Cushman 646442 Owner'S Manual Download Page 176

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HAULER 4X4 DIESEL

Problem

check item

Maintenance code

15. Parking brake is malfunc

tioning (Vehicle rolls down

on slope)



Improperly adjusted parking brake cable



Worn parking brake pad

16. Steering wheel feels heavy



Insufficient inflation pressure of front tires



Insufficient lubrication and contamination due to torn steering rack boots

17. Steering wheel is not

operated smoothly



Faulty steering knuckle



Improperly adjusted toe-in



Excessive steering wheel play

18. Hydraulic pressure is faulty

(if equipped with dumping

kit or auxiliary hydraulic kit)



Lack of

Hydraulic fluid in hydraulic tank



Improper hydraulic oil used



Faulty valve and pump

※

f you do not find the cause of trouble, consult your dealer for assistance.

UTV-EZGO-Hauler 4X4 Diesel-09.in8 8

2015-05-26 오전 8:49:37

Summary of Contents for 646442

Page 1: ...hauler 4x4 diesel 2 passenger owner s manual 646442...

Page 2: ...UTV EZGO Hauler 4X4 Diesel 00 in2 2 2015 05 26 8 58 20...

Page 3: ...best quality products It is strongly recommended for all customers and operators to read this owner s manual thoroughly before using this vehicle as the manual contains a lot of valuable information s...

Page 4: ...UTV EZGO Hauler 4X4 Diesel 00 in2 2 2015 05 26 8 58 20...

Page 5: ...IFICATIONS SPECIFICATIONS CONTROLS AND FEATURES OPERATION REPLACEMENT PARTS MAINTENANCE STORAGE AND DISPOSAL TROUBLESHOOTING INDEX SECTION 1 2 3 4 5 6 7 8 9 10 TABLE OF CONTENTS UTV EZGO Hauler 4X4 Di...

Page 6: ...ocation 1 19 DeCALs 1 20 Cautions for decal maintenance 1 26 PRECAUTIONS BEFORE OPERATION 2 1 Vehicle Identification Number 2 2 Vehicle serial number 2 2 Engine serial number 2 2 SPECIFICATIONS 3 1 SP...

Page 7: ...l 4 32 Rear screen optional 4 33 Front hitch receiver optional 4 33 Safety lamp kit optional 4 8 Switches 4 9 Key switch 4 9 Combination switch 4 11 Hazard lamp switch optional 4 13 Spare switch panel...

Page 8: ...per inflation pressure 4 42 OPERATION 5 1 PRE OPERATION 5 2 Daily inspection 5 2 OPERATING THE ENGINE 5 2 Starting the engine 5 2 Checking warning lamps after starting engine 5 5 Operating principle o...

Page 9: ...table 7 4 LUBRICANTS 7 6 Daily inspection 7 7 Access for service 7 7 Opening inspection shield A 7 7 Opening seat cushion B 7 8 Raising cargo bed C 7 8 Applying grease D 7 9 Checking engine oil level...

Page 10: ...sting suspension AB 7 35 Checking suspension shockabsorber AC 7 36 Battery sealed AD 7 36 Replacing headlamp bulb AE 7 38 Checking and replacing fuse AF 7 39 Main fuse slow blow fuse AG 7 40 Aligning...

Page 11: ...erious 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 vehicle o...

Page 12: ...AL SYMBOLS Fuel Level low Parking Brake Battery Charging Condition Engine Oil Pressure Turn Signal Differential Lock Hazard Warning Lights Headlight Low Beam Headlight High Beam Four Wheel Drive ON H...

Page 13: ...en 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 mounting lo...

Page 14: ...66O101a 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 sa...

Page 15: ...ur 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 avoidabl...

Page 16: ...whenever 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 en...

Page 17: ...nuts have been tightened to the specified torque 8 Always check the tire pressure be fore start engine For more infor mation about tire pressure see chapter 4 9 Make sure that all pressure lines are...

Page 18: ...applicable 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 dange...

Page 19: ...tial 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 whee...

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: ...und 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 obstacles and slopes are ahead and when...

Page 22: ...ditions UUVO124A 18 Never attempt abrupt wheelies jumps or other stunts UUVO125A 19 Always keep your both hands on the steering wheel and your both feet on the floor of the vehicle during operation 20...

Page 23: ...ck 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 t...

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: ...gnition 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 only fr...

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: ...ap 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 completely If...

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: ...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 should b...

Page 30: ...g as this can weaken the ROPS structure If any components of the ROPS unit is damaged it must be replaced If the ROPS unit is removed or loos ened for any reason the parts should be fitted back to the...

Page 31: ...SAFETY PRECAUTIONS 1 19 1 Safety decal mounting location UUVO142f UTV EZGO Hauler 4X4 Diesel 01 in19 19 2015 05 26 8 54 00...

Page 32: ...pen or unlatched could lead to impaired visibility or the loss of vehicle control Turn engine off and apply parking brake before exiting the vehicle WARNING 4 Part No U3215 85681 1 The owner s manual...

Page 33: ...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 exiti...

Page 34: ...rt No U3215 85161 NOTICE THIS ROPS IS TESTED IN ACCORDANCE WITH SAE J2194 METHOD MAXIMUM VEHICLE MASS INCLUDING CARGO DECK AND PERMANENT ATTACHMENTS IS 850kg 1874 lbs MEC2200 U3215 2610 ROPS P Number...

Page 35: ...ped with hydraulic dump only operate while sitting in the seat Do not place hands behind the seat or underneath the bed when lowering or raising the cargo bed Never work underneath a raised bed if not...

Page 36: ...inals or bypassing the safety start switch The vehicle may start in gear and move if normal starting circuitry is bypassed 2 Only Start the engine from the operator s seat with range shift lever in ne...

Page 37: ...or towing navigate turns and rough or uneven terrain at reduced speeds DO NOT haul or tow unsecured loads or cargo 18 Part No U3215 85201 19 Part No U3215 85111 Option 20 Part No U3215 85862 Driving U...

Page 38: ...lvent such as thinner 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 CAUTION If a decal is damaged or lost contact...

Page 39: ...2 PRECAUTIONS BEFORE OPERATION 2 Vehicle Identification Number 2 2 Vehicle serial number 2 2 Engine serial number 2 2 UTV EZGO Hauler 4X4 Diesel 02 in1 1 2015 05 26 8 41 52...

Page 40: ...Number Vehicle serial number Engine serial number UUVO202A UUVO201A Have the vehicle serial number and engine serial number with you when ordering parts or asking for service information Fill in the...

Page 41: ...SPECIFICATIONS SPECIFICATION 3 2 Exterior dimensions 3 2 General specifications 3 3 OPTION List and FEATURES 3 6 3 3 UTV EZGO Hauler 4X4 Diesel 03 in1 1 2015 05 26 8 42 13...

Page 42: ...ll height C Wheel base D Front wheel tread E Rear wheel tread F Ground clearance G 112 3 2 852 60 7 1 543 76 4 1 940 76 4 1 940 49 7 1 262 48 3 1 228 12 304 D A E F B C G C UUVO301a Notes The specific...

Page 43: ...ation N A Max torque Nm rpm 83 2000 Emission EPA Tier4 Final g kW hr NOx HC 7 5 CO 6 6 PM 0 4 Fuel consumption at Max Power g kW hr Below 275 Torque rise Over 15 Cold start 20 C with Pre Heat Noise dB...

Page 44: ...on Strut type Rear suspension Independent Double A Arm Wishbone type Steering type Rack pinion Tire Front wheel 25 x 10 12 Worksite Rear wheel 25 x 10 12 Worksite Cargo bed Dimension L x W x D in mm 3...

Page 45: ...Winch mount Option Mounting bolts on brush guard Combination switch Standard For lamps and horn Seat Capacity 3 Seat Bench Dump Box Actuation Manual Front Guard Standard Body Color Blue Hydraulic Uti...

Page 46: ...Kit Protection for rear area for operator Highly recommended for worksite using with cargo Muffler Spark Arrester Kit To prevent wild fire by collecting exhaust sparks Install at the end of exhaust pi...

Page 47: ...er 4 15 Fuel gauge 4 16 Coolant temperature gauge 4 16 Engine oil pressure warning lamp 4 17 Battery charging lamp 4 18 Head light high beam lamp 4 18 Turn Signal Lamp 4 18 Glow plug indicator 4 19 Pa...

Page 48: ...storage boxes 4 34 Cargo bed 4 34 Cargo bed control lever 4 34 Cargo bed control lever OPTIONAL 4 35 Remote hydraulic lever OPTIONAL 4 36 Hand throttle lever OPTIONAL 4 37 Cargo bed extension optional...

Page 49: ...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 UUVO401A STANDARD MODEL Exte...

Page 50: ...nt Working Lamp 2 Sun Canopy 3 Head Rest 4 Rear View Mirror 5 Front Turn Signal Lamp 6 Windshield 7 Cargo Bed Extension UUVO461A FULL OPTION MODEL 8 Tail Lamp 9 Fog Lamp 10 Rear Screen UTV EZGO Hauler...

Page 51: ...CAUTION UUVO402A UUVO452A 1 Hood Support ELECTRIC COOLING FAN MOTOR The fan motor runs when the coolant temperature raises over 80 and stops when the coolant temperature drops below 75 The 5 gap be t...

Page 52: ...vehicle is equipped with the rear hitch receiver as standard The rear hitch receiver is a 2 inch square boss type and is used to in stall a trailer or 3 point hitch imple ment Make sure to observe th...

Page 53: ...ing 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...

Page 54: ...signal lamps and horn as these can be operated by the combination switch standard NOTE Always check that the reflex reflector are clean before driv ing Driving with the dirty re flective mirrors espe...

Page 55: ...E Start A When the key switch is in position A the engine and all electrical devices in the vehicle stop except horn hazard lamps and turn sig nal There are five positions for the ig nition key switc...

Page 56: ...e the preheat system s life E The position E indicates the Start In order to start the engine the shift lever should be in the neutral position As soon as the engine is started release the key then th...

Page 57: ...he combination switch consists of the head light turn signal light and horn switches Headlamp switch The headlamp switch can be operat ed while the key switch is in the ON position then head lights ta...

Page 58: ...ich is included in the Safety lamp kit as an option Check if the safety lamp kit is installed before using this switch UUVO414A The turn signal lamp lever is not the self return type Therefore make su...

Page 59: ...on oc curs in the vehicle while driving on a public road Pressing this switch up blinks the hazard lamp and returning it turns off the lamp The turn signal lights cannot be operated while this switch...

Page 60: ...witch panel 1 Spare Switch Panel The spare switch panel is prepared in case that the owner wants to in stall the switches for the option al hazard warning lamp working lamps wiper and other implements...

Page 61: ...key switch is in the ON posi tion Check the hourmeter to service the vehicle at the correct interval SPEEDOMETER Hourmeter 1 Speedometer 2 Hourmeter U12O417A 1 Fuel Gauge 2 Speedometer 3 Coolant Temp...

Page 62: ...the ON position C Coolant is cold H Coolant is hot The range marked 2 in the figure indicates the normal engine temper ature normal driving range If the needle is in the H zone dur ing driving it indi...

Page 63: ...tor fan is operating If the fan is not operating stop the engine and have your vehicle checked by your dealer This lamp comes on when the en gine oil pressure or oil level is low This lamp comes on wh...

Page 64: ...ur local Dealer or work shop as soon as possible CAUTION UUVO420A Head light high beam lamp This lamp comes on in blue when the high beam head light is switched on Driving with high beam head light di...

Page 65: ...is warm In this case the engine can be started without the preheat operation Glow plug indicator UUVO423A Parking brake indicator This lamp comes on in red when the parking brake is engaged If this in...

Page 66: ...s If the air enters into the fuel system refer to maintenance chapter page 7 20 for Bleeding fuel line UUVO426A engine check warning lamp This warning lamp comes on when any major electric device or e...

Page 67: ...FAULT LAMP CODE with the number of blinking of the CEL warning lamp Based on this identified FAULT LAMP CODE engine malfunction type can be determined If the CEL warning lamp blinks as described cont...

Page 68: ...gital circuit power supply dropout is detected CEL 21 DOUT 1 OVERCURRENT CEL DOUT 1 OPEN CIRCUIT CEL Activated when DO1 CEL over current or open circuit is detected CEL 22 DOUT 2 OVERCURRENT Glow Lamp...

Page 69: ...r replace MPU sensor CEL 41 MAP POWER SUPPLY 5V 2 Activated when Air Pressure Sensor power sup ply output short to ground for at least 100ms is detected CEL 42 OVERSPEED Activated when configured engi...

Page 70: ...ault lamp code identification Code 11 CEL lamp blinking 1 time at a long interval and then 1 time at a short interval Code 12 CEL lamp blinking 1 time at a long interval and then 2 time at a short int...

Page 71: ...e H L or R po sition Shifting during driving can damage parts in the gear box Shift the lever into the L Low speed position when driv ing on a hill or a bumpy area so that the vehicle can utilize more...

Page 72: ...n Make sure to set the steering wheel in the straight ahead po sition and drive at a low speed while the differential lock lever is in the Lock position Oth erwise you can lose control of the vehicle...

Page 73: ...nd steerability can be deteri orated if using the 4WD unnecessarily UUVO430A Brake pedal The brake pedal is located on the left of the accelerator pedal Depress the brake pedal slowly to stop the vehi...

Page 74: ...is vehicle is equipped with the CVT Continuous Variable Transmission Therefore the vehicle may roll down a slope if the parking brake is not en gaged even though the shift le ver is in the H L or R po...

Page 75: ...The seat cushion and seatback can be separated Re moving the seat cushion can access to the engine compartment Seat 1 Seat Cushion 2 Seat Back UUVO434A The seat belts for a driver and pas senger are...

Page 76: ...to fasten the seat belt during driving The ROPS cannot protect you if not wear ing the seat belt WARNING As the safety belt can reduce or prevent injuries in an acci dent make sure to wear the seat be...

Page 77: ...The vehicle can be equipped with the convex outside rearview mirror on the driver and passenger sides as an option Objects seen in the convex mirror are closer than they ap pear Therefore avoid abrupt...

Page 78: ...sure that the vehicle does not hit the ceiling or entrance of the garage CAUTION UUVO403A The transparent optional acrylic windshield is to block wind from the front 1 Windshield Windshield optional...

Page 79: ...braking Make sure to secure cargo with ropes even though the ve hicle is equipped with the rear screen Wearing helmet for a riders is highly recommended especial ly when there is no rear screen insta...

Page 80: ...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 set into the...

Page 81: ...age the latch before driving WARNING UUVO454A 1 Cargo Bed Support 1 Hydraulic Lever 2 Lever Lock Bracket A Up B Down C Floating 1 Hydraulic Cylinder UUVO463A UUVO446A Cargo bed control lever OPTIONAL...

Page 82: ...rgo bed raised Make sure to lower the cargo bed to its original position and en gage the latch before driving When raising or lowering the cargo bed be careful not to let any part of your body such as...

Page 83: ...d pull the lever up to operate the implement or hydrau lic motor Return the lever to stop op erating implement or hydraulic motor As the valve is ON OFF style it is not good to operate the hydraulic c...

Page 84: ...n condi tions Make sure to stop the en gine and remove the key before fueling 4 Never smoke while fueling Add fuel in a well ventilated area and keep away from spark and flame 5 Do not fill the tank w...

Page 85: ...mended to use diesel fuel with high cetane number in order to enhance power and starting of the engine in a cold weather Fuel requirements Engine inspection 1 Inspection Shield UUVO450A UUVO453A It is...

Page 86: ...n recreatiONal UUVO460A tire tread patterns Coolant brake fluid and electrical devices The coolant radiator cooling fan and brake fluid can be checked by open ing the hood Also various relays and cont...

Page 87: ...them as necessary before driving Driving with loose wheel nuts can lead to a serious accident UUVO458A UUVO457A Do not use tires larger or smaller than specified Do not disassemble or assem ble the t...

Page 88: ...l terrain 25x10 12 18 PSI 4 0 4 6 kgf m 28 9 33 3 lb ft Turf 26x10 5 12 18 PSI 4 0 4 6 kgf m 28 9 33 3 lb ft If tires with a different size from the ones specified are installed contact the dealer for...

Page 89: ...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 D...

Page 90: ...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 91: ...ver 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 that t...

Page 92: ...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 93: ...ngine 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 cluster...

Page 94: ...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 95: ...asten 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 is...

Page 96: ...lease 3 Release the parking brake UUVO503A UUVO505A 4 Place the shift lever to the H High speed or L Low speed 5 Depress the accelerator pedal gradually to start off the vehicle 6 The 4WD system can b...

Page 97: ...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 gine is ru...

Page 98: ...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 99: ...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 neg ative cab...

Page 100: ...In this case drive at a low speed and al ways consider the actual stop ping distance WARNING This vehicle does not have an engine brake function Always check the brake function before operating the v...

Page 101: ...necessary Never park on a slope with only the transmission en gaged The vehicle may roll down leading to an accident If it is unavoidable to park on a slope and leave the vehicle apply the parking bra...

Page 102: ...ncrease the driv ing force of the wheels as well as the braking performance on a slippery road Also it re duces a chance of the vehicle skidding at abrupt braking It is a best measure to drive at a lo...

Page 103: ...he 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 is a h...

Page 104: ...n 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 overtu...

Page 105: ...e 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 through...

Page 106: ...lope backward 3 Never depress the accelerator pedal abruptly and pay close at tention to the surroundings before driving backward Driving backward If precautions are not taken during driving backward...

Page 107: ...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 driving WARNING Tra...

Page 108: ...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 109: ...ding 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 vibra tion the car...

Page 110: ...ck to lower down the cargo bed 1 Hydraulic Lever 2 Lever Lock Bracket A Up B Down C Floating 1 Hydraulic Cylinder UUVO463A UUVO446A Make sure to check the ground condition before driving back wards to...

Page 111: ...on 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 A part of your body may get between the vehicle body and cargo bed or y...

Page 112: ...ing 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 the...

Page 113: ...eels 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 drivin...

Page 114: ...ving 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 4WD...

Page 115: ...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 UUVO523A 1 Gate Tailgate back door 1 Latch Lever 1 When...

Page 116: ...MEMO MEMO UTV EZGO Hauler 4X4 Diesel 05 in28 28 2015 05 26 9 33 18...

Page 117: ...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 UTV EZGO Hauler 4X4 Diesel 06 in1 1 2015 05 26 8 48 02...

Page 118: ...ith the maintenance intervals Refer to chapter 7 Maintenance Essential replacement part Oil and fluid NO ITEM SPECIFICATION CAPACITY 1 Engine Oil SAE 15W40 8 45 3 0 2 Gear Box DAEDONG UTF55 Exxonmobil...

Page 119: ...arts 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 CVT...

Page 120: ...MEMO MEMO UTV EZGO Hauler 4X4 Diesel 06 in4 4 2015 05 26 8 48 03...

Page 121: ...fuel FILTER L 7 18 Bleeding fuel line M 7 20 Checking injection nozzle and fuel injection pump N 7 21 Cleaning radiator core O 7 21 Checking coolant in auxiliary coolant tank P 7 22 Changing coolant Q...

Page 122: ...AF 7 39 Main fuse slow blow fuse AG 7 40 Aligning wheel and checking wheel nut AH 7 40 Checking differential lock cable AI 7 41 Checking shiftand 4WD cables AJ 7 42 Using Biodiesel AK 7 42 Adjusting b...

Page 123: ...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 and ad...

Page 124: ...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 Re...

Page 125: ...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 bol...

Page 126: ...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 127: ...ction 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 seat and...

Page 128: ...align the pins under the cushion with the holes and then push down the cushion gently Most of the engine services includ ing engine oil change and head cover repair can be performed by opening the sea...

Page 129: ...rive shaft UUVO707b UUVO775A 1 Grease fitting Front wheel hubstrut Be sure to lock the dumping lever and remote hydraulic lever with lever lock bracket while driving the vehicle CAUTION There are sixt...

Page 130: ...e spline area of front axle drive shaft around the gear box Raise up the cargo bet to feed the grease to this fitting UUVO778a UUVO779a The remaining 12 are located in the rear suspension section Remo...

Page 131: ...bolts of the inspection shield from under the seat cushion 4 Pull out the engine oil dipstick and wipe it clean 5 Insert the dipstick into the end and then pull it out to check the engine oil level 1...

Page 132: ...shield and seat cushion UUVO709A 1 Oil filter 5 Remove the oil filter through the inspection shield and discard it 6 Apply a thin film of oil to the rub ber O ring of a new oil filter Then install it...

Page 133: ...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 the...

Page 134: ...ut passing through the air filter could enter the system for a long period of time resulting in short ening the service life of the engine Carry out the check according to the service intervals in thi...

Page 135: ...ne remove the seat cushion and remove the side cov er on the left of the vehicle 1 Side cover UUVO715A 3 Remove the battery 1 Battery You can get burnt by touching hot parts such as the muffler Wait u...

Page 136: ...ut 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 UUVO719A 7 Remove the CVT cover 1 CVT cover UUVO720A UTV EZG...

Page 137: ...the speed reduction ratio would be 3 22 and 0 76 respectively There fore the maximum speed would be reduced by 10 and the max torque at a low speed would be reduced by 9 NOTE Never apply grease oil or...

Page 138: ...A OFF B Open It is recommended to start servic ing after filling the fuel tank to its top for easy bleeding as it might be needed to bleed the fuel line after servicing the fuel system NOTE 4 If water...

Page 139: ...n bleed more easily by assembling the filter cup after filling clean fuel to two thirds of its level 7 Turn the fuel cock to the AIR side and crank for several seconds un til the filter cup is filled...

Page 140: ...t the start motor and battery 4 If there is air in the fuel strainer turn its fuel cock to the AIR side and wait for a moment When the fuel tank is fully filled the fuel strainer can be filled with fu...

Page 141: ...injection nozzle and fuel injection pump N The injection nozzle and injection pump can be inspected only by a qualified service personnel For de tailed information contact your Deal er Cleaning radiat...

Page 142: ...olant tank P When the coolant in the radiator ex pands by heat it overflows into the auxiliary coolant tank On the other hand when the coolant temperature in the radiator decreases the radi ator is de...

Page 143: ...e auxil iary coolant tank flows to the radi ator 4 When the coolant is cooled down sufficiently add water an anti freeze mix to the auxiliary cool ant tank so that the coolant level is between the MAX...

Page 144: ...ard upper 2 Brush guard middle 3 Brush guard lower 6 Remove the lowest grille from the brush guard 1 Coolant Drain Plug Of Radiator 7 Place a container with wide open ing under the vehicle and open th...

Page 145: ...he hose to the auxil iary coolant tank 1 Air Bleeder Bolt 13 Make sure to install the drain plugs for radiator and engine be fore filling new coolant 14 Fill the tank with water and an ti freeze Ethyl...

Page 146: ...rester with a new one 1 Filler plug 4 Clean around filler plug then re move the filler plug 5 Check that the gearbox surface is not hot Then check the oil lev el and condition with a finger bent sligh...

Page 147: ...et the engine cooled down sufficiently 3 Raise the hood and support it with the support rod Checking and changing front axle oil T 1 Filler Plug 4 Clean around filler plug then re move the filler plug...

Page 148: ...O762A 1 Funnel 11 Wipe the differential case and 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 the oil it me...

Page 149: ...or viscosity of the oil is not normal or it is at the oil change interval change the oil 6 To change oil place a container with wide opening under the drain plug Then remove the drain plug 7 After dr...

Page 150: ...r Wheel 4 Check 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 You can get burnt...

Page 151: ...Rod End 5 Turn steering wheel fully to the right and inspect the boots of the tie rod end and nut then turn wheel fully to the left and inspect boot of the tie rod end and nut 6 If the above componen...

Page 152: ...is severely con taminated or insufficient contact your Dealer Checking brake pedal free play Y The master cylinder rod of the vehi cle is adjusted so that the brake ped al free play is 0 59 0 79 in 15...

Page 153: ...de of the disc is too thin close to 0 04 in 1 mm both pads for that disc as well as the pads for the wheel on the other side should be replaced 6 Check the brake pads on the oth er axle using the same...

Page 154: ...s on the sides of the parking brake disc If any of the pads are close to 0 04 in 1 mm both pads should be replaced 5 After replacing the pads test the parking brake and adjust the cable length accordi...

Page 155: ...he hydraulic jack so that the vehi cle chassis sits on the stand 1 Wheel Nut The rear suspension equipped on this vehicle is adjustable to allow for ride quality and weight hauling To adjust the suspe...

Page 156: ...rber is malfunc tioning your riding comfort can be harmed In this case check the shock absorber as follows 1 Park the vehicle on level ground and apply the parking brake firmly 2 Stop the engine 1 Sho...

Page 157: ...the positive battery ca ble 6 Remove the battery mounting bracket 7 When connecting cables connect the positive cable first and then the negative cable The battery discharges natu rally if the vehicle...

Page 158: ...t smoke near the battery Do not leave 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...

Page 159: ...fuse tongs in the center of the box 1 Fuse Tong 4 Check or replace the fuse with the fuse tongs 5 If fuses are blown repeatedly con tact your Dealer UUVO755A UUVO756A UUVO757A UUVO774B 4 Hold and pull...

Page 160: ...the fuse with insulation tape after replacement Make sure that the inspection shield is visible 5 If this fuse is repeatedly blown contact your Dealer Aligning wheel and checking wheel nut AH 1 Wheel...

Page 161: ...u can get burnt by touching hot parts such as the muffler Make sure the vehicle is not hot before starting servicing WARNING 3 Unscrew the nut and adjust the cable length 4 To check the differential l...

Page 162: ...and move the 2WD 4WD lever to 4WD and 2WD positions to check rotation of each wheel Using Biodiesel AK 1 It is allowed to use 5 biodiesel fuel If biodiesel fuel of higher ratio is used the engine can...

Page 163: ...ctric fan is not installed to the engine but to the radiator under the hood NOTE 3 Loosen the adjusting bolt on the top of the alternator as well as the hinge bolt on the bottom of the al ternator 4 L...

Page 164: ...ecommended to wash your ve hicle with water of moderate pres sure and with or without soap When washing your vehicle in a car wash make sure high pressure water is not directly sprayed to the followin...

Page 165: ...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 UTV EZGO Hauler 4X4 Diesel 08 in1 1 2015 05 26 8 49 15...

Page 166: ...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 167: ...ing 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 rodents lea...

Page 168: ...When 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 169: ...TROUBLESHOOTING vehicle Troubleshooting 9 2 9 9 UTV EZGO Hauler 4X4 Diesel 09 in1 1 2015 05 26 8 49 37...

Page 170: ...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 foreig...

Page 171: ...orrect 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 hydrauli...

Page 172: ...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 173: ...ngine 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 pre heat sta...

Page 174: ...art 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 canno...

Page 175: ...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 brak...

Page 176: ...n 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 pressur...

Page 177: ...10 INDEX index 10 2 10 UTV EZGO Hauler 4X4 Diesel 10 in1 1 2015 05 26 8 49 56...

Page 178: ...decal maintenance 1 26 Changing coolant Q 7 23 Changing engine oil and filter F 7 12 Check item 5 2 Checking air hose and clamp I 7 14 Checking and changing front axle oil T 7 27 Checking and changin...

Page 179: ...pection 5 2 Daily inspection 7 7 daily storage 8 2 DeCALs 1 20 Differential lock lever REAR WHEEL 4 25 DiffERENTIAL lock operation 5 26 Disposal 8 4 Driving backward 5 18 Driving in forest 5 17 Drivin...

Page 180: ...rest optional 4 30 Hill inclined sideward 5 16 Hood 4 5 Horn switch 4 13 HOW TO DRIVE 5 7 How to warm up engine 5 10 I index 10 2 Inspection 7 36 Instrument panel 4 15 J Jump start 5 11 K Key switch 4...

Page 181: ...d surface AO 7 44 R Raising cargo bed C 7 8 Rear hitch receiver 4 6 Rear screen optional 4 33 Rear wheel mudguard 4 7 Reflex Reflector 4 7 Remote hydraulic lever OPTIONAL 4 36 Replacement 7 37 Replaci...

Page 182: ...Unloading If the dumping kit is installed 5 22 Uphill and downhill 5 15 Using Biodiesel AK 7 42 Using vehicle after long term storage 8 3 V Vehicle Identification Number 2 2 Vehicle serial number 2 2...

Page 183: ...UTV EZGO Hauler 4X4 Diesel 00 in2 2 2015 05 26 8 58 20...

Page 184: ...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...

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Cushman 646442, Owner'S Manual

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