Cushman 1600XD4, Owner'S Manual

Page 1: ...1600XD4 OWNER S MANUAL 640282...

Page 2: ......

Page 3: ...ted to provide the best quality products It is strongly recommended for all customer to read this owner s manual thoroughly before using 1600XD4 as the manual contains a lot of valuable information su...

Page 4: ...tside the European Community local laws will prevail Main protections on the tractors discussed in this manual DESCRIPTION NON CANOPY CANOPY 1 ROPS protection against overturning Yes Yes 2 FOPS protec...

Page 5: ...DENTIFICATIONS SPECIFICATIONS CONTROLS AND FEATURES OPERATION REPLACEMENT PARTS MAINTENANCE STORAGE AND DISPOSAL TROUBLESHOOTING INDEX 1 2 3 4 5 6 7 8 9 10 TABLE OF CONTENTS SECTION UD120 OM 1600XD4 0...

Page 6: ...ing location 1 19 DeCALs 1 20 Cautions for decal maintenance 1 23 PRECAUTIONS BEFORE OPERATION 2 1 Vehicle Identification Number 2 2 Vehicle serial number 2 2 Engine serial number 2 2 SPECIFICATIONS 3...

Page 7: ...4 29 Coolant brake fluid and electrical devices 4 30 Tire 4 30 Switches 4 7 Key switch 4 8 Combination switch 4 9 Hazard lamp switch 4 11 Spare switch panel 4 12 12V power outlet 4 12 Instrument pane...

Page 8: ...Jump start 5 11 Stopping 5 12 Parking 5 12 Shifting 5 13 Driving on slippery surfaceS 5 14 Turning 5 15 Driving on slope 5 15 Driving in forest 5 17 Driving through water 5 17 Driving backward 5 18 Dr...

Page 9: ...clamp I 7 13 Checking CVT belt J 7 14 Checking CVT driven pulley clutch buttons K 7 16 Checking fuel FILTER L 7 17 BLEEDING FUEL LINE M 7 17 Checking injection nozzle and fuel injection pump N 7 19 Cl...

Page 10: ...blow fuse AG 7 37 Aligning wheel and checking wheel nut AH 7 38 Checking differential lock cable AI 7 39 Checking shift and 4WD cables AJ 7 39 Using Biodiesel AK 7 40 Adjusting belt tension AL 7 40 W...

Page 11: ...arm serious in jury or death to you or other persons if the warning is not hee ded Follow the advice provided with the warning CAUTION This indicates that a condition may result in damage to your vehi...

Page 12: ...Fuel Level low Parking Brake Battery Charging Condition Engine Oil Pressure Turn Signal Engine Check Warning Lamp Differential Lock Hazard Warning Lights Headlight Low Beam Headlight High Beam Four W...

Page 13: ...4 When starting the engine 1 4 When driving the vehicle 1 6 When parking the vehicle 1 13 Safety precautions during servicing 1 14 Safety precautions when using the ROPS 1 18 Safety decal 1 19 mounti...

Page 14: ...T66O101a Precautions before operation General precautions A careful operator is the best oper ator Most accidents can be avoid ed by observing certain precautions To help prevent accidents use these s...

Page 15: ...te your intentions 8 This vehicle should be driven only by a driver with a valid driver s li cense driver s license UUVO114A 9 Never let anyone under 5 years of age ride in the vehicle If it is un avo...

Page 16: ...henever driving this vehi cle in an aggressive manner Eye protection is recommended at all times UUVO123A Precautions during op eration When starting the engine 1 Do not operate your vehicle in an enc...

Page 17: ...el nuts have been tightened to the specified torque 8 Always check the tire pressure be fore starting the engine For more information about tire pressure see chapter 4 9 Make sure that all pressure li...

Page 18: ...plicable regula tions and laws If the vehicle is not equipped with the Safety lamp kit there will be no brake lamps turn signal lamps and tail lamps on the vehicle In this condition it is very dangero...

Page 19: ...rential lock while traveling at road speeds As the vehicle may run out of control 7 Do not use 4WD while traveling at road speeds in a normal road con dition 8 Avoid sudden movements of the steering w...

Page 20: ...features which may col lapse under the vehicle s weight The risk of vehicle upset is even higher when the ground is loose or wet KUVO162A 11 Watch where you are going at all times so that you are able...

Page 21: ...d around other obstructions UUVO109A 15 Never try to get on or off a mov ing vehicle UUVO110A 16 To minimize the risk of a rollover crash be especially careful when driving over obstacles on slopes an...

Page 22: ...ting conditions UUVO124A 18 Never attempt wheelies jumps or other stunts UUVO125A 19 Always keep both hands on the steering wheel and both feet on the floor of the vehicle during op eration 20 Always...

Page 23: ...the ter rain carefully before attempting to climb any hill Never climb hills with excessively slippery or loose surfaces Never open the throttle suddenly or make sudden gear changes Never go over the...

Page 24: ...his manual Wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them light ly several times to let friction dry out the pads UUVO130A 28 Never exceed th...

Page 25: ...the ignition key when the vehicle is not in use to prevent unauthorized use or acci dental starting 3 Never leave the vehicle without setting the parking brake and shut ting off the vehicle 29 Pull on...

Page 26: ...Safety precautions during servicing 1 In order to service your vehicle you must park it on a flat level sur face set the parking brake place the gear shift lever in neutral and stop the engine KUVO12...

Page 27: ...tor cap while the coolant is hot When cool slowly rotate the cap to the first stop and allow sufficient time for excess pressure to escape Af ter all the pressure is released re move the cap completel...

Page 28: ...ining correct tire pres sure is important for the life of your tires Do not inflate the tires above the recommended pres sure specified in the owner s manual 12 Securely support the vehicle when chang...

Page 29: ...olant or oil dispose of it the right way Be sure to observe all relevant regulations when you dispose of the engine oil transmission oil fuel coolant filters and battery UUVO139A 14 No alterations sho...

Page 30: ...never can protect the riders against falling objects Aviod driving the vehicle into a dangerous area such as falling rocks zone IMPORTANT UUVO143A A ROPS should never be modified by welding grinding o...

Page 31: ...SAFETY PRECAUTIONS 1 19 1 Safety decal mounting location U12O102A UD120 OM 1600XD4 01 indd 19 2014 05 08 4 33 31...

Page 32: ...ssenger compartment can be hazardous This vehicle is designed to carry a maximum of 4 persons 2 per bench seat including the operator 5 Protective head gear reduces the risk of head injuries Use of he...

Page 33: ...duced speeds Apply brakes when going down slopes to prevent the vehicle from accelerating suddenly freewheeling Reduce speeds on rough or uneven terrain Turn engine off and apply parking brake before...

Page 34: ...en may not be able to sit safely in the passenger seat and use handholds properly 6 Read and follow the operator s manual and warning labels UNDER 16 U3215 85562 8 Part No U3215 85611 U3215 85611 Chec...

Page 35: ...pulling implement such as snow blade etc CAUTION U3215 85861 11 Part No U3215 85601 TO PREVENT DRIVETRAIN DAMAGE Do not shift ranges with the engine RPM s above idle Do not shift ranges while the veh...

Page 36: ...nner or acetone since it can ruin the decals Do not spray high pressure water directly onto the decal The decal may fall off the vehi cle If a decal is damaged or lost contact your local dealer im med...

Page 37: ...2 PRECAUTIONS BEFORE OPERATION 2 Vehicle Identification Number 2 2 Vehicle serial number 2 2 Engine serial number 2 2 UD120 OM 1600XD4 02 indd 1 2014 03 28 9 36 39...

Page 38: ...Number Vehicle serial number Engine serial number Have the vehicle serial number and engine serial number with you when ordering parts or asking for service information Fill in the following boxes wit...

Page 39: ...SPECIFICATIONS SPECIFICATION 3 2 Exterior dimensions 3 2 General specifications 3 3 OPTION List and FEATURES 3 5 3 3 UD120 OM 1600XD4 03 indd 1 2014 03 28 9 49 27...

Page 40: ...ength A Overall width B Overall height C Wheel base D Front wheel tread E Rear wheel tread F Ground clearance G 144 6 3 672 60 7 1 543 76 4 1 940 108 7 2 760 49 7 1 262 48 30 1 228 12 304 D A E F B C...

Page 41: ...Gal L 0 16 0 6 Rear differential case oil U S Gal L 0 21 0 8 Coolant U S Gal L 1 66 6 3 Driving unit Main shift CVT Continuous Variable Transmission with belt Range shift High Low Neutral Reverse Max...

Page 42: ...lbs kg 1 325 600 Others Seat 3 Seat Bench X 2 Cargo dumping Manual Front guard Standard Speedometer Standard ROPS Standard Instrument cluster Standard Tachometer fuel gauge odometer Gas Spring Kit St...

Page 43: ...Receiver 2 inch square type Remove lower screen of brush guard for installation Swing Drawbar kit EEC Hand Throttle Hand throttle lever and cable Oil Cooler Kit Sprayer Kit Skid Plate To protect impor...

Page 44: ...PTION REMARKS Rear View Mirror Kit two Convex rear view mirror Strongly recommended for public road driving License Plate For mounting vehicle license plate Working Lamp Kit ROPS 2 Lamps Add on to the...

Page 45: ...4 14 Coolant temperature gauge 4 15 Engine oil pressure warning lamp 4 15 Battery charging lamp 4 16 Head light high beam lamp 4 16 Turn Signal Lamp 4 17 Glow plug indicator 4 17 Parking brake indica...

Page 46: ...control lever manual model 4 27 Fuel tank 4 28 Fuel requirements 4 29 Engine inspection 4 29 Coolant brake fluid and electrical devices 4 30 Tire 4 30 tire tread patterns 4 30 Proper inflation pressu...

Page 47: ...k 2 Seat 3 Dumping Handle 4 Dumping Latch 5 Fuel Tank Cap 6 ROPS 7 Steering Handle 8 Hood 9 Headlamp 10 Brush Guard 11 Rear Reflex Reflector 12 Cargo Bed 13 Rear Hitch Receiver 14 Rear Wheel Mudguard...

Page 48: ...he hood CAUTION UUVO452A 1 Hood Support ELECTRIC COOLING FAN MOTOR The fan motor runs when the cool ant temperature raises over 80 and stops when the coolant temperature drops below 75 The 5 gap be tw...

Page 49: ...turing refined design 1 Headlamp LH 2 Headlamp RH Driving with high beam head lamps disturbs the approaching driver s visibility for safe driving Use high beams only if neces sary WARNING Rear hitch r...

Page 50: ...cargo weight does not exceed 590 kg 1 300 lbs When connecting a trailer at tach it only to the trailer hitch bracket Never connect a trailer to any point other than the specified Otherwise you can los...

Page 51: ...cially in cloudy weather or at night can cause an accident In some counties and states it is illegal to drive UTV in the public road Be aware the traf fic law before driving CAUTION Switches 1 Combina...

Page 52: ...y the glow plug in dicator Make sure to preheat the engine until the glow plug indica tor goes off approx 9 seconds in cold weather HEAT D The position D indicates the manual preheat position which is...

Page 53: ...y leaving the vehicle with the key in the ignition switch an unauthorized person can oper ate the vehicle and cause a se rious accident and even death Make sure to keep the key with you when leaving t...

Page 54: ...th high beam head lights makes it difficult for the driver of an on coming vehicle to see Use high beams only if necessary WARNING Turn signal lamp switch 1 Turn Signal Lamp Switch A Turn signal lamps...

Page 55: ...ery NOTE 1 Horn Switch The horn switch can be operated without the key in the key switch Pressing this switch sounds the horn Horn switch UUVO455A This switch can be used to warn other vehicles when m...

Page 56: ...outlet operates with the key in the ACC or ON position Using the power outlet for an extend ed period of time with the engine off or connecting an electric device with its capacity over the limit into...

Page 57: ...G Instrument panel U12O417A 1 Fuel Gauge 2 Speedometer 3 Coolant Temperature Gauge 4 Turn Signal Indicator LH 5 Neutral Indicator 6 High Beam Indicator 7 Lower Fuel Level Warning Indicator 8 Preheatin...

Page 58: ...maining fuel lev el after the key switch is turned to the ON position F Fuel is completely filled E Replenish the fuel tank If driving is continued with the nee dle below the position E the warn ing l...

Page 59: ...is sucked through it freely for fast cool ing Never open the radiator cap when it is hot You can get burnt badly CAUTION Stop the vehicle or operation for a while without stopping the engine un til th...

Page 60: ...will turn off If this warning lamp comes on while driving the charging system such as the alternator is malfunctioning Therefore turn off all electrical devices and have the vehicle checked by your l...

Page 61: ...ended to start the engine as soon as this in dicator goes off for best starting per formance This indicator may not turn on if the engine is warm In this case the engine can be started without the pre...

Page 62: ...it comes on you should add fuel as soon as possible Driving with the this lamp on or with the fuel level be low E can cause the engine to mis fire and damage the engine parts If the air enters into th...

Page 63: ...tions H High speed L Low speed N Neutral and R Reverse This vehicle is equipped with the in line type shift lever system for conve nient control Also there is a stopper between the H and N positions t...

Page 64: ...rential system should be unlocked to secure safe turning When the wheel on one side is on a slippery surface such as mud or icy road the wheels on a slippery sur face lose traction and rotate fast whi...

Page 65: ...ving the lever during driving can affect the life of the differential system CAUTION LSD Differential Lock Front Wheel The LSD Limited Slip Device is in stalled on the front axle The LSD differential...

Page 66: ...stop the vehicle Press the pedal before starting downhill to prevent the vehicle from gaining too much speed 1 Brake Pedal A Depress IMPORTANT UUVO431A Parking brake lever 1 Parking Brake Lever A Dow...

Page 67: ...to apply the parking brake before leaving your vehicle WARNING To avoid possible injury death or loss of property from a ma chine runaway With the engine off unexpect ed machine movement could result...

Page 68: ...til a clicking sound is heard 2 Press the red button to un buckle 1 Seat Belt Seat belt UUVO435c As the safety belt can reduce or prevent injuries in an acci dent make sure to wear the seat belt durin...

Page 69: ...t you in a rollover accident not to pro tect you from falling objects Never drive in a dangerous or construction area that may have falling objects Occu pants can be seriously injured WARNING NOTE ROP...

Page 70: ...g a garage make sure that the vehicle does not hit the ceiling or entrance of the garage CAUTION KUVO403A U12O453a Cup holders and storage boxes 1 Cup Holders 2 Glovebox Driver Side 3 Glovebox Center...

Page 71: ...ing Handle A Turn B Pull Up To raise the cargo bed pull up the handle with one hand while turning the dumping latch lever with the oth er hand Take your hand off the han dle after the support rod is s...

Page 72: ...autions when fueling 1 Make sure that the fuel to be filled into the tank is diesel fuel UUVO449A 2 Avoid using electrical devices such as a cellular phone during fueling 3 The fuel is highly flammabl...

Page 73: ...recommended to use diesel fuel with high cetane number in order to enhance power and starting of the engine in a cold weather Fuel requirements Adding gasoline or kerosene to the fuel tank can damage...

Page 74: ...in spected without opening hood right behind the right front wheel 1 Radiator Cap 2 Drain Plug UUVO451A T56O530A Tire Though the tire inflation pressure is factory set to the prescribed level it natur...

Page 75: ...ghtened and tighten them as necessary before driving Driving with loose wheel nuts can lead to a serious accident UUVO458A Do not use tires larger or smaller than specified Do not disassemble or assem...

Page 76: ...ndard All terrain 25x10 12 4PR 12 PSI 4 0 4 6 kgf m 28 9 33 3 lb ft Option Turf 25x10 12 4PR 12 PSI 4 0 4 6 kgf m 28 9 33 3 lb ft Option Rear wheel Work site 25x11 12 6PR 18 PSI 4 0 4 6 kgf m 28 9 33...

Page 77: ...VE 5 7 Warming up 5 10 Jump start 5 11 Stopping 5 12 Parking 5 12 Shifting 5 13 Driving on slippery surfaceS 5 14 Turning 5 15 Driving on slope 5 15 Driving in forest 5 17 Driving through water 5 17 D...

Page 78: ...mps Check the fuel level Visually check the tire inflation pressure and wheel nut tightness For more information refer to the chapter Maintenance PRE OPERATION Daily inspection OPERATING THE ENGINE St...

Page 79: ...t lever without releas ing the parking brake Make sure to release the parking brake be fore starting off Failure to do so could reduce the life of the park ing brake disk NOTE 1 Shift Lever 3 Check th...

Page 80: ...If the engine cannot be started within 10 seconds wait for 30 seconds and try again When trying to start the engine again make sure that the fly wheel is stopped in advance Do not turn the key switch...

Page 81: ...he engine immediate ly and check the engine oil level If the engine oil level is within safe operating limits contact your local Dealer 9 Check to see that all the warning lamps on the instrument clus...

Page 82: ...he ignition key If the vehicle is operated for an extended period of time idle the engine at low speed for 2 to 3 minutes in order to cool down the engine before shut down IMPORTANT Operating principl...

Page 83: ...T Fasten the seat belt firmly when you are seated in the ve hicle The seat belt can reduce or prevent injuries in an accident Make sure to wear the seat belt during driving Also be sure the seat belt...

Page 84: ...lease 3 Release the parking brake UUVO503A 4 Place the shift lever to the H High speed or L Low speed 5 Press the accelerator pedal gradu ally to start off the vehicle 6 The 4WD system can be used as...

Page 85: ...sed to these controls Place the shift lever into the L position when driving on a soft or bumpy surface or car rying a heavy load CAUTION Do not shift the gear when the vehicle is moving or the en gin...

Page 86: ...ing up the engine exces sively increases fuel consump tion and affects the durability of the vehicle negatively Never warm up the engine and leave the vehicle for an extend ed period of time It can ca...

Page 87: ...emove the bat tery terminal cover as necessary 4 Connect the alligator clips on both ends of the red positive cable to the positive terminals of both bat teries 5 Connect one clip of the black negativ...

Page 88: ...with the parking brake system and main brake system separately for safe ty The parking brake should be used in an emergency such as brake pedal failure Never press the accelerator and brake pedals si...

Page 89: ...the shifting operation is au tomatic according to the accelerator pedal operation and outer load con dition Make sure to move the shift lever to the H L or R position when the vehicle is stationary I...

Page 90: ...this circumstance observe the fol lowing 1 Slow down before you enter a slip pery area 2 Before entering a slippery area move the shift lever to the L po sition and 2WD 4WD lever to the 4WD position...

Page 91: ...If the dif ferential lock system is used during turning on a normal road with suffi cient friction the durability of the in ternal gears related to the differential system can be damaged Also there i...

Page 92: ...a road in clined vertically or sideward make sure to drive at a low speed Otherwise the vehicle can roll over leading to a seri ous accident Driving with excessive load on a slope can lead to overtur...

Page 93: ...erve the spec ified water depth limit Never drive through swift water flow even though its depth is below the height of the vehicle floor 1 Drive at a low speed when driving in a mountainous area or t...

Page 94: ...ty CAUTION Consider the following when driving backward 1 Drive backward at a low speed To stop the vehicle press the brake pedal gently 2 Avoid abrupt turning and driving down the slope backward 3 Ne...

Page 95: ...and tail lamps on the vehicle In this condition it is very dan gerous to drive on a road In some countries or states it is illegal to drive a UTV on public roads Be aware of traf fic laws before drivi...

Page 96: ...oad when driving on a slope with excessive cargo Therefore load only up to half of the specified load limit when driving on a slope 6 When loading heavy material such as sand and earth distribute it e...

Page 97: ...loading manual model 4 After raising the cargo bed make sure support is latched in the groove A firmly 5 Never drive the vehicle with the cargo bed raised If the support rod comes off the groove by vi...

Page 98: ...ation is not met the vehicle can turn over backward 3 It is very hard to drive backward with a trailer connected Keep the speed low Make sure to check the ground condition before driving back wards to...

Page 99: ...rting vehicle or trailer 2 Set ramps to the transporting vehi cle firmly 3 It is recommended to drive back ward onto the transporting vehicle to drive out of it more easily later 4 Make sure to set th...

Page 100: ...wheels are driven in the 4WD mode Keep the following instructions to use the 4WD correctly 1 It is recommended to use the 4WD when driving on a slippery muddy or icy road driving through water or dri...

Page 101: ...moving or the engine is running at a high speed The power transfer sys tem can be severely damaged and an accident can occur 5 In some cases it may be hard to move the 2WD 4WD shift lever out of the 4...

Page 102: ...py road for better traction 2 Keep your feet as far as possible as any object can fall off the car go bed when the tailgate opens abruptly H11O585A U12O523A 1 Gate Tailgate back door 1 Latch Lever 1 W...

Page 103: ...REPLACEMEnT PARTS 6 Essential replacement part 6 2 Oil and fluid 6 2 Filters 6 2 Belts and rubber parts 6 3 eLECTRIC PARTS 6 3 6 UD120 OM 1600XD4 06 indd 1 2014 05 08 3 19 48...

Page 104: ...he maintenance intervals Refer to chapter 7 Maintenance Essential replacement part Oil and fluid NO ITEM SPECIFICATION CAPACITY 1 Engine Oil SAE 15W40 8 45 30 2 Gear Box DAEDONG UTF55 Exxonmobil Mobil...

Page 105: ...ber parts N0 PART NO DESCRIPTION QTY 1 E5205 32091 Engine Oil Filter 1 2 84612 4316 0 Fuel Filter Element 1 3 T2350 11641 Air Filter 1 N0 PART NO DESCRIPTION QTY 1 E5760 72532 Fan Belt 1 2 U3215 29081...

Page 106: ...MEMO MEMO UD120 OM 1600XD4 06 indd 4 2014 05 08 3 19 49...

Page 107: ...ns K 7 16 Checking fuel FILTER L 7 17 BLEEDING FUEL LINE M 7 17 Checking injection nozzle and fuel injection pump N 7 19 Cleaning radiator core O 7 19 Checking coolant in auxiliary coolant tank P 7 20...

Page 108: ...g fuse AF 7 37 Main fuse slow blow fuse AG 7 37 Aligning wheel and checking wheel nut AH 7 38 Checking differential lock cable AI 7 39 Checking shiftand 4WD cables AJ 7 39 Using Biodiesel AK 7 40 Adju...

Page 109: ...O P Q Seat Belt Check the condition of seat belt and mounting hardware Tires Check for wear damaged tires and air pressure Check wheel hub nuts are tightened Parking Brake condition Check operation a...

Page 110: ...L M 5 Air cleaner filter Check H Replace 6 Air intake hose connection and filter body anti dust valve Check I 7 Valve clearance Check 8 Injection nozzle Check N 9 Spark arrester Check R 10 Coolant Rep...

Page 111: ...rear wheel and parking brake pads Check AA AC 19 Suspension mounting bushing play and mounting rubber Check AC 20 Leakage from shock absorber Check AC 21 Wheel hub bearing clearance Check 22 Wheel hub...

Page 112: ...ezing solution Ethylene glycol Pure water 50 50 3 Engine oil 0 9 3 2 SAE 15W40 4 Gear Box Oil 0 24 0 9 DAEDONG UTF55 Exxonmobil Mobilfluid 424 Exxonmobil Hydraulic 560 Shell Donax TD 5 Front different...

Page 113: ...inspection shield This vehicle is designed so that it is easy to access the inspection points for service Most of regular services can be performed by opening the in spection shield under the seat sea...

Page 114: ...ngine services includ ing engine oil change and head cover repair can be performed by opening the seat cushion 1 Pin KUVO704A 1 Ratchet lever 2 Lever Lock Bracket A Up B Down It is possible to check t...

Page 115: ...NLGI grade No 2 grease 1 Grease fitting Rear axle drive shaft UUVO707b The other two are located on the front wheel knuckle Remove the front wheels to give grease UUVO775A 1 Grease fitting Front wheel...

Page 116: ...ld be fore starting it The oil level should always be between the MAX and MIN lim its Be sure to stop the engine to prevent an accident when checking the engine oil or re fueling IMPORTANT Checking en...

Page 117: ...he vehicle 2 Park the vehicle on level ground stop the engine and apply the parking brake firmly 3 Remove the inspection shield and seat cushion UUVO709A 1 Oil filter 5 Remove the oil filter through t...

Page 118: ...nd and apply the parking brake firmly 2 Stop the engine and raise the car go bed In case the hydraulic dumping kit is installed raise the car go bed before stopping the en gine 3 Press the corner of t...

Page 119: ...e and raise the car go bed 3 Open the cover of the air filter can ister to replace the filter 4 Make sure to fit the filter to the center of the canister 5 Install the canister cover after checking th...

Page 120: ...gine remove the seat cushion and remove the rear cov er on the left of the vehicle 1 Rear cover U12O715B 3 Remove the battery 1 Battery You can get burnt by touching hot parts such as the muffler Wait...

Page 121: ...e but leave the muffler in place 1 Exhaust pipe 2 Muffler UUVO718A 6 Remove the air hoses 1 and 2 from the CVT cover 1 Air hose 1 2 Air hose 2 U12O719A 7 Remove the CVT cover 1 CTV cover UUVO720A UD12...

Page 122: ...uch as the CVT belt or CVT pulley or there is dust inside the CVT cover clean thor oughly with vaccum cleaner and reassemble them Never apply grease oil or sim ilar fluids on the surface of the belt a...

Page 123: ...Unscrew the plug on the bottom of the fuel filter to drain fuel 3 Remove the fuel filter 4 Remove foreign materials such as dirt thoroughly and replace the fuel filter with a new one BLEEDING FUEL LIN...

Page 124: ...the shift lever in the neutral position when driv ing downhill Do not use any engine oil ad ditive or fuel additive Avoid driving with any warn ing lamp illuminated Do not allow any flammable material...

Page 125: ...ar ranty Cleaning radiator core O 1 Park the vehicle on level ground and apply the parking brake firmly 2 Stop the engine open the hood and support it 3 Remove the three grilles from the brush guard 1...

Page 126: ...Perform the following steps to check the auxiliary coolant tank 1 Auxiliary coolant tank A MAX limit B MIN limit IMPORTANT UUVO728A 1 Park the vehicle on level ground and apply the parking brake firml...

Page 127: ...emove the radiator cap while the engine is hot You can get burnt by hot steam Make sure to remove it after the engine and radiator have cooled down enough 1 Radiator Cap IMPORTANT WARNING UUVO729A 4 A...

Page 128: ...lant from the en gine by removing the engine cool ant drain plug U12O733A 9 Loosen the air bleeder bolt for fast drain 10 Disconnect the hose from the bottom of the auxiliary coolant tank to drain the...

Page 129: ...hoses 17 Make sure all plugs and caps for the cooling system have been re placed and tightened 18 Test run the engine to find any leakage 19 The coolant mixture ratio may differ by local climate Ther...

Page 130: ...he oil is not normal or it is at the oil change interval change the oil 1 Drain plug 7 To change oil place a container with wide opening under the drain plug Then remove the drain plug 8 After drainin...

Page 131: ...the oil level and condition with a finger bent slightly If you cannot reach the oil it means the oil level is low Add oil as needed You can get burnt badly by hot oil Make sure to work on it after it...

Page 132: ...its surrounding with a rag thorough ly 12 Test drive the vehicle for 5 to 10 minutes to check for leakage Oil Capacity 0 16 U S Gal 0 6 L 1 Park the vehicle on level ground and apply the parking brake...

Page 133: ...it through a long hose into the fill plug location Fill till oil starts to spill out of filler plug hole 9 Check the oil level by performing the step 4 in the previous page If the oil level is normal...

Page 134: ...eck if the CV boots of the drive shaft for the rear wheels are torn or have a sign of leakage 5 If the CV boots should be re placed contact your Dealer UUVO740A UUVO741A 1 Park the vehicle on level gr...

Page 135: ...on of such components is in doubt contact your Dealer im mediately IMPORTANT UUVO743A 1 Park the vehicle on level ground and apply the parking brake firmly 2 Stop the engine open the hood and support...

Page 136: ...d and support the hood 3 Measure the free play of the brake pedal According to the measure ment adjust the length of the mas ter cylinder rod 1 1 Master Cylinder Rod UUVO745A Brake fluid DOT 3 Checkin...

Page 137: ...us and can lead to overturn and collision Make sure that they are firmly tightened WARNING UUVO747A The vehicle should be stopped on a slope up to 10 degrees when the parking brake is ful ly applied W...

Page 138: ...he parking brake disc If any of the pads are close to 0 04 inch 1 mm both pads should be replaced 5 After replacing the pads test the parking brake and adjust the cable length accordingly 6 Check if t...

Page 139: ...and weight hauling To adjust the suspension perform the following steps 4 Unscrew the wheel nuts complete ly to remove the wheel 1 Hole 5 Fit a special service tool to the hole and turn it to adjust...

Page 140: ...ion Never open or service the battery and never add electrolyte to the bat tery Doing so will not be covered by your warranty Therefore when checking the battery observe the fol lowing 1 Keep the batt...

Page 141: ...able UUVO753A U12O715B The battery terminals and ca bles contains lead The body accumulates lead which can cause cancer Make sure to wash your hands after han dling these parts CALIFORNIA BATTERY WARN...

Page 142: ...the battery near flame or spark Do not touch the both termi nals of the battery with a metal object simultaneously When disconnecting the bat tery disconnect the negative battery cable first When con...

Page 143: ...OR FAN HEAD LAMP FOG LAMP COMBI NATION METER BRAKE LAMP HORN FLASHER UNIT WASHER WIPER MOTOR FUSE PULLER SPARE 30A 5A 5A 20A 20A 10A 10A 5A 20A 20A 15A 15A 20A 30A 7 USE ONLY RATED FUSE WORKING LAMP U...

Page 144: ...ty stand Then lower the hydraulic jack so that the vehi cle chassis sits on the stand 4 Unscrew the wheel nuts complete ly to remove the wheel 5 After reinstalling the wheel after inspection tighten t...

Page 145: ...ith a jack so that the rear wheels are off the ground 5 Set the differential lock lever to the Lock position and rotate one of the wheels manually It is normal that the other wheel rotates in the same...

Page 146: ...s about biodiesel use contact your Dealer Make sure that no one espe cially children near the vehi cle WARNING Adjusting belt tension AL The engine belt drives the alterna tor and coolant pump If the...

Page 147: ...If getting too close to rotating parts such as the belt dur ing the engine is running your clothes or part of your body can be caught WARNING UUVO761A Washing AM It is recommended to wash your ve hicl...

Page 148: ...ide near the vehicle Do not spill the brake fluid on the vehicle parts It can damage the painted surface If the brake fluid is spilled wipe it immediately Never spill fuel on the vehicle com ponents I...

Page 149: ...8 STROAGE AND DISPOSAL 8 vehicle sTORAGE 8 2 daily storage 8 2 Long term storage 8 2 Using vehicle after long term storage 8 3 Disposal 8 4 UD120 OM 1600XD4 08 indd 1 2014 03 28 9 58 57...

Page 150: ...period of time fol low the instructions below to prevent corrosion and perfor mance deterioration of the ve hicle while it is stored 1 Check the bolts and nuts for loose ness and tighten if necessary...

Page 151: ...parking brake operation for normal opera tion Using vehicle after long term storage If the battery is not to be re moved disconnect its nega tive terminal at least The wir ing can be gnawed by rodent...

Page 152: ...hen changing the oil or coolant by yourself be careful not to spill it and dispose used oil and coolant properly according to the applica ble regulations 2 Never leave or discard the ex pired vehicle...

Page 153: ...TROUBLESHOOTING vehicle Troubleshooting 9 2 9 9 UD120 OM 1600XD4 09 indd 1 2014 03 28 9 59 28...

Page 154: ...operation such as pre heat relay controller Extra manual preheating is required in extremely cold weather Insufficient fuel Air in fuel line loose fuel line clamp or pinched fuel line Water or foreign...

Page 155: ...l Incorrect injection of injection nozzle or carbon accumulated onto it N Improper valve clearance 3 Engine power is insufficient knocking vibration smoke Excessive engine oil overfilling water or hyd...

Page 156: ...overheated Clogged radiator grille and core O Insufficient or leaking coolant loose hose connection Q Broken cooling fan Defected temperature sensor Improper mixing ratio of antifreeze Defected radia...

Page 157: ...ted engine 5 Engine stops abruptly during operation Engine oil leakage Q Coolant leakage Q Faulty solenoid Injection pump malfunctioning 6 Electrical device is malfunc tioning parts related to preheat...

Page 158: ...rt and stop lack of time to charge Excessive electricity use from external device additionally attached device such as implement Prolonged cranking in severe condition Expired battery 8 Vehicle cannot...

Page 159: ...D not used Worn CVT belt J K 12 Vehicle cannot reach its max speed Worn CVT belt J K Improperly adjusted accelerator pedal cable engine cannot reach its full speed 13 Braking force is insufficient Wet...

Page 160: ...and contamination due to torn steering rack boots W 17 Steering wheel is not operated smoothly Faulty steering knuckle W Improperly adjusted toe in Excessive steering wheel play 18 Hydraulic pressure...

Page 161: ...10 INDEX index 10 2 10 UD120 OM 1600XD4 10 indd 1 2014 03 28 9 59 56...

Page 162: ...g air hose and clamp I 7 13 Checking and changing front axle oil T 7 25 Checking and changing gearbox oil S 7 24 Checking and changing rear axle oil U 7 26 Checking and replacing fuse AF 7 37 Checking...

Page 163: ...0 Differential lock lever REAR WHEEL 4 20 DiffERENTIAL lock operation 5 25 Disposal 8 4 Driving backward 5 18 Driving in forest 5 17 Driving on road 5 19 Driving on slippery surfaceS 5 14 Driving on s...

Page 164: ...5 11 k Key switch 4 8 l Long term storage 8 2 Lower fUEL LEVEL WARNING INDICATOR 4 18 LUBRICANTS 7 6 M Main fuse slow blow fuse AG 7 37 MAINTENANCE 7 1 Maintenance check list 7 3 MAINTENANCE interval...

Page 165: ...placing air filter H 7 13 Replacing fuel filter 7 17 Replacing headlamp bulb AE 7 36 ROPS 4 25 S Safety decal 1 19 SAFETY PRECAUTIONS 1 1 Safety precautions during servicing 1 14 Safety precautions wh...

Page 166: ...Unloading manual model 5 21 Uphill and downhill 5 15 Using Biodiesel AK 7 40 Using vehicle after long term storage 8 3 v Vehicle Identification Number 2 2 Vehicle serial number 2 2 vehicle sTORAGE 8 2...

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Page 168: ...6 800 241 5855 I Fax 706 796 4540 I www ezgo com e mail ezgo textron com I 2011 E Z GO Division of Textron Inc Read all this manual to become thoroughly familiar with this vehicle Pay particular atten...