Husqvarna HUV4210 2005 Series Maintenance Service Manual Download Page 4 | Manualshive

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2005-2006 HUV4210-G, 4210-E, 4210-GXP, 4210-EXP Maintenance and Service Manual

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WARNING

• Read Section 1 – Safety before attempting any service on the vehicle.
• Before servicing vehicle, read complete section(s) and any referenced information that may

be relevant to the service or repair to be performed.

NOTE:

This manual represents the most current information at the time of publication. Husqvarna is con-
tinually working to further improve its vehicles and other products. These improvements may affect
servicing procedures. Any modification and/or significant change in specifications or procedures
will be forwarded to all Husqvarna dealers and will, when applicable, appear in future editions of
this manual.

Husqvarna reserves the right to change specifications and designs at any time without notice and
without the obligation of making changes to units previously sold.

There are no warranties expressed or implied in this manual. See the limited warranty found in the
vehicle Owner’s Manual.

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Summary of Contents for HUV4210 2005 Series

Page 1: ... 89 DVROLQH DQG OHFWULF 9HKLFOHV 0 17 1 1 6 59 0 18 3XEOLFDWLRQ 3DUW 1XPEHU GLWLRQ RGH ...

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Page 3: ...the vehicle may render the vehicle unsafe For this reason Husqvarna advises that all repairs and or service be performed by an authorized Husqvarna distributor dealer representative or by a Husqvarna fac tory trained technician It is the policy of Husqvarna to assist its distributors and dealers in continually updating their service knowl edge and facilities so they can provide prompt and efficien...

Page 4: ...na is con tinually working to further improve its vehicles and other products These improvements may affect servicing procedures Any modification and or significant change in specifications or procedures will be forwarded to all Husqvarna dealers and will when applicable appear in future editions of this manual Husqvarna reserves the right to change specifications and designs at any time without n...

Page 5: ...Storage 3 4 Returning the Stored Electric Vehicle to Service 3 5 SECTION 4 BODY AND TRIM Cleaning the Vehicle 4 1 Seat Cleaning 4 1 Front and Rear Body Repair 4 2 Minor Scratches and Surface Blemishes 4 2 Small Scratches That Cannot Be Buffed Out 4 2 Gouges Punctures Tears Large Scratches and Abrasions 4 2 Touch Up Paint Color Chart 4 3 Front Body 4 3 Bumper Removal 4 3 Bumper Installation 4 3 Bru...

Page 6: ...al Removal 5 1 Brake Pedal Installation 5 2 Park Brake Removal 5 3 Park Brake Installation 5 4 Accelerator Pedal Gasoline Vehicles 5 5 Accelerator Pedal Removal 5 5 Accelerator Pedal Installation 5 7 Accelerator Pedal Electric Vehicles 5 8 Accelerator Pedal Removal 5 8 Accelerator Pedal Installation 5 10 Pedal Group Adjustment Gasoline Vehicle 5 11 Pedal Group Adjustment Electric Vehicles 5 16 SEC...

Page 7: ...ag Link 7 12 Tie Rod and Drag Link Removal 7 12 Tie Rod and Drag Link Installation 7 12 Front Suspension 7 13 Lubrication 7 13 Wheel Alignment 7 13 Front Suspension Components 7 15 Tapered Leaf Spring Removal 7 15 Tapered Leaf Spring Installation 7 15 Kingpin and Steering Spindle Removal 7 16 Kingpin and Steering Spindle Installation 7 16 Delta A Plate Removal 7 16 Delta A Plate Installation 7 19 ...

Page 8: ... Schedules 10 1 Periodic Lubrication Schedules 10 4 Batteries Electric Vehicles 10 6 Battery Care 10 6 Battery Charger Electric Vehicles 10 6 Charging Batteries 10 7 Plug and Receptacle 10 8 Receptacle Fuse Link 10 9 Battery Gasoline Vehicles 10 9 Engine Oil Gasoline Vehicles 10 10 Engine Oil Level Check 10 10 Engine Oil And Filter Change 10 11 Oil Viscosity 10 13 Fueling Instructions Gasoline Veh...

Page 9: ... Gauge Hour Meter 12 21 Fuel Level Sending Unit 12 22 RPM Limiter 12 22 Ignition Coil 12 23 Oil Level Sensor 12 26 Headlights 12 27 Headlight Diode 12 28 Light Switch 12 28 Battery 12 29 Ground Cables 12 32 SECTION 13 FE290 AND FE350 ENGINES General Information 13 1 Before Servicing 13 1 Engine Rotation 13 1 Spark Plug 13 1 Cylinder Head 13 3 General Information 13 3 Breather Valve Reed Valve 13 3...

Page 10: ...1 Engine RPM Adjustment 14 11 Choke and Air Intake System 14 12 Choke Button Removal 14 12 Choke Button Installation 14 12 Air Box Removal 14 12 Air Box Installation 14 12 Intake Duct Removal 14 13 Intake Duct Installation 14 13 Air Filter 14 15 Fuel Filters 14 15 Fuel Filter Removal 14 15 Fuel Filter Installation 14 17 Fuel Pump 14 17 General Information 14 17 Fuel Pump Removal 14 17 Fuel Pump Di...

Page 11: ...Cable 16 19 Forward Reverse Shifter Cable Removal 16 19 Forward Reverse Shifter Cable Installation 16 19 Forward Reverse Shifter Cable Adjustment 16 20 SECTION 17 TORQUE CONVERTER GASOLINE VEHICLE General Information 17 1 Troubleshooting 17 1 Drive Belt 17 2 Drive Belt Removal 17 2 Drive Belt Installation 17 3 Drive Clutch 17 4 Drive Clutch Removal 17 4 Drive Clutch Cleaning and Inspection 17 5 Dr...

Page 12: ...Data from the Onboard Computer 18 36 CDM Troubleshooting Guide 18 37 SECTION 19 ELECTRICAL COMPONENTS ELECTRIC VEHICLE Key Switch 19 1 Forward Reverse Rocker Switch 19 2 Tow Run Switch 19 3 Motor Controller Output Regulator MCOR 19 4 Reverse Buzzer 19 5 Solenoid 19 6 Onboard Computer OBC 19 7 Solid State Speed Controller 19 9 Charger Receptacle 19 10 Receptacle Fuse Link 19 12 Battery Warning Ligh...

Page 13: ... Battery Pack that has Low Voltage 20 12 SECTION 21 BATTERY CHARGER ELECTRIC VEHICLE Refer to the battery charger maintenance and service manual Husqvarna 603 00 28 15 SECTION 22A MOTOR MODEL 5BC59JBS6365 General Information 22a 1 Motor Identification 22a 1 External Motor Testing 22a 1 Motor 22a 2 Motor Component Testing and Inspection 22a 5 Armature 22a 5 Field Windings Inspection 22a 6 Motor Com...

Page 14: ...Motor Frame and Field Windings Inspection 22b 8 Motor Brush Spring and Terminal Insulator Inspection 22b 8 Reconditioning the Motor 22b 11 Motor Assembly 22b 11 Motor Installation 22b 13 SECTION 23 TRANSAXLE TYPE G ELECTRIC VEHICLE Transaxle Identification 23 1 Lubrication 23 1 Axle Bearing and Shaft 23 1 Axle Shaft 23 1 Axle Bearing 23 4 Transaxle 23 4 Transaxle Removal 23 4 Transaxle Disassembly...

Page 15: ...ntially hazardous situation that could result in property damage GENERAL WARNING The following safety statements must be heeded whenever the vehicle is being operated repaired or ser viced Service technicians should become familiar with these general safety statements Also other specific safety statements appear throughout this manual and on the vehicle ý DANGER Battery Explosive gases Do not smok...

Page 16: ... batteries as shown Figure 1 1 or 1 2 on page 1 3 After disconnecting the batteries wait 90 seconds for the controller capacitors to discharge All vehicles Wear safety glasses or approved eye protection when servicing the vehicle Wear a full face shield and rubber gloves when working on or near batteries Do not wear loose clothing or jewelry such as rings watches chains etc when servicing the vehi...

Page 17: ...area Keep hands clear of all crush areas Do not drop cargo bed lower gently and keep entire body clear Failure to heed this warning could result in severe personal injury or death Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle performance severe personal injury or death Do not leave children unattended on vehicle Figure 1 1 Gasoline Vehicle Figure ...

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Page 19: ...Automatic variable speed dry type Electrical system 48 volts DC reduced speed reverse Electrical system 12 volt 500 cca at 0 F 17 8 C 650 at 32 F 0 C 105 minute reserve capacity and 35 amp charging capacity Batteries High capacity deep cycle Trojan PowerDrive 12 volt 117 min capacity Charger Automatic 48 volt UL and CSA listed STEERING SUSPENSION BRAKES Steering Self adjusting rack and pinion Susp...

Page 20: ... km Standard seating capacity 2 Liquid Capacities Transaxle 22 oz 0 67 L Engine crankcase without filter 32 oz 0 95 L Engine crankcase with filter 38 oz 1 12 L Unitized transaxle 27 oz 0 8 L Fuel tank 7 gallons 26 5 L Tire Pressure Front and rear 18 20 psi 1 24 1 38 Bars 18 20 psi 1 24 1 38 Bars SPECIFICATIONS Electric HUV4210 E Electric HUV4210 EXP Gasoline HUV4210 G Gasoline HUV4210 GXP ...

Page 21: ...Controls and Indicators Pre Operation and Daily Safety Checklist Driving Instructions Towing Transporting on a Trailer Subsequent Owner Registration Warranties SERIAL NUMBER IDENTIFICATION The serial number of the vehicle is printed on a bar code decal mounted on the frame directly above the accel erator pedal Example AQ0401 123456 for Electric or AG0401 123456 for Gasoline Figure 3 1 Page 3 1 The...

Page 22: ...corrosion Wash tops and terminals of batteries with a solution of baking soda and water 1 cup 237 mL baking soda per 1 gallon 3 8 L of water Rinse solution off bat teries Do not allow this solution to enter the batteries Be sure terminals are tight Let the terminals dry and then coat them with Battery Terminal Protector Spray Husqvarna 603 00 00 03 2 Store vehicle in a cool dry place This will min...

Page 23: ...he fuel tank vent nipple and reconnect fuel vent line to nipple Open the fuel shut off valve Figure 3 4 Page 3 4 Make sure the valve is fully open A partially closed fuel shut off valve Figure 3 5 Page 3 4 combined with the use of the choke can result in a fouled spark plug and engine failure 2 2 Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout cam to the MAINTENANC...

Page 24: ...e of pressure washing or steam cleaning equipment to wash the vehicle Electric vehicles only Place Tow Run switch in the TOW position PREPARING THE ELECTRIC VEHICLE FOR EXTENDED OFF SEASON STORAGE 1 Fully charge batteries See Battery Charger Section 20 Page 20 4 2 Batteries should be clean and free of corrosion Wash tops and terminals of batteries with a solution of baking soda and water 1 cup 237...

Page 25: ...owerDrive Battery Chargers Leave PowerDrive battery chargers plugged in during storage The onboard computer will automatically activate the charger when necessary If charger cannot remain plugged in or AC power will not be available during extended storage disconnect the bat teries for storage See WARNING To avoid unintentionally starting in General Warning Section 1 Page 1 2 CAUTION Check the veh...

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Page 27: ...ical compo nents can result in water damage and subsequent component failure Use non abrasive wax products Battery acid fertilizers tars asphalt creosote paint or chewing gum should be removed immediately to prevent possible stains See following NOTE NOTE Dispose of waste water properly SEAT CLEANING To preserve seat appearance clean regularly with mild soap or detergent applied with a sponge or s...

Page 28: ...uster and weather protection SMALL SCRATCHES THAT CANNOT BE BUFFED OUT 1 Thoroughly clean the affected area with alcohol and then dry thoroughly 2 Using 240 grit or finer sandpaper lightly sand the scratch to feather the edges Finish sand the scratch with 320 grit or finer paper to remove gloss from the surface Sand as little body surface as possible beyond the scratch See following CAUTION CAUTIO...

Page 29: ...ely during removal to avoid personal injury BUMPER INSTALLATION 1 Position bumper against body and front frame and loosely install top bolts and lock nuts See following WARNING ý WARNING Have another person hold bumper firmly when installing first bolt The bumper weighs approximately 40 pounds Hold the bumper securely during installation to avoid personal injury 2 Install bottom bolts and lock nut...

Page 30: ... lb 24 N m FRONT BODY REMOVAL 1 Remove bumper or brush guard See Bumper Removal or Brush Guard Removal Page 4 4 2 Remove caps 5 from body and dash screws Figure 4 3 Page 4 5 3 Remove screws 4 and plastic scalloped washers 6 from body and body support and slide body away from dash 4 Remove plastic screws from sides of dash and body 5 Pull front body 9 from body covers 12 and 13 NOTE Body cover is n...

Page 31: ...dy See Front Body Installation on page 4 5 FRONT BODY INSTALLATION 1 Position front body onto frame and attach head lights to wire harness at spade connectors 2 Install body 9 under body covers 12 and 13 and align holes with dash and body support Figure 4 3 Page 4 5 3 Install body and dash screws and scalloped washers on the top of the body Tighten to 45 in lb 5 N m 4 Attach plastic caps 5 onto da...

Page 32: ...E This procedure requires two people Lubricate the hinge clevis pins with light motor oil prior to assembly 1 Position the bed to align with the hinge locations 2 Install hinge clevis pins and washers with the head of the pin to the inside portion of the bed See fol lowing CAUTION and WARNING CAUTION Keep bed hinges as close to alignment as possible to avoid binding the pins during removal ý WARNI...

Page 33: ... or use cotter pins and washers Catch Rod and Catch Plate Installation 1 Install new bronze bearings into the catch plates 2 Install the bolts and use new mechanical lock nuts to assemble the catch plates and latch link Tighten hardware to 75 in lb 8 4 N m then back off 1 2 turn so that latch operates freely 3 Install bed catch rods Use new push nuts or use a flat washer and cotter pin to secure t...

Page 34: ...wing NOTE NOTE Note the location of the two different size bolts It may be necessary to deflect the rear fender slightly to remove support bolts BED LATCH ASSEMBLY INSTALLATION 1 Position latch link and catch plate assembly onto bed with support located at bolt holes and catch rods positioned into bed slots 2 Attach latch link with screws Tighten hardware to 7 ft lb 9 5 N m Figure 4 4 Page 4 7 SEA...

Page 35: ...ove from vehicle Figure 4 12 Page 4 9 SEAT BACK SUPPORT BRACKET INSTALLATION 1 Align passenger and driver side seat back support brackets with holes in body Figure 4 12 Page 4 9 See following NOTE NOTE Striker plates should be to the outside of each bracket 2 Install bracket bolts to body and tighten hardware to 14 5 ft lb 19 6 N m 3 Position bed support with bumpers onto seat back supports and fr...

Page 36: ...neral Warning Section 1 Page 1 2 Remove cargo bed See Cargo Bed Removal on page 4 6 3 Remove seat back support brackets See Seat Back Support Bracket Removal on page 4 9 4 Remove the two screws nuts and washers located at the bottom edge of the seat support panel in kick plate just above the floormat Figure 4 13 Page 4 10 5 Electric vehicles 5 1 Disconnect or remove charger receptacle 5 1 1 Remove...

Page 37: ...essary after the rear body is reinstalled 8 Remove two bolts washers and nylon lock nuts from rear fenders at frame locations Figure 4 15 Page 4 11 9 Lift rear body and fenders from the vehicle FORWARD REVERSE SWITCH Forward Reverse Switch Removal 1 Electric vehicles 1 1 Disconnect the four pin connector 12 and the three pin connector 13 from the Forward Reverse switch Figure 4 16 Page 4 12 Figure...

Page 38: ...everse switch shifter on back of the body at hole locations 2 Install screws and lock nuts to Forward Reverse switch or shifter to 33 in lb 2 8 N m 2 1 Gasoline vehicles Install Forward Reverse handle and wave washer and tighten to 14 in lb 1 6 N m 2 2 Check the choke push rod for position and adjust if necessary 2 3 Route shifter cable up into driver side corner of body on onto cable hook 2 4 Ins...

Page 39: ... Rear Body Removal on page 4 10 3 6 Place body and fender on a clean flat surface and remove the top body and fender bolt 3 7 Remove the two outside body and fender bolts and separate the passenger side fender from the rear body REAR FENDER INSTALLATION NOTE If both fenders have been removed attach them to the rear body first then install the rear body with fenders attached Rear Body and Fenders N...

Page 40: ...lt to 25 in lb 2 8 N m FLOOR MAT See General Warning Section 1 Page 1 1 FLOOR MAT REMOVAL 1 Remove the brake and accelerator pedals See Section 5 Accelerator and Brake Pedal Group 2 Slide the mat from under the edge of the rear body Loosen the rear body screws if necessary 3 Slide the mat away from the trim up under the dash and remove the floor matt FLOOR MAT INSTALLATION 1 Reverse the removal pr...

Page 41: ...Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 lb 454 kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires mov...

Page 42: ...ten the jam nut 12 at this time 2 Secure the equalizer rod 13 to the brake pedal assembly 8 with the clevis pin 14 and bow tie pin 15 as shown 3 Position and attach brake pedal assembly mounting blocks 23 and washers 2 to vehicle frame as shown Tighten the bolts and nuts to 113 in lb 12 8 N m Figure 5 1 Brake and Park Brake Pedal Assembly STOP 29 5 3 7 TYPICAL 2 PLACES 1 6 2 23 TYPICAL 2 PLACES 2 ...

Page 43: ... Place chocks under the rear wheels and lift the front end of the vehicle with a chain hoist or floor jack Place jack stands under the front cross tube of the vehicle frame and lower the vehicle onto the jack stands See following WARNING ý WARNING Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 lb 454 kg minimum lifting capacit...

Page 44: ... 3 Install the spacer 22 and torsion spring 21 on the park brake pedal shaft on the brake pedal assembly 4 Install the two bushings 25 in the park brake pedal and position the park brake pedal on the shaft on the brake pedal assembly weldment Figure 5 3 Page 5 4 Then attach the ends of the torsion spring to the park brake pedal and to the brake pedal weldment as shown Figure 5 4 Page 5 4 5 Install...

Page 45: ...icle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes 3 Disconnect the accelerator rod assembly 17 18 and 19 Figure 5 5 Page 5 6 at the front and rear ball studs and remove it from the vehicle 4 Use a 9 16 inch socket and 9 16 inch wrench to remove the nut 23 two washers 25 and bolt 4 securing the acc...

Page 46: ...cessary If the pivot rod supports do not require replacement loosen but do not remove the four bolts 22 and lock nuts 15 to make installation of the pivot rod easier 13 Remove the accelerator pedal 1 from the vehicle 14 Inspect all parts for wear and damage Replace as necessary Figure 5 5 Accelerator Pedal Assembly Gasoline Vehicles TYPICAL 4 PLACES FLOORBOARD REMOVED FOR CLARITY 26 24 22 21 20 21...

Page 47: ...ghtly and with the park brake ratchet oriented so that the tip of the ratchet is pointed toward the rear of vehicle slide the ratchet onto the pivot rod do not slide the ratchet onto the pivot rod splines Release the brake pedal and allow the ratchet to rotate until its tip is pointed downward Figure 5 6 Page 5 7 The ratchet should now rotate freely on the rod 9 Rotate ratchet clockwise until it t...

Page 48: ...and drive bar 3 as instructed Figure 5 7 Page 5 9 See MCOR Removal Section 19 Page 19 5 4 Use a 9 16 inch socket and 9 16 inch wrench to remove the nut 7 two washers 5 and bolt 4 secur ing the accelerator pedal 1 to the pivot rod 6 Figure 5 7 Page 5 9 5 Remove the nut 10 and bolt 8 from the accelerator pivot rod assembly 6 6 Slide the spring retainer 11 off of the accelerator pivot rod 7 Inspect t...

Page 49: ...r Pedal Electric Vehicles 2005 2006 HUV4210 G 4210 E 4210 GXP 4210 EXP Maintenance and Service Manual Page 5 9 5 Figure 5 7 Accelerator Pedal Electric Vehicle GO 3 2 11 10 7 5 4 5 1 8 9 6 TYPICAL 4 PLACES TYPICAL 4 PLACES 23 24 21 21 20 16 15 22 ...

Page 50: ... m 8 Press the brake pedal slightly and with the park brake ratchet oriented so that the tip of the ratchet is pointed toward the rear of the vehicle slide the ratchet onto the pivot rod do not slide the ratchet onto the pivot rod splines Release the brake pedal and allow the ratchet to rotate until its tip is pointed down ward Figure 5 8 Page 5 10 The ratchet should now rotate freely on the rod 9...

Page 51: ...g nuts 2 and 3 on the equalizer rods 1 Figure 5 9 Page 5 11 2 3 Loosen the brake stop jam nut 31 then relieve pedal pressure on the stop by pushing down slightly on the pedal Next adjust the brake stop bumper 22 up or down Figure 5 10 Page 5 11 Adjusting the bumper upward decreases distance between pedal and floorboard Adjusting the bumper downward increases distance between pedal and floorboard P...

Page 52: ...the park brake pawl and ratchet for excessive wear grooves cracks or chips If either the pawl or ratchet is damaged both must be replaced 4 2 Adjust retaining nut 7 on spring support rod until there is a 0 060 inch 1 5 mm gap between the pawl and the tips of the ratchet teeth Use a feeler gauge to verify the gap Figure 5 13 Page 5 13 The gap should be consistent through range of pawl movement If t...

Page 53: ...t tooth engagement is too deep and must be adjusted 4 6 If ratchet pawl engagement must be adjusted disconnect the ball joint at the top of the brake rod and rotate the ball joint sleeve clockwise to increase engagement or counterclockwise to decrease engagement Reconnect ball joint Figure 5 16 Page 5 14 4 7 If the accelerator push rod was disconnected from the accelerator pedal reconnect it 4 8 C...

Page 54: ... a rubber strap to hold pedal in position against the floorboard and then tighten nut to 26 ft lb 35 3 N m 6 Adjust the accelerator rod See following DANGER ý DANGER Before servicing turn the key switch to OFF and place the Forward Reverse handle in the NEUTRAL position To prevent accidentally starting the vehicle disconnect the battery as instructed in WARNING To avoid unintentionally starting in...

Page 55: ...nuts on the accelerator rod hold the disconnected ball joint with locking pliers 6 3 Reconnect the accelerator rod at the accelerator pedal 6 4 Before tightening jam nuts on accelerator rod set park brake to first ratchet and pawl position Press accelerator pedal and make sure the following events occur in the exact order shown 6 5 If the events above occur as they should hold the ball joint at ea...

Page 56: ...g nuts 2 and 3 on the equalizer rods 1 Figure 5 20 Page 5 16 2 3 Loosen the brake stop jam nut 31 then relieve pedal pressure on the stop by pushing down slightly on the pedal Next adjust the brake stop bumper 22 up or down Figure 5 21 Page 5 16 Adjusting the bumper upward decreases distance between pedal and floorboard Adjusting the bumper downward increases distance between pedal and floorboard ...

Page 57: ...rrect position Figure 5 23 Page 5 17 4 Adjust park brake ratchet pawl gap and pawl engagement 4 1 Inspect the park brake pawl and ratchet for excessive wear grooves cracks or chips If either the pawl or ratchet is damaged both must be replaced 4 2 Adjust retaining nut 7 on spring support rod until there is a 0 060 inch 1 5 mm gap between the pawl and the tips of the ratchet teeth Use a feeler gaug...

Page 58: ... accelerator pedal to floorboard If the measurement has changed ratchet tooth engagement is too deep and must be adjusted 4 6 If ratchet pawl engagement must be adjusted disconnect the ball joint at the top of the brake rod and rotate the ball joint sleeve clockwise to increase engagement or counterclockwise to decrease engagement Reconnect ball joint Figure 5 27 Page 5 19 4 7 Check for proper bra...

Page 59: ...erator pedal height closest to the floorboard Figure 5 29 Page 5 19 Press the accelerator pedal until the end of the tool rests against the floorboard pedal height should be 5 5 8 inches 14 3 cm Use a rubber strap to hold pedal in position against the floorboard and then tighten nut to 26 ft lb 35 3 N m 6 Adjust the brakes See Brake Adjustment Section 6 Page 6 8 Figure 5 27 Brake Rod Adjustment Fi...

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