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Cushman 1600XD4, Руководство пользователя

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Cushman 1600XD4 Скачать руководство пользователя страница 157

TROUBLESHOOTING

9

9

-

Problem

check item

Maintenance code

4. Engine is overheated

 

Insufficient engine oil

5.  Engine  stops  abruptly  during   

operation

 

Insufficient fuel or clogged filter and hose  

H

 

Air in fuel line or contaminated fuel

 

Seizure due to overheated 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, 

starting, illumination, horn, 

etc.)

 

Blown fuse

AF, AG

 

Improperly connected wiring

 

Faulty relay and controller (in engine compartment)

 

Discharged battery

7. Battery is discharged

 

Key switch left in the "ON" position

UD120-OM-1600XD4-09.indd   5

2014-03-28   오전 9:59:28

Содержание 1600XD4

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

Страница 2: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 167: ......

Страница 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...

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