Husqvarna HUV 5420 DX Owner'S Manual Download

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HUV 5420 DX All-Wheel Drive

CE Mark Diesel Vehicle

Owner’s Manual

[Refer to back cover for applicable build code range]

Summary of Contents for HUV 5420 DX

Page 1: ...HUV 5420 DX All Wheel Drive CE Mark Diesel Vehicle Owner s Manual Refer to back cover for applicable build code range ...

Page 2: ......

Page 3: ...manual This manual contains proprietary information that is protected by copyright All rights are reserved No part of this manual may be photocopied reproduced or translated to another language without the written consent of Husqvarna Inc The information contained in this document is subject to change without notice Husqvarna reserves the right to make design changes to vehicles without obligation...

Page 4: ...others we recommend that you ask them to read this manual before they operate the vehicle Husqvarna products are backed by a customer support system designed to offer you fast courteous service In the event your Husqvarna vehicle needs repairs or service please contact your local authorized Husqvarna dealer or distributor he will be able to provide technical advice perform warranty work and sell p...

Page 5: ...ading and Unloading Cargo 25 Vehicle Load Capacities 26 Towing with the Vehicle 27 Transporting on a Trailer 27 Storage 28 Maintenance 29 Periodic Service Schedule 30 Periodic Lubrication Schedule 33 Brake Fluid Reservoir 34 Engine Oil 35 Gearcase Lubrication 39 Engine Coolant Diesel Vehicles 40 Air Intake System 41 Fueling Instructions 42 Battery 44 Using A Booster Battery Jump Starting 46 Cleani...

Page 6: ...elow seat with winch option 5 102459201 Decal Diesel Fuel Warning on frame near fuel tank 2 102458901 Decal Hot Surface Warning on coolant pipes and underside of seats on bed seal 6 102459301 Decal Bed Latch Warning on vehicle body below bed latch 3 102459001 Decal Hot Manifold Warning on engine near manifold 7 102459501 Decal Rotating Hot Parts Warning on frame near battery 4 102459101 Decal Grou...

Page 7: ... 101609401 Decal Crush Area Warning behind seat near cargo bed 7 103202601 Decal Vehicle Loading Instructions on cargo bed 3 102224001 Decal Rotating Parts Warning on frame 8 103210401 Decal Vehicle Loading Instructions on cargo bed 4 102459401 Decal Young Driver Warning on ROPS 9 Serial Number 5 102884401 Decal Rollover Warning on instrument panel 15 HUV 5420 DX All Wheel Drive CE Mark Diesel Veh...

Page 8: ...ES 1398 1 3 2 1 102460201 Decal Rotating Parts Warning on vehicle body under seat 3 103687501 Decal CE Mark Husqvarna HUV 5420 DX on front fender 2 103687601 Decal CE Mark Husqvarna HUV 5420 DX HD on front fender Page 6 HUV 5420 DX All Wheel Drive CE Mark Diesel Vehicle Owner s Manual ...

Page 9: ...ost importance to us That is why before operating the vehicle we urge you to review the information in this manual Understand and become familiar with the DANGER WARNING and CAUTION statements and procedures it contains along with the safety decals that are affixed to your vehicle Take time to understand the language of safety It is a language that can save your life HUV 5420 DX All Wheel Drive CE...

Page 10: ...ld result in minor personal injury CAUTION A CAUTION without the safety alert symbol indicates a potentially hazardous situation that could result in property damage GENERAL WARNINGS The following safety statements must be heeded whenever the vehicle is being operated repaired or serviced See Safety Decal and Feature Identification on page 4 Other specific safety statements appear throughout this ...

Page 11: ...with a prop rod ensure that it is securely engaged while bed is raised Do not close bed until all persons are clear of cargo bed 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 Only trained technicians should service or repair the vehicle Anyone doing even simple repa...

Page 12: ...3 00 00 03 to minimize corrosion RECYCLING LEAD ACID BATTERIES WARNING Lead acid batteries contain lead Pb other metals acids and other compounds If improperly handled they can contaminate both water and soil causing environmental damage and personal injury Lead acid batteries are identified by the symbol shown below and should be properly recycled Figure 4 They cannot be disposed as municipal was...

Page 13: ... hazard 2 Read and follow operating instructions 4 Keep away from children 6 Explosive gas hazard Refer to General Warnings for more information 1642 Figure 5 International Safety Symbols on Batteries GENERAL INFORMATION This manual includes operating procedures maintenance and regular servicing information for all diesel Husqvarna HUV 5420 DX vehicles All operating procedures maintenance and regu...

Page 14: ...the build code range indicated on the back cover of this owner s manual PH0901 123456 BC54679 SERIAL NUMBER 4 1 2 3 1400 Figure 6 Serial Number Decal CONTROLS AND INDICATORS See General Warnings on page 8 WARNING Before allowing anyone to drive the vehicle make sure the driver is familiar with all controls and operating procedures Do not tamper with the high idle speed setting on the diesel vehicl...

Page 15: ...of the steering column Figure 7 It has four positions PREHEAT OFF ON and START Use the PREHEAT feature if the temperature falls below 5 C 23 F Do not hold the key in the PREHEAT position longer than 20 seconds To preheat the glow plugs in cold weather turn the key to the PREHEAT position and hold it there for 10 15 seconds Then turn the key to the START position and hold it there until the engine ...

Page 16: ... on page 4 ACCELERATOR PEDAL The accelerator pedal 1 is the pedal farthest to the right Figure 7 With the engine running and the Forward Reverse handle in the FORWARD or REVERSE position vehicle speed will increase as the accelerator pedal is pressed When the accelerator pedal is released it will return to the original position and the engine will idle See preceding WARNING and CAUTION BRAKE PEDAL...

Page 17: ...igure 7 It provides a constant 12VDC with the key switch in the ON or OFF position See following NOTE NOTE Extended use of this accessory outlet can cause the battery to become heavily discharged LOW OIL WARNING LIGHT The low oil warning light 9 is located on the instrument panel just to the left of the steering column Figure 7 If the warning light comes on oil should be checked and added to the e...

Page 18: ...switch Figure 7 See following NOTE NOTE Remove cargo before raising the bed To lift the bed push up and hold the rocker switch in the upper position Release the switch to stop the lifting operation To close the bed press down and hold the switch in the lower position The bed lift will make a loud clicking sound to signal that the bed is in the rest position HIGH TEMPERATURE WARNING LIGHT DIESEL VE...

Page 19: ...and the occupant can move freely If the seat belt cannot be pulled out of the retractor firmly pull the belt and release it It should then pull smoothly out of the retractor To release the seat belt press the buckle release button 1 and allow the belt to retract Figure 9 If the belt does not retract smoothly pull it out and check for kinks or twists Then make sure it remains free of twists as it r...

Page 20: ...le or modify the system Keep seat belts clean and dry If cleaning is necessary use a mild soap and lukewarm water solution Do not use bleach dye or abrasive cleaners as they may severely weaken the seat belts Do not insert coins clip etc in the buckle as this may prevent the tab from locking into the buckle properly If the seat belt does not function normally contact your dealer distributor or tra...

Page 21: ... level Figure 29 Check battery posts Wires should be tight and free of corrosion and battery should be fully charged Engine Check for proper engine oil and coolant levels and leaks See Engine Oil on page 35 Check air filter and replace if necessary Fuel Check fuel level See Fueling Instructions on page 42 Check fuel tank lines fuel cap pump and fuel filters for fuel leakage Drain water from the fu...

Page 22: ...nvestigate anything unusual DRIVING INSTRUCTIONS WARNING Only licensed drivers should be allowed to drive the vehicle Before allowing anyone to drive the vehicle make sure the driver is familiar with all controls and operating procedures No one under the age of 16 years should be allowed to drive the vehicle No more than one person per bucket seat at one time No more than two persons per bench sea...

Page 23: ...ard braking in reverse This vehicle is not intended to be used where risk of falling objects exists If your vehicle will be used in such an environment contact your local dealer No one should drive the vehicle without first being instructed in the proper operation and use of vehicle controls An experienced operator should accompany each first time driver on a test drive before allowing the driver ...

Page 24: ...r will be directed to the rear passenger side wheel The all wheel drive vehicle can adapt traction for a wide variety of driving surfaces and conditions See following WARNING WARNING When servicing the vehicle with part of the vehicle on jack stands do not operate the engine with the Forward Reverse handle in either the FORWARD or REVERSE position The all wheel drive system will engage any wheel s...

Page 25: ...he brake pedal until the vehicle comes to a complete stop See following WARNING and CAUTION WARNING Driving through water may affect the brakes After driving through water check effectiveness of the brakes by gently pressing the brake pedal If the vehicle does not slow down at the normal rate continue to press the brake pedal until the brakes dry out and normal performance returns CAUTION When sto...

Page 26: ...ER Use caution when working under bed Be sure prop rod is secure Otherwise the bed will fall resulting in severe personal injury or death WARNING For vehicles with cargo beds remove all cargo before raising the bed or servicing the vehicle If the vehicle is equipped with a prop rod ensure that it is securely engaged Do not close bed until all persons are clear of cargo bed area Keep hands clear of...

Page 27: ...er of gravity of load should never exceed 15 inches 38 cm above the bottom of the cargo bed The cargo s center of gravity may affect handling steering and braking of the vehicle When the vehicle is loaded reduce speed and drive slowly in turns Unload cargo bed before raising vehicle with a lift hoist or jack Avoid stopping on a hill when loaded If you must stop on a hill avoid sudden starts or rol...

Page 28: ...ombination of the vehicle weight and the maximum vehicle capacity The stated maximum gross vehicle weight must not be exceeded to maintain safe vehicle operation Maximum payload capacity must be reduced accordingly when any option or accessory is installed on the vehicle See following NOTE NOTE A standard vehicle with a cab accessory that weighs 235 lb 107 kg must reduce its maximum payload capaci...

Page 29: ...rts sudden stops and tight turns when towing Avoid stopping on a hill when towing If you must stop on a hill avoid sudden starts or rolling backwards and stopping suddenly Failure to heed this warning could cause the vehicle to overturn possibly resulting in severe personal injury Reduce normal driving speed when transporting a vehicle on a trailer For use on public roads the trailer must meet all...

Page 30: ...ry If the battery is dead see Using A Booster Battery Jump Starting on page 46 3 Make sure the key switch is in the OFF position and the Forward Reverse handle is in the NEUTRAL position Chock the wheels 4 Diesel vehicles If Biodiesel fuel is used see Biodiesel Fuel Diesel Vehicles Only on page 42 Prepare the fuel tank 4 1 Fill the fuel tank with fresh fuel 4 2 Disconnect the fuel vent line from t...

Page 31: ...ng from unsafe conditions Contact your local Husqvarna dealer distributor for repairs and semiannual and annual periodic service WARNING Only trained technicians should service or repair the vehicle Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair The appropriate instructions must be used when performing maintenance service or acc...

Page 32: ...hat remain on the floor When servicing the vehicle with part of the vehicle on jack stands do not operate the engine with the Forward Reverse handle in either the FORWARD or REVERSE position The all wheel drive system will engage any wheel s front or rear with traction Figure 3 PERIODIC SERVICE SCHEDULE See General Warnings on page 8 WARNING Service repairs and adjustments must be made per instruc...

Page 33: ...ecessary See Vehicle Specifications on page 49 Transmission and differentials Check lubricant levels Add if necessary See Lubrication Level Check for Front Differential Transmission and Rear Differential on page 39 Monthly service by owner or trained technician General vehicle Wash engine compartment and underside of vehicle Do not wash engine when hot Battery Clean terminals and wash dirt from ca...

Page 34: ...oses for cracks Replace if necessary Replace air filter element See Air Intake System on page 41 Engine air intake system Check clamps for tightness check hose for cracks General vehicle Check for loose hardware and tighten if necessary Annual service by trained technician only or every 100 hours of operation whichever comes first Fuel filters Replace Dispose of used filters properly WARNING If an...

Page 35: ...ation whichever comes first Rear suspension 2 fittings Chassis Lube EP NLGI Grade 2 First change 50 hours additional change every 100 hours of operation or annually whichever comes first Change front differential lubricant 5 oz 150 mL Mobil 424 Exxon Hydraul 560 or Esso Hydraul 56 lubricant Change rear differential lubricant 20 oz 600 mL Mobil 424 Exxon Hydraul 560 or Esso Hydraul 56 lubricant Fir...

Page 36: ... The presence of brake fluid on the exterior surface of the master cylinder indicates a leak The brake fluid reservoir diaphragm located in the cap should not have holes or other damage BRAKE FLUID Brake fluid level should be within 1 4 inch 6 mm from the top of the reservoir Figure 15 Also brake fluid should be clean with no residue in the bottom of the reservoir or other evidence of contaminatio...

Page 37: ...ot remove dipstick while engine is running 2 Check oil level by fully inserting the dipstick into the tube and immediately removing it 3 If the oil level is at or below the low level mark on the dipstick gauge add oil to the engine until the level is between low and full levels safe level See following CAUTION CAUTION Do not exceed recommended oil capacity Doing so will decrease engine performance...

Page 38: ...e oil when the engine is hot or even warm Hot engine oil can cause skin burns Wear safety glasses or approved eye protection when servicing the vehicle Wear rubber gloves when handling oil drain plug oil filter and oil drain pan 6 Clean the oil drain plug threads with solvent to remove oil and oil residue Make sure that the compression washer remains on the drain plug Inspect the compression washe...

Page 39: ...filter P N 603 00 00 41 onto the engine oil filter port See following NOTE NOTE Use only Husqvarna oil filters designed for your engine 6 Tighten the oil filter by hand 2 3 turn after gasket contact Do not use a band wrench or channel lock pliers Engine Oil Filling 1 Add engine oil use a funnel or pour spout to direct the oil into the opening Figure 20 With filter change the engine requires 3 qt 2...

Page 40: ...llowing NOTE NOTE Use engine oil with API classification CF for diesel engines Using multi grade oils 5W 20 10W 30 and 10W 40 will increase oil consumption If multi grade oil is used check the oil level more frequently SAE 10W 30 SAE 10W 40 SAE 20 SAE 30 SAE 10W 214 Figure 21 Oil Viscosity Chart Diesel Vehicles Page 38 HUV 5420 DX All Wheel Drive CE Mark Diesel Vehicle Owner s Manual ...

Page 41: ...ifferential Clean and install the drain plug 2 and washer before filling the front differential with new lubricant Figure 22 Tighten the drain plug to 108 in lb 12 N m Use a funnel when filling the front differential through the lubricant level indicator hole 1 See Periodic Lubrication Schedule on page 33 Tighten the level indicator plug to 120 in lb 14 N m 1 2 1 2 215 Figure 22 Front Differential...

Page 42: ...s of the level indicator plug and tighten to 21 ft lb 28 N m 1 2 217 Figure 24 Rear Differential Lubrication Level ENGINE COOLANT DIESEL VEHICLES ENGINE COOLANT LEVEL CHECK The coolant reserve tank 2 is located under the hood on the passenger side Figure 14 Raise the hood to check the coolant level before every operation 1 Check the coolant level of the reserve tank 2 If the coolant is at or below...

Page 43: ...ne service the air filter immediately Air Filter Removal 1 Raise the cargo bed and locate the air filter canister 2 Release both canister tab locks Figure 25 3 Pull the canister cap away from the canister 4 Remove the air filter cartridge 1 See following NOTE NOTE The air filter cartridge is specifically designed for this engine It only fits into the canister one way Use only the Husqvarna part P ...

Page 44: ... and following NOTE NOTE Diesel vehicles Use only diesel fuel grade no 2 with a cetane rating of 45 or higher 2 Replace the fuel cap Ensure that the cap is tightened securely 3 Clean any spilled fuel from the cap or around the fuel cap area 220 Figure 26 Fuel Tank Diesel Vehicles BIODIESEL FUEL DIESEL VEHICLES ONLY Biodiesel has unique qualities that should be considered before it is used in the K...

Page 45: ... See Draining Water from Fuel Filter Check the engine oil level daily before the engine is started See Engine Oil Level Check on page 35 Before vehicle storage run the engine with conventional diesel fuel for at least 30 minutes to flush the biodiesel from the engine See Preparing the Vehicle for Extended Storage on page 28 See following NOTE NOTE Biodiesel does not have long term stability and mu...

Page 46: ...ield and rubber gloves when working on or near batteries Battery Poison Contains acid Causes severe burns Avoid contact with skin eyes or clothing Antidotes External Flush with water Call a physician immediately Internal Drink large quantities of milk or water followed with milk of magnesia or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes Call a physician immediat...

Page 47: ...s 2 Remove driver side seat to access engine compartment See WARNING For vehicles with cargo beds in General Warnings on page 8 3 Disconnect battery See Disconnecting the Battery Diesel Vehicles on page 10 4 Use a flat blade screwdriver and carefully remove the battery cell caps from the battery See following WARNING WARNING Wear safety glasses or approved eye protection when servicing the vehicle...

Page 48: ...attery to start the engine BE CAREFUL 1 Turn the key switch to the OFF position Place the Forward Reverse handle in the NEUTRAL position engage the park brake and chock the wheels 2 Ensure the booster battery is 12 volt 3 Access the engine compartment by raising the cargo bed See WARNING For vehicles with cargo beds in General Warnings on page 8 4 Locate the vehicle battery on the driver s side of...

Page 49: ... washing or steam cleaning Such a process will expose electrical components to moisture Moisture entering electrical components 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 The seats of the vehicle will last longer with proper cle...

Page 50: ...w all manufacturer safety warnings and instructions in the winch operator manual as well as the following WARNING and CAUTION statements Make sure a winch warning decal is affixed to the vehicle on the seat support panel next to the receptacle for the remote operation switch The winch kit available from Husqvarna includes a remote operation switch which enables the operator to move away from the v...

Page 51: ...er shock absorbers Rear Swing arms with coil over shock absorbers Steering Self adjusting rack and pinion Ackerman Brakes Hydraulic brake system brake pads and discs on each wheel with separate foot operated park brake BODY CHASSIS Frame Chassis Box tube aluminum Side and rear body Plastic Cargo bed Powder coated steel or aluminum Front body Geloy XTWM206 Tires All Terrain 25 x 10 5 12 front and r...

Page 52: ...cessories 2750 lb 1247 kg High capacity option 3012 lb 1366 kg Standard seating capacity 2 NOISE AND VIBRATION SPECIFICATIONS Drive by noise level to operator Test method EN 12053 2001 81 6 dBA Noise Power Level 102 6 dBA Uncertainty 2 dBA Vibration at driver s seat Test method EN 13059 2002 9 m s2 Uncertainty 0 33 m s2 CLIMATIC EXTREMES Operating temperature range 20 to 40 C 4 to 104 F LIQUID CAP...

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Page 56: ...ber 103472545 Edition Code 0409F0110E 103472545 This manual is valid for vehicles built during the 2009 model year It is also valid for vehicles with build codes between 54699 and the one indicated at the top of this page ...

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