 X 1.00 G5 ZN
2 043570 043570 1 SINGLE HOSE CLIP
3 029868 029868 1 LW .250 INT-EXT ZN
4 025403 025403 1 FW .281 X .625 X .062 ZN
5 024927 024927 1 NT .25-20 HX G5 ZN
6 000174 000174 2 CE .375 X 1.250 .156 X 1.090 ZN
7 017251 017251 6 CP .156D X 1.00 LG HML ZN
8 711127 711127 2 NYLON ROLLER GUIDE
9 705178 705178 2 CS .375-16 X 1.750 HX G5 ZN
MFG. PART
NO.
QTY. DESCRIPTION
NOTES:
1. Coat sides & ID of pulley bushing and ID & OD of spacers with anti-
seize lubricant 705715.
766238 6/07 3-5
3-6 766238 6/07
Chapter 4 Contents
Fuel System - 4500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Fuel System - 4600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Fender Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
766238 6/07 4-1
Fuel System - 4500
2
6
15
1
3
8
9
10
11
5
3
4
5
14
10
13
1
12
10
3
4
5
6
Fuel
Pump
3
4
5
5
4
7
4-2 766238 6/07
Fuel System - 4500
INDEX
NO.
10 041491 041491 4 HOSE CLAMP
11 034264 034264 2 FUEL HOSE .312 I.D. X 30”
12 060889 060889 3 PLASTIC STRAP
13 034264 034264 1 FUEL HOSE .312 I.D. X 11”
14 708677 708677 1 FUEL FILTER
15 347815 347815 1 4500 AIR SCOOP ANGLE SUPPORT
SERVICE
PART NO.
1 385773 385773 1 FUEL TANK
2 084756 084756 1 FUEL CAP AND GAUGE
3 036236 036236 4 CS .312-18 X 1.00 HX G5 ZN
4 017004 017004 4 LW .312 MEDIUM SPRING ZN
5 070664 070664 5 FW .344 X .750 X .060 ZN
6 084921 084921 2 PIPE PLUG .125
7 034272 034272 1 NT .312-18 HX G5 ZN
8 068486 068486 1 SHUT-OFF VALVE
9 039131 039131 1 HOSE ADAPTER
MFG. PART
NO.
QTY. DESCRIPTION
NOTES:
1. See “Hydraulic & Fuel Line Routing - 4500” on page 12- 8.
766238 6/07 4-3
Fuel System - 4600
1
3
3
4
5
2
23
7
14
8
15
9
12
1
16
14
10
11
13
14
9
21
20
5
3
4
22
5
3
4
5
14
5
4
6
19
2
18
1
17
4-4 766238 6/07
Fuel System - 4600
INDEX
NO.
10 043661 043661 1 CUSHIONED TUBE CLAMP
11 038398 038398 1 FUEL HOSE 31”
12 016147 016147 1 CS .25-20 X .750 HX FLK ZN
13 016816 016816 1 NT .25-20 HXFL LK ZN
14 041491 041491 4 HOSE CLAMP
15 034264 034264 1 FUEL HOSE .312 I.D. X 11”
16 032706 N/A 1 FUEL FILTER ASSEMBLY
17 042341 N/A 1 FUEL FILTER ELEMENT
18 034264 034264 1 FUEL HOSE .312 I.D. X 43”
19 060889 060889 3 PLASTIC STRAP
20 039131 039131 1 HOSE ADAPTER .312
21 068486 068486 1 SHUT-OFF VALVE
22 084921 084921 1 PIPE PLUG .125
23 353045 353045 1 4600 AIR SCOOP ANGLE SUPPORT
SERVICE
PART NO.
1 385773 385773 1 FUEL TANK
2 084756 084756 1 FUEL CAP AND GAUGE
3 036236 036236 4 CS .312-18 X 1.00 HX G5 ZN
4 017004 017004 4 LW .312 MEDIUM SPRING ZN
5 070664 070664 5 FW .344 X .750 X .060 ZN
6 034272 034272 1 NT .312-18 HX G5 ZN
7 078246 078246 1 BRASS ELBOW
8 038984 038984 1 HOSE ADAPTER
9 041483 041483 2 HOSE CLAMP
MFG. PART
NO.
QTY. DESCRIPTION
NOTES:
1. Part of engine group.
2. See “Hydraulic & Fuel Line Routing - 4600” on page 12- 10.
766238 6/07 4-5
Fender Assembly
25
24
23
18
20
2
17
16
19
15
3
4
AIR SCOOP
ANGLE
SUPPORT
7
6
9
2
4
1
4
3
5
8
12
10
11
13
14
15
13
13
14
23
24
25
14
23
4-6 766238 6/07
22
21
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