Cushman 1600XD4 Owner's Manual
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Cushman 1600XD4 Owner's Manual

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1600XD4
OWNER'S MANUAL
640282

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  • Page 1 1600XD4 OWNER’S MANUAL 640282...
  • Page 3 FORWARD Thank you for choosing 1600XD4, our off-road diesel utility vehicle. We are committed 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, such as safe driving guide, explanation for operations, maintenance interval, simple maintenance guide, trouble shootings and etc. If you have any question about the product or manual, please feel free to contact us. We are always trying to deliver ultimate satisfaction and safety to customers. < NOTE > Make sure to read this manual carefully and keep it handy for future reference.   When leasing or transferring this vehicle, deliver this manual together with the vehicle. The specifications in this manual are subject to change without notice. ...
  • Page 4 ISO 3600 EU STANDARDS This manual was compiled in compliance with ISO 3600, standards and instructions contained in this manual comply with the requirements of the Machinery Directive 2010/52/EU in force in the European Community. For tractors sold or used outside the European Community, local laws will prevail. Main protections on the tractors discussed in this manual.
  • Page 5 TABLE OF CONTENTS SAFETY PRECAUTIONS ........ VEHICLE IDENTIFICATIONS ......SPECIFICATIONS ..........CONTROLS AND FEATURES ......SECTION OPERATION ............ REPLACEMENT PARTS ......... MAINTENANCE ..........STORAGE AND DISPOSAL ......TROUBLESHOOTING ........INDEX ...............

  • Page 6: Table Of Contents

    TABLE OF CONTENTS vEhIClE IDEnTIFICaTIOn nUMbER ..2-2 SAFETY PRECAUTIONS ....... 1-1 vEhIClE SERIal nUMbER ......2-2 PRECaUTIOnS bEFORE OPERaTIOn ..1-2 EnGInE SERIal nUMbER ........2-2 GEnERal PRECaUTIOnS ........1-2 SPECIFICATIONS ........... 3-1 PRECaUTIOnS DURInG OPERaTIOn ..1-4 SPECIFICaTIOn .......... 3-2 WhEn STaRTInG ThE EnGInE .......1-4 WhEn DRIvInG ThE vEhIClE ........1-6 ExTERIOR DIMEnSIOnS ..........3-2 WhEn PaRkInG ThE vEhIClE ......1-13 GEnERal SPECIFICaTIOnS ........3-3 OPTIOn lIST anD FEaTURES .........3-5 SaFETy PRECaUTIOnS DURInG SERvICInG ........... 1-14 CONTROLS AND FEATURES ......4-1 SaFETy PRECaUTIOnS WhEn ExTERIOR vIEW .........
  • Page 7 TABLE OF CONTENTS SWITChES ........... 4-7 COnTROlS ..............4-19 ShIFT lEvER ............4-19 kEy SWITCh .............4-8 DIFFEREnTIal lOCk lEvER (REaR WhEEl) .....4-20 COMbInaTIOn SWITCh ...........4-9 2WD/4WD ShIFT lEvER .........4-21 hazaRD laMP SWITCh ......... 4-11 bRakE PEDal ............4-22 SPaRE SWITCh PanEl ..........4-12 PaRkInG bRakE lEvER ........4-22 12v POWER OUTlET ..........4-12 aCCElERaTOR PEDal ..........4-23 SEaT .................4-24 InSTRUMEnT PanEl ........ 4-13 SEaT bElT ...............4-24 SPEEDOMETER / hOURMETER ......4-14 ROPS .
  • Page 8 TABLE OF CONTENTS TIRE TREaD PaTTERnS .........4-30 PaRkInG ..............5-12 PROPER InFlaTIOn PRESSURE ......4-32 ShIFTInG ..............5-13 DRIvInG On SlIPPERy SURFaCES .....5-14 OPERATION ........... 5-1 TURnInG ..............5-15 DRIvInG On SlOPE ..........5-15 PRE-OPERaTIOn ........5-2 DRIvInG In FOREST ..........5-17 DaIly InSPECTIOn ...........5-2 DRIvInG ThROUGh WaTER ........5-17 DRIvInG baCkWaRD ..........5-18 OPERaTInG ThE EnGInE ......5-2 DRIvInG On ROaD ..........5-19 TRanSPORTInG CaRGO ........5-19 STaRTInG ThE EnGInE ...........5-2 UnlOaDInG (ManUal MODEl) ......5-21 ChECkInG WaRnInG laMPS TOWInG TRaIlER ...........5-22 aFTER STaRTInG EnGInE .........5-5 TRanSPORTInG .............5-23 OPERaTInG PRInCIPlE OF PREhEaT SySTEM ........5-6...
  • Page 9 TABLE OF CONTENTS bElTS anD RUbbER PaRTS........6-3 ChECkInG CvT bElT (J) ........7-14 ElECTRIC PaRTS ............6-3 ChECkInG CvT DRIvEn PUllEy ClUTCh bUTTOnS(k) ......7-16 ChECkInG FUEl FIlTER(l) ........7-17 MAINTENANCE ..........7-1 blEEDInG FUEl lInE (M) ........7-17 MaInTEnanCE ChECk lIST ..... 7-3 ChECkInG InJECTIOn nOzzlE anD FUEl InJECTIOn PUMP (n) ......7-19 DaIly ChECk ChaRT ..........7-3 ClEanInG RaDIaTOR CORE (O) ......7-19 MaInTEnanCE InTERval TablE ......7-4 ChECkInG COOlanT In aUxIlIaRy COOlanT Tank (P) ....7-20 lUbRICanTS ..........7-6 ChanGInG COOlanT (q) ........7-21 DaIly InSPECTIOn ........7-7 ChECkInG SPaRk aRRESTER OF ExhaUST PIPE (IF EqUIPPED) (R) ....7-23 aCCESS FOR SERvICE ........... 7-7 ChECkInG anD OPEnInG InSPECTIOn ShIElD (a) ......7-7 ChanGInG GEaRbOx OIl (S) ......7-24...
  • Page 10 TABLE OF CONTENTS ChECkInG bRakE FlUID (x) ........7-29 vEhIClE STORaGE ........8-2 ChECkInG bRakE PEDal FREE Play (y) ...7-30 DaIly STORaGE ............8-2 ChECkInG bRakE PaD (z) ........7-30 lOnG-TERM STORaGE ..........8-2 ChECkInG PaRkInG bRakE (aa) ......7-31 USInG vEhIClE aFTER lOnG-TERM STORaGE ..8-3 aDJUSTInG SUSPEnSIOn (ab) ......7-33 ChECkInG SUSPEnSIOn DISPOSal ............ 8-4 ShOCk abSORbER (aC) ........7-34 baTTERy (SEalED) (aD) ........7-34 TROUBLESHOOTING ........9-1 REPlaCInG hEaDlaMP bUlb (aE) ......7-36 vEhIClE TROUblEShOOTInG .......9-2 ChECkInG anD REPlaCInG FUSE (aF) ....7-37 MaIn FUSE (SlOW-blOW FUSE) (aG) ....7-37...
  • Page 11 SAFETY AND VEHICLE DAMAGE WARNING This manual includes information titled as WARNING, CAUTION, IMPORTANT and NOTE. These titles indicate the following: This indicates that a condition may result in harm, serious in- jury or death to you or other persons if the warning is not hee- ded. Follow the advice provided with the warning. WARNING This indicates that a condition may result in damage to your vehicle or its equipment if the caution is not heeded.
  • Page 12 UNIVERSAL SYMBOLS various universal symbols have been used on the instruments and controls of your vehicle. below is a list of the universal symbols and their meanings. Fuel-level low Differential lock Preheat Parking brake hazard Warning lights neutral Position battery Charging Condition headlight-low beam high Speed Travel light Engine Oil-Pressure headlight-high beam low Speed Travel light Four-Wheel Drive-On Reverse Travel light Turn Signal Engine Check Warning lamp...
  • Page 13 SAFETY PRECAUTIONS PRECAUTIONS bEFORE OPERATION ...... 1-2 General precautions ............1-2 PRECAUTIONS dURINg OPERATION ....... 1-4 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 ............

  • Page 14: Safety Precautions

    1600Xd4 PRECAUTIONS bEFORE OPERATION gENERAl PRECAUTIONS a careful operator is the best oper- 4. replace any missing or damaged ator. most accidents can be avoid- decals as soon as it is practical. ed by observing certain precautions. a list of decals is shown on page to help prevent accidents, use these 1-19~24.
  • Page 15 safetY precautions driver's license UUVO102a UUVO114a UUVO115a 6. never operate this vehicle or any 8. this vehicle should be driven only 9. never let anyone under 5 years of other agricultural equipment while by a driver with a valid driver’s li- age ride in the vehicle.

  • Page 16: Precautions During Operation

    1600Xd4 PRECAUTIONS dURINg OP- ERATION whEN STARTINg ThE ENgINE UUVO116a UUVO123a UUVO108a 10. never allow anyone to operate 11. it is recommended to wear a hel- 1. do not operate your vehicle in this vehicle unless person has met whenever driving this vehi-...
  • Page 17 safetY precautions UUVO103a UUVO131a UUVO105a C56O164a 2. When starting the vehicle make 4. never start the engine while not 7. make sure that wheel nuts have sure your path is clear of people to seated. been tightened to the specified avoid accidents caused by sudden torque.

  • Page 18: When Driving The Vehicle

    1600Xd4 whEN dRIvINg ThE vEhIClE UUVO133a UUVO122a KUVO157a T66O127a 10. always activate the brake pedal 1. in some countries or states, it is 2. When driving on a public road, before releasing the park brake. illegal to drive a utv on public make sure to install the "safe-...
  • Page 19 safetY precautions KUVO158a UUVO112a UUVO125a 3. When the headlights are turned 4. always slow the vehicle before 6. do not apply the differential lock on, dim them when meeting an- turning. turning at high speed may while traveling at road speeds. as other vehicle.
  • Page 20 1600Xd4 KUVO162a KUVO101a KUVO109a C56O164a 9. When working in groups, always 11. Watch where you are going at 13. for your safety ROPS with a seat let the others know what you are all times so that you are able to belt is recommended for all appli- going to do before you do it.
  • Page 21 safetY precautions UUVO109a UUVO110a UUVO121a 14. Watch front and rear to avoid ob- 15. never try to get on or off a mov- 16. to minimize the risk of a rollover stacles at row ends, near trees ing vehicle. crash, be especially careful when and around other obstructions.
  • Page 22 1600Xd4 UUVO124a UUVO125a UUVO126a 17. Never drive the vehicle at ex- 18. never attempt wheelies, jumps 19. always keep both hands on the cessive speeds. always travel at or other stunts. steering wheel and both feet on speed proper for the terrain, visi- the floor of the vehicle during op- bility and operating conditions.
  • Page 23 safetY precautions UUVO111a UUVO129a KUVO166a 21. Never drive in excessively rough, 23. always follow proper procedures 24. drive slowly across sloped ter- slippery or loose terrain. for climbing hills as described rain. Excessive speed can cause in this manual. check the ter- vehicle to roll over leading to se- 22.
  • Page 24 1600Xd4 UUVO110a UUVO130a UUVO132a 26. always be careful of skidding 27 never operate your vehicle in 28. Never exceed the stated load or sliding. on slippery surfac- fast-flowing water or in water capacity for this vehicle. car- es such as ice, travel slowly and...

  • Page 25: When Parking The Vehicle

    safetY precautions whEN PARkINg ThE vEhIClE UUVO140a UUVO113a UUVO134a (1) rear hitch receiver 29. pull only from the rear hitch re- 1. place all control levers in the neu- 2. always remove the ignition key ceiver. pulling from any other lo- tral position, set the parking brake, when the vehicle is not in use to cation can cause the damage of...

  • Page 26: Safety Precautions During Servicing

    1600Xd4 SAFETY PRECAUTIONS dURINg SERvICINg UUVO107a KUVO127a UUVO117a 4. never park on a slope with only 2. d o n o t s m o k e w h i l e w o r k i n g 1. in order to service your vehicle the transmission engaged.
  • Page 27 safetY precautions KUVO113a UUVO118a UUVO119a 3. You must always stop the engine 4. It is recommended to keep a first 5. do not remove the radiator cap before refueling the vehicle. avoid aid kit and fire extinguisher handy while the coolant is hot. When overfilling the vehicle or spilling at all times.
  • Page 28 1600Xd4 T66O130a UUVO120a UUVO135a 7. When working with your vehicles 10. tire mounting should be done by 13. fluid escaping from pinholes may electrical components, you must qualified professionals, with the be invisible. do not use hands to first disconnect the battery cables.
  • Page 29 safetY precautions UUVO104a UUVO139a 14. no alterations should be made to 15. keep environmental pollution in your vehicle. mind. When replacing coolant 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.

  • Page 30: Safety Precautions When Using The Rops

    1600Xd4 SAFETY PRECAUTIONS whEN USINg ThE ROPS UUVO104a U12O101a UUVO143a (1) rops 1. rops (roll over protective struc- a ROPS should never be modified IMPORTANT ture) is equipped to protect driver by welding, grinding or cutting, as ROPS, Sun canopy or cabin and passengers when the vehicle ...

  • Page 31: Safety Decal

    safetY precautions SAFETY dECAl mOUNTINg lOCATION U12O102a...

  • Page 32: Decals

    1600Xd4 dECAlS (1) part no. : u3215-85691 (3) part no. : u3215-85631 ������� ������� ���������������������������������� ����������� ������������������������������������������������� ������ � ������������������������ ��������������������������������������������������������������� ����������������������� �������������������������������������������������������� ���� ����������������������������� ���������������������������������������������������������� U3215-85691 MAX 7.3 INCH �������������������� (185MM) �������������������������������������� U3215-85631 (2) part no. : u3215-85161 (4) part no. : u3215-85641 (5) part no.
  • Page 33 safetY precautions (6) part no. : u3215-85181  SEVERE INJURY OR DEATH COULD OCCUR AS A RESULT OF RIDERS FALLING OFF, IMPROPER USE OF THE VEHICLE OR VEHICLE ROLLOVER. · Read the owner's manual · Familiarize yourself with all safety information ·...
  • Page 34 1600Xd4 (7) part no. : u3215-85562 (9) part no. : u3215-85171 ������� ������� 1. Never drive this utility vehicle unless you're 16 or older or have a driver's license. 2. This machine is designed for off-road use only. Never drive on public Roads and avoid UNDER paved surfaces as the handling characteristics of the machine may be adversely affected.
  • Page 35 safetY precautions (10) part no. : u3215-85861 (13) part no. : u3215-85651 CAUTION ������� Driving UTV in “H” gear with heavy load could shorten the life time of the CVT belt. Please be to sure the use “L” gear rather than “H” gear when driving UTV in the following conditions.

  • Page 36: Cautions For Decal Maintenance

    1600Xd4 CAUTIONS FOR dECAl mAINTENANCE safety decals are attached to the ve- (14) part no. : u3215-85661 IMPORTANT hicle for safe operation. make sure If a decal is damaged or lost, ������� to follow the instruction on the decals ...

  • Page 37: Precautions Before Operation

    PRECAUTIONS BEFORE OPERATION VEhIClE IdENTIFICATION NUmBER ......2-2 VEhIClE SERIAl NUmBER ........2-2 EnginE sErial numbEr ............2-2...

  • Page 38: Vehicle Identification Number

    1600XD4 VEhIClE IdENTIFICATION 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 with appro- priate information as the vehicle seri-...

  • Page 39: Specifications

    SPECIFICATIONS SPECIFICATION............3-2 ExtErior dimEnsions ............3-2 GEnEral spEcifications .............3-3 option list and fEatUrEs ..........3-5...

  • Page 40: Specification

    1600xd4 SPECIFICATION ExTErIOr.dImENSIONS E, f U12O301a in. (mm) Overall..length Overall.width. Overall.height. Wheel.base Front.wheel.tread. rear.wheel.tread. Ground.clearance. .(A) .(d) 144.6 60.7 76.4 108.7 49.7 48.30 (3,672) (1,543) (1,940) (2,760) (1,262) (1,228) (304)

  • Page 41: General Specifications

    GENErAl.SPECIFICATIONS ITEmS 1600xd4 rEmArKS model 3c100lfU-U number of cylinders total displacement 1,007 fuel diesel Gross Hp/KW 22/16.40 rated speed 2,800 Engine oil U.s.Gal.(l) 0.85 (3.2) fuel tank U.s.Gal.(l) 7.40 (28.0) Gear box oil U.s.Gal.(l) 0.24 (0.9) front differential case oil U.s.Gal.(l) 0.16 (0.6)
  • Page 42 1600xd4 ITEmS 1600xd4 rEmArKS front wheel 25 x 10-12(Worksite) rear wheel 25 x 10-12(Worksite) 38.6 x 56.2 x 11.5 dimension (l x W x H) in.(mm) (980 x 1,427 x 293) load capacity lbs(kg) 661.5 (300) min. turning radius ft(m) 17.7(5.4)

  • Page 43: Option List And Features

    spEcifications OPTION.lIST.ANd.FEATUrES ITEm dESCrIPTION rEmArKS Wind shield(saftety With Wiper) Body color ornage / Green / Blue Hydraulic cargo dumping kit with hydraulic pump, Hydraulic Bed lift oil tank, cylinder, valve, hoses and control lever Hydraulic Utility Valve Beacon light Winch mtG Bracket sun canopy plastic moulding canopy Wind shield...
  • Page 44 1600xd4 ITEm dESCrIPTION 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 sun canopy deck Extinsion Kit(cargo) cargo bed extension kit in height made by metal pipes...
  • Page 45 CONTROLS AND FEATURES ExTERiOR viEw ........4-3 ENGINE.oIL.pRESSuRE.wARNING.LAMp..4-15 bATTERy.CHARGING.LAMp......4-16 Hood...............4-4 HEAd.LIGHT.HIGH.bEAM.LAMp....4-16 ELECTRIC.CooLING.FAN.MoToR....4-4 TuRN.SIGNAL.LAMp........4-17 SuSpENSIoN..........4-5 GLow.pLuG.INdICAToR......4-17 HEAdLAMp............4-5 pARKING.bRAKE.INdICAToR...... 4-17 REAR.HITCH.RECEIvER........ 4-5 NEuTRAL.INdICAToR........4-18 REAR.wHEEL.MudGuARd......4-6 LowER.FuEL.LEvEL.wARNING.INdICAToR..4-18 REFLEx.REFLECToR........4-6 ENGINE.CHECK.wARNING.LAMp....

  • Page 46: Controls And Features

    CONTROLS AND FEATURES SuN.CANopy..........4-26 Cup.HoLdERS.ANd.SToRAGE.boxES..4-26 CARGo.bEd..........4-27 CARGo.bEd.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.pRESSuRE....4-32...

  • Page 47: Exterior View

    CONTROLS AND FEATURES ExtErior viEw U12O401a (1) Seat Back (6) ROPS (11) Rear Reflex Reflector (2) Seat (7) Steering Handle (12) Cargo Bed (3) Dumping Handle (8) Hood (13) Rear Hitch Receiver (4) Dumping Latch (9) Headlamp (14) Rear Wheel Mudguard (5) Fuel Tank Cap (10) Brush Guard (15) Sun Canopy...

  • Page 48: Hood

    1600xd4 hOOD 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- tween.two.points.is.to.prevent.contin- ual.“oN”.and.“oFF”.operation.of.fan. motor..The. fan. motor. can. run. even. when.the.engine.is.stopped.if.the.key. is.in.“oN”.position.and.the.coolant.is. still.hot. To. prevent. engine. failure,. the. fan. U12O402a UUVO452a motor.keeps.running.even.if.there.is.

  • Page 49: Suspension

    CoNTRoLS.ANd.FEATuRES. SUSpENSiON hEADLAmp REAR hiTCh RECEivER U12O405a U12O404a U12O406a (1) Front Axle (2) Rear Axle (1).Headlamp.(LH). (2).Headlamp.(RH) (1).Rear.Hitch.Receiver The. Mcpherson. strut. type. suspen- The. headlamps. consist. of. Halogen. This.vehicle.is.equipped.with.the.rear. sion. for. front. wheel. and. adjustable. lamps.for.high.beam.and.low.beam.. hitch.receiver.as.standard. dual.A-arm.(wishbone).type.suspen- Their. reflective. mirrors. are. chrome- The. rear. hitch. receiver. is. a. 2-inch. sion.

  • Page 50: Rear Wheel Mudguard

    1600xd4 REAR whEEL mUDGUARD REFLEx REFLECTOR wARNiNG Never drive this vehicle with a  person in the trailer or cargo bed. Do not apply vertical load for  more than 59 Kg (130 lbs) onto the towing bracket. when towing, do not exceed ...

  • Page 51: Switches

    CoNTRoLS.ANd.FEATuRES. SwiTChES CAUTiON make sure that the reflectors  are clean before driving the vehicle. Driving with dirty re- flectors, especially 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.

  • Page 52: Key Switch

    1600xd4 KEy SwiTCh ACC (B) used. in. very. cold. weather. to. pre- heat the engine manually for extra when. the. key. switch. is. turned. to. period. of. time.. using. this. position. the. position. “b”,. only. electrical. for. more. than. 30. seconds. con- power. outlet. and. brake. lights. can.

  • Page 53: Combination Switch

    CoNTRoLS.ANd.FEATuRES. COmBiNATiON SwiTCh NOTE CAUTiON The.ignition.key.is.not.directional. Stop the engine immediately if   and.can.be.inserted.in.any.direc- the oil pressure warning lamp tion..Also,.be.careful.not.to.leave. does not go off after the en- the. vehicle. unattended. as. the. gine is started. The engine can same.key.is.used.for.all.vehicles.. be seriously damaged. It.can.be.stolen.
  • Page 54 1600xd4 hEADLAmp SwiTCh TURN SiGNAL LAmp SwiTCh wARNiNG Driving with high beam head-  lights makes it difficult for the driver of an on coming vehicle to see. Use high beams only if necessary. UUVO413a UUVO414a (1) Headlamp.Switch. (1).Turn.Signal.Lamp.Switch (A). OFF : Headlamps Off (A).

  • Page 55: Hazard Lamp Switch

    CoNTRoLS.ANd.FEATuRES. hAzARD LAmp SwiTCh hORN SwiTCh NOTE The.turn.signal.lamp.lever.is.not.  the. self-return. type.. Therefore,. make. sure. to. return. the. lever. manually. after. turning. the. vehi- cle. The turn signal lamps and flash-  er.can.be.operated.even.with.the. key.switch.in.the."oFF".position.. Leaving. the. turn. signal. lamps. UUVO455a UUVO415a flashing with the key switch in the (1) Horn Switch...

  • Page 56: Spare Switch Panel

    1600xd4 SpARE SwiTCh pANEL 12v pOwER OUTLET CAUTION The hazard lamp can be oper-  ated without the key inserted. if the hazard lamps are turned  o n f o r a n e x t e n d e d p e r i o d...

  • Page 57: Instrument Panel

    CoNTRoLS.ANd.FEATuRES. iNSTRUmENT pANEL wARNiNG Do not wear a headphone to  listen to the radio or music during driving. Use only D.C. electric devices with  its capacity of 12v 10A or less. Never use an electric heater. it  can cause a fire.

  • Page 58: Speedometer / Hourmeter

    1600xd4 SpEEDOmETER / hOURmETER FUEL GAUGE This.is.due.to.air.entered.into.the.fuel. supply.system..In.this.case,.the.sys- tem.should.be.bled..(For.details,.re- fer. to.page.7-19."bleeding.fuel.sys- tem".in.the.chapter."Maintenance".) NOTE Make.sure.that.good.quality.fuel.is.  used,.poor.quality.fuel.can.cause. damage.to.the.engine. U12O418a T46O568a use. fuel. formulated. for. cold.  weather.during.the.winter,.the.en- (1).Fuel.Gauge....(1).Speedometer.....(2).Hourmeter gine.will.start.easier..“E”:. Empty....“F”:.Full The. speedmeter. operates. correctly. This.indicates.the.remaining.fuel.lev- when the specified tires with the cor- el.after.the.key.switch.is.turned.to.the. rect. inflation. pressure. are. installed..

  • Page 59: Coolant Temperature Gauge

    CoNTRoLS.ANd.FEATuRES. COOLANT TEmpERATURE GAUGE ENGiNE OiL pRESSURE wARNiNG LAmp Stop. the. vehicle. or. operation. for. a. while.without.stopping.the.engine.un- til. the. engine. is. cooled. down.. If. the. engine. temperature. does. not. drop,. open.the.hood.and.check.if.the.radi- ator.fan.is.operating..If.the.fan.is.not. operating,.stop.the.engine.and.have. your.vehicle.checked.by.your.dealer. CAUTiON H11O425a make sure to control the work U12O419a ...

  • Page 60: Battery Charging Lamp

    1600xd4 BATTERy ChARGiNG LAmp hEAD LiGhT hiGh BEAm LAmp CAUTiON if the oil level is below the  specified range, the engine can seize. The engine can be severely  damaged if driving or operat- ing the vehicle with the engine oil warning lamp ON.

  • Page 61: Turn Signal Lamp

    CoNTRoLS.ANd.FEATuRES. TURN SiGNAL LAmp GLOw pLUG iNDiCATOR pARKiNG BRAKE iNDiCATOR U12O424a U12O422a U12O423a o p e r a t i n g. t h e. t u r n. s i g n a l. l a m p. This. indicates. the. operating. condi- This.lamp.comes.on.in.red.when.the.

  • Page 62: Neutral Indicator

    1600xd4 NEUTRAL iNDiCATOR LOwER FUEL LEvEL wARN- ENGiNE ChECK wARNiNG iNG iNDiCATOR LAmp U12O425a U12O426a U12O452a If.the.shift.lever.is.in.neutral.position,. This. lamp. comes. on. when. the. fuel. This.comes.on.when.any.major.elec- this.lamp.turns.green. tank. is. approaching. empty.. when. it. tric. device. or. engine. fuel. system. is. comes. on,. you. should. add. fuel. as.

  • Page 63: Controls

    CoNTRoLS.ANd.FEATuRES. CONTROLS ShiFT LEvER UUVO428a (1).Shift.lever. .H:.High.speed. L:.Low.speed .N:.Neutral.. R:.Reverse U12O427a The.shift.lever.has.four.positions;."H". (1).Steering.wheel (4).2wd/4wd.Shift.Lever (High. speed),. "L". (Low. speed),. "N". (2).differential.Lock.Lever (5).brake.pedal (3).Shift.Lever (6).Accelerator.pedal (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. to.ensure.safe.shift.between.the.for- ward.and.reverse.operation.

  • Page 64: Differential Lock Lever (Rear Wheel)

    1600xd4 DiFFERENTiAL LOCK LEvER (REAR whEEL) to.prevent.this.situation,.this.vehicle. impORTANT is.equipped.with.the.differential.lock. This vehicle is equipped with  system. a CvT (Continuous variable Transmission). [Differential lock system] make sure to stop the vehi-  The.differential.lock.system.is.to.con- cle before moving the shift le- nect. the. wheel. on. the. left. and. right.

  • Page 65: 2Wd/4Wd Shift Lever

    CoNTRoLS.ANd.FEATuRES. 2wD/4wD ShiFT LEvER LSD Differential Lock (Front wheel) CAUTiON The.LSd.(Limited.Slip.device).is.in- T h e d i f f e r e n t i a l l o c k l e v e r  stalled on the front axle. should always be returned to The.LSd.differential.lock.system.will.

  • Page 66: Brake Pedal

    1600xd4 BRAKE pEDAL pARKiNG BRAKE LEvER impORTANT press the brake pedal light-  ly several times to dry the disc bakes after driving through water or mud. UUVO431a U12O432a (1).brake.pedal. (A).depress (1).parking.brake.Lever (A).down.to.release.with.pushing.. (b).pull.up.to.set.button. The.brake.pedal.is.located.on.the.left. The.parking.brake.lever.is.similar.to. of. the. accelerator. pedal.. press. the.

  • Page 67: Accelerator Pedal

    CoNTRoLS.ANd.FEATuRES. ACCELERATOR pEDAL wARNiNG wARNiNG To avoid possible injury, death An unauthorized person or  or loss of property from a ma- child can move or operate the chine runaway vehicle. Therefore, make sure to apply the parking brake and with the engine off, unexpect- ...

  • Page 68: Seat

    1600xd4 SEAT SEAT BELT wARNiNG As the safety belt can reduce  or prevent injuries in an acci- dent, make sure to wear the seat belt during driving. Also, be sure the seat belt is not twisted as the seat belt may not protect an occupant prop- erly, leading to an accident.

  • Page 69: Rops

    CoNTRoLS.ANd.FEATuRES. ROpS FRONT GUARD wARNiNG The ROpS is to protect 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. NOTE U12O439a U12O437a...

  • Page 70: Sun Canopy

    1600xd4 SUN CANOpy CUp hOLDERS AND STORAGE BOxES There. are. 3. cup. holders,. 2. up. front. and.one.in.the.back. KUVO403a U12O453a (1).Sun.Canopy The.sun.canopy.is.available.for.this. vehicle. as. an. option..This. is. to. im- prove. the. driver's. comfort. in. rain. or. sunlight.. CAUTiON when entering a garage, make ...

  • Page 71: Cargo Bed

    CoNTRoLS.ANd.FEATuRES. CARGO BED CARGO BED CONTROL LEvER (mANUAL mODEL) U12O446a U12O470a (1).dumping.Latch. (2).dumping.Handle (1).Cargo.bed.Support (A).Turn. (b).pull.up To. raise. the. cargo. bed,. pull. up. the. wARNiNG handle. with. one. hand. while. turning. Never let anyone ride on the  the.dumping.latch.lever.with.the.oth- cargo bed during driving. he/ er.hand..Take.your.hand.off.the.han- she can fall off the bed and be dle.

  • Page 72: Fuel Tank

    1600xd4 FUEL TANK 2..Avoid. using. electrical. devices,. wARNiNG such. as. a. cellular. phone,. during. when raising or lowering the  fueling.. cargo bed, be careful not to let 3.. The. fuel. is. highly. flammable. and. any part of your body, such as...

  • Page 73: Engine Inspection

    CoNTRoLS.ANd.FEATuRES. FUEL REqUiREmENTS ENGiNE iNSpECTiON Make.sure.to.use.high.quality.diesel. It. is. possible. to. inspect. the. engine. fuel. for. durability. and. performance. for.most.items.by.removing.the.seat. of.the.engine..The.cetane.number.of. cushion. and. raising. the. cargo. bed.. the.fuel.should.be.at.least.40.(ASTM. For. engine. oil. level. check,. just. re- d975).in.any.circumstance..It.is.rec- move. the. inspection. shield. on. the. ommended.

  • Page 74: Coolant, Brake Fluid And Electrical Devices

    1600xd4 COOLANT, BRAKE FLUiD AND TiRE TiRE TREAD pATTERNS ELECTRiCAL DEviCES STANDARD TiRE FOR wORKSiTE UUVO460a UUVO451a T56O530a (1).Radiator.Cap. (2).drain.plug (A) Insufficient (B) Standard (C) Excessive ALL TERRAiN (RECREATiONAL) The.coolant,.radiator.cooling.fan.and. Though. the. tire. inflation. pressure. is. brake fluid can be checked by open- factory-set.to.the.prescribed.level,.it. ing.the.hood.. naturally. drops. slowly. in. the. course.
  • Page 75 CoNTRoLS.ANd.FEATuRES. TURF wARNiNG D o n o t u s e t i r e s l a r g e r o r  smaller than specified. Do not disassemble or assem-  ble the tire. if it is necessary to disassemble/assemble the tire, let a qualified service person perform the work.

  • Page 76: Proper Inflation Pressure

    1600xd4 pROpER iNFLATiON pRESSURE Always maintain the proper tire inflation pressure. Make sure the tire pressure does not exceed the pressure recommended in the manual. Inflation wheel nut item Type Remarks pressure torque 4.0~4.6.kgf.m work.site 25x10-12(6PR) 12.pSI Standard 28.9~33.3.lb.ft Front. 4.0~4.6.kgf.m All.terrain 25x10-12(4PR) 12.pSI option wheel 28.9~33.3.lb.ft 4.0~4.6.kgf.m Turf 25x10-12(4PR) 12.pSI option 28.9~33.3.lb.ft UUVO459a 4.0~4.6.kgf.m work.site 25x11-12(6PR) 18.pSI Standard 28.9~33.3.lb.ft...

  • Page 77: Operation

    OPERATION PRE-OPERATION....... 5-2 shifting ..........5-13 DriVing on slippery surfaces ..5-14 Daily inspection ........5-2 turning ..........5-15 DriVing on slope .......5-15 OPERATING.THE.ENGINE....5-2 DriVing in forest .......5-17 starting the engine ......5-2 DriVing through water ....5-17 checking warning lamps DriVing backwarD ......5-18 after starting engine ....5-5 DriVing on roaD .........5-19 operating principle...

  • Page 78: Pre-Operation

    1600XD4 PRE-OPERATION OPERATING.THE.ENGINE DAILy.INSPECTION STARTING.THE.ENGINE CHECk.ITEM it is a good practice to know the con- check the engine oil level.  WARNING dition of your vehicle before you start check the engine coolant level.  To.avoid.accidents: it. you should do routine check be- clean the radiator grille.
  • Page 79 operation 1. make sure there is no obstacle around the vehicle. 2. make sure to fasten your seat belt on the driver's seat and apply the parking brake firmly. NOTE the parking brake indicator on  the instrument panel comes on while the parking brake is en- UUVO501A H11O503A...
  • Page 80 1600XD4 WARNING Never. operate. the. start. mo-  tor.for.10.consecutive.seconds. as.it.consumes.a.lot.of.battery. power..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. U12O411A U12O504A Do. not. turn. the. key. switch. to.  (1) Key switch (a) stop (b) acc (1) glow plug indicator the."START".position.while.the.

  • Page 81: Checking Warning Lamps After Starting Engine

    operation CHECkING.WARNING.LAMPS. AFTER.STARTING.ENGINE 9. check to see that all the warning 1. if the oil pressure warning lamp WARNING lamps on the instrument cluster does not go off in 4 to 5 seconds Driving. the. vehicle. for. an. ex-  turn "off".

  • Page 82: Operating Principle Of Preheat System

    1600XD4 OPERATING.PRINCIPLE.OF. STOPPING.THE.ENGINE PREHEAT.SySTEM 1. when the key switch is turned to 1. make sure to reduce the engine CAUTION the “on” position, the glow plug rpm before stopping the engine. Apply. the. parking. brake. and.  indicator comes on for 9 seconds 2.

  • Page 83: Operating The Vehicle

    operation OPERATING.THE.VEHICLE HOW.TO.DRIVE IMPORTANT WARNING W h e n. l e a v i n g. t h e. v e h i c l e ,. Fasten. the. seat. belt. firmly.   make. sure. to. remove. the. key. when.you.are.seated.in.the.ve- after.
  • Page 84 1600XD4 UUVO503A UUVO506A U12O505A (1) shift lever (1) parking brake (1) shift lever h: high speed (a) push (b) release l: low speed n: neutral r: reverse 2. start the engine after checking 4. place the shift lever to the "h"...
  • Page 85 operation CAUTION IMPORTANT Do.not.shift.the.gear.when.the. Avoid. abrupt. acceleration. or.   vehicle. is. moving. or. the. en- braking.for.safe.driving. When.driving.on.a.steep.hill.or. gine.is.running.at.a.high.idling.  loading. or. unloading. the. vehi- speed.. To. stop. the. vehicle,. cle.from.the.transportation.ve- press. the. brake. pedal,. and. then.move.the.shift.lever.. hicle,. set. the. shift. lever. into. the.

  • Page 86: Warming Up

    1600XD4 WARMING.UP it is recommended always to warm 5. The engine is sufficiently warmed up the engine before driving in order up when the temperature gauge to maintain the durability of the en- on the instrument panel indicates gine and prevent malfunction of the 1/4 of the normal temperature engine.

  • Page 87: Jump Start

    operation JUMP.START 1. check that the voltage of the dis- 5. connect one clip of the black charged battery is the same as negative cable to the negative the voltage of the other vehicle for terminal of the normal battery jump start (specification for this and the other clip to the vehicle vehicle: 12 V).

  • Page 88: Stopping

    1600XD4 STOPPING PARkING press the brake pedal to control the NOTE driving speed. this vehicle does not have an  1. release the accelerator pedal engine brake function. always completely. check the brake function before 2. press the brake pedal evenly and operating the vehicle.

  • Page 89: Shifting

    operation SHIFTING when parking, make sure to pull up this vehicle is equipped with the WARNING the parking brake fully. cVt (continuous Variable transmis- To. avoid. possible. injury,. death. sion) and the shifting operation is au- the parking brake in the vehicle is or.

  • Page 90: Driving On Slippery Surfaces

    1600XD4 DRIVING.ON.SLIPPERy.SURFACES 3. avoid abrupt acceleration and WARNING turning during driving on a slippery It. is. recommended. to. use. the.  road. 4WD.on.a.slippery.road..Using. 4. if the vehicle cannot move for- the.4WD.can.increase.the.driv- ward due to spinning wheels, stop ing.force.of.the.wheels.as.well. the vehicle, engage the differential as.

  • Page 91: Turning

    operation TURNING DRIVING.ON.SLOPE UPHILL.AND.DOWNHILL before entering a curved road, slow WARNING down your speed. turning at a high To. prevent. an. accident. due. to. speed can lead the vehicle off the loss.of.steering.control: course, resulting in a severe acci- If. turning. at. a. high. speed,. the. dent.
  • Page 92 1600XD4 HILL.INCLINED.SIDEWARD 3. it is hard to steer the vehicle 1. when driving on a road inclined WARNING and the front section of the ve- sideward, be extra careful not to When. driving. on. a. road. in- hicle can be lifted off the ground let the vehicle overturn sideward.

  • Page 93: Driving In Forest

    operation DRIVING.IN.FOREST DRIVING.THROUGH.WATER consider the following when driving through water: 1. check the depth and speed of wa- ter or water flow before entering it. 2. avoid a steep path when driving through water. 3. be careful not to hit a rock or ob- stacle and drive at a low speed.

  • Page 94: Driving Backward

    1600XD4 DRIVING.BACkWARD CAUTION WARNING Salty.water.corrodes.paint.and. If. precautions. are. not. taken.   exterior. parts. of. the. vehicle.. during.driving.backward,.a.se- Make.sure.to.wash.the.vehicle. rious.accident.can.occur. thoroughly.with.tap.water..Check. if. there. is. any. obstacle. If.any.part.is.corroded.by.salty. or. person. behind. the. vehicle.  (sea).water,.it.may.not.be.cov- before.driving.backward..Also,. ered.by.warranty. keep.the.speed.slow. NOTE...

  • Page 95: Driving On Road

    operation DRIVING.ON.ROAD TRANSPORTING.CARGO observe the following when driving 1. Distribute cargo evenly onto the WARNING on a road: cargo bed when driving. When. driving.on. a. road,. make.  1. it is recommended to attach the 2. for the vehicle without the hy- sure.to.install.the."Safety.lamp.
  • Page 96 1600XD4 6. when loading heavy material, 11. if an object, such as a rock, is such as sand and earth, distribute loaded, but not secured onto the it evenly in the cargo bed and do cargo bed, driving on a slope,...

  • Page 97: Unloading (Manual Model)

    operation UNLOADING.(MANUAL.MODEL) 1. open the tailgate with both hands. 4. after raising the cargo bed, make be careful as the tailgate can open sure support is latched in the abruptly due to cargo on the cargo groove (A) firmly. bed. 5.

  • Page 98: Towing Trailer

    1600XD4 TOWING.TRAILER this vehicle is equipped with a 2-inch WARNING square hitch receiver in the back as A. part. of. your. body. may. get. standard. be careful of the following  between. the. vehicle. body. and. when towing a trailer cargo.

  • Page 99: Transporting

    operation TRANSPORTING [Tips.for.driving.backward.with.trailer] if a trailer is about to go out of a cor- rect course during driving backward, turn the steering wheel to the direc- tion which the trailer goes then the trailer returns to its original course. UUVO518A UUVO519A 4.

  • Page 100: 4Wd Operation

    1600XD4 4WD.OPERATION 5. after getting onto the transporting WARNING vehicle, apply the parking brake Make. sure. to. secure. the. vehi- firmly and secure the vehicle onto  cle. firmly. during. transporta- the body frame or bracket of the tion. transporting vehicle with chains or The.canopy,.windshield.or.oth-...

  • Page 101: Differential Lock Operation

    operation DIFFERENTIAL.LOCk.OPERATION 2. when moving the 2wD/4wD le- 5. in some cases, it may be hard to ver, push up the detent knob with move the 2wD/4wD shift lever a finger and then move the lever. out of the "4wD" position. this is because parts related to the shift- 3.

  • Page 102: Tailgate (Back Door)

    1600XD4 TAILGATE.(BACk.DOOR) [Differential.lock.system] the differential lock system is to con- nect the wheel on the left and right mechanically to rotate them at the same speed regardless of friction ap- plied to them even on a slippery or bumpy road for better traction.

  • Page 103: Replacement Parts

    REPLACEMEnT PARTS ESSEnTiAL REPLACEMEnT PART ......6-2 Oil and fluid ................6-2 filters ..................6-2 Belts and ruBBer parts.............6-3 eleCtriC parts ..............6-3...

  • Page 104: Essential Replacement Part

    1600Xd4 1600Xd4 ESSEnTiAL REPLACEMEnT PART OiL And fLuid fiLTERS u.s.Gal.(l iTEM SPECifiCATiOn CAPACiTY engine sae 15W40 8.45 (30) Gear daedOnG 0.23 (0.9) utf55 exxonmobil front 0.16 (0.6) Mobilfluid 424 differ. exxonmobil rear Hydraulic 560 0.21(0.8) differ. shell:donax td UUVO601A UUVO602A...

  • Page 105: Belts And Rubber Parts

    replaCeMent parts replaCeMent parts BELTS And RuBBER PARTS ELECTRiC PARTS PART nO dESCRiPTiOn e5205-32091 engine Oil filter 84612-4316-0 fuel filter element t2350-11641 air filter UUVO603A UUVO604A rubber belts, hoses and boots get PART nO dESCRiPTiOn tender and cracked as they age. con- tinuos use of a belt, hose or boot in 2350-69571 Headlight Bulb poor condition can result in pact fail-...
  • Page 106 MEMO MEMO...

  • Page 107: Maintenance

    MAINTENANCE MAINTENANCE ChECk lIsT ....7-3 bleeDiNg fuel liNe (M) ......7-17 checkiNg iNJectioN Nozzle Daily check chart .........7-3 aND fuel iNJectioN puMp (N) ..7-19 MaiNteNaNce iNterval table .....7-4 cleaNiNg raDiator core (o) ....7-19 checkiNg coolaNt lUBRICANTs ........7-6 iN auxiliary coolaNt taNk (p) ..7-20 chaNgiNg coolaNt (Q) ......7-21 DAIly INspECTIoN ......7-7 checkiNg spark arrester of...
  • Page 108 MAINTENANCE aDJustiNg suspeNsioN (ab) ....7-33 checkiNg suspeNsioN shock absorber (ac) .....7-34 battery (sealeD) (aD) ......7-34 replaciNg heaDlaMp bulb (ae) ..7-36 checkiNg aND replaciNg 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 shift aND 4WD cables (aJ) ..7-39...

  • Page 109: Maintenance Check List

    MAINTENANCE Maintenance check list Daily check chart serVice scheDUle Maintenance cODes iteM serVice reQUireD Clean debris from radiator, screen and grills. Check coolant level in the reser- Engine Cooling System O, P ,Q voir tank. Seat Belt Check the condition of seat belt and mounting hardware. Check for wear, damaged tires and air pressure.

  • Page 110: Maintenance Interval Table

    1600xD4 Just once initially, in every interval MAINTENANCE INTERVAl TABlE ※ ⊙: ○: RUN hoUR RUN AGE INTERVAl MAINTENANCE ChECk ITEM CoDEs 1000 1yEAR 2yEAR 1 Engine oil and filter replace ⊙ ○ 2 Fuel filter replace ○ 3 fuel line and hose connection check ⊙...
  • Page 111 MaiNteNaNce Just once initially, in every interval ※ ⊙: ○: RUN hoUR RUN AGE INTERVAl MAINTENANCE ChECk ITEM CoDEs 1000 1yEAR 2yEAR hydraulic oil replace ⊙ ○ (if equipped with hydraulic kit) pump, cylinder, levers, oil tank and hoses related to hydraulic check ○...

  • Page 112: Lubricants

    1600xD4 lUBRICANTs To prevent serious equipment damage, use only indicated fluids, oils and greases, or equivalents. ITEM Capacity [ U.s. gal (l) ] lUBRICANTs fuel 7.4 (28.0) Diesel fuel antifreezing solution (ethylene glycol) + pure coolant 1.7 (6.3) water (50:50) engine oil 0.9 (3.2)

  • Page 113: Daily Inspection

    MaiNteNaNce DAIly INspECTIoN ACCEss foR sERVICE opENING INspECTIoN shIElD (A) 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 cargo bed.

  • Page 114: Opening Seat Cushion (B)

    1600xD4 opENING sEAT CUshIoN (B) RAIsING CARGo BED (C) U12O446A UUVO703A U12O704A (1) seat (1) pin (1) Ratchet lever (2) Lever Lock Bracket (A) Up (B) Down to close the seat cushion, align the pins under the cushion with it is possible to check the gearbox oil,...

  • Page 115: Applying Grease (D)

    MaiNteNaNce ApplyING GREAsE (D) UUVO707b UUVO775A U12O776A (1) Grease fitting (Rear axle drive shaft) (1) Grease fitting (Front wheel hubstrut) (1) Grease Fitting (Front Axle Drive Shaft Around Gear Box) there are four greasing points. two the other two are located on the of them are located on both ends of front wheel knuckle.

  • Page 116: Checking Engine Oil Level (E)

    1600xD4 ChECkING ENGINE oIl lEVEl (E) IMpoRTANT T h e e n g i n e o i l s h o u l d b e  checked regularly. Driving without sufficient engine oil can lead to severe engine dam- age.

  • Page 117: Changing Engine Oil And Filter (F)

    MaiNteNaNce ChANGING ENGINE oIl AND fIlTER (f) 1. Warm up the engine oil by operat- ing the engine for approx. 10 min- utes or driving the vehicle. 2. park the vehicle on level ground, stop the engine and apply the parking brake firmly.

  • Page 118: Dust Valve (G)

    1600xD4 DUsT VAlVE (G) 12. stop the engine and wait for ap- it is necessary to remove dust from 4. check if the anti-dust valve is torn prox. 5 minutes. then, check the the anti-dust valve of the air filter fre-...

  • Page 119: Replacing Air Filter (H)

    MaiNteNaNce REplACING AIR fIlTER (h) ChECkING AIR hosE AND ClAMp(I) if there is a tiny gap caused by a loose connecting clamp on the air hose, air without 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.

  • Page 120: Checking Cvt Belt (J)

    1600xD4 ChECkING CVT BElT (J) it is not easy to inspect the cvt on your own. it is recommended to have it inspected by your Dealer. 1. park the vehicle on level ground and apply the parking brake firmly. UUVO716A...
  • Page 121 MaiNteNaNce UUVO718A UUVO720A U12O719A (1) Exhaust pipe (2) Muffler (1) air hose 1 (2) air hose 2 (1) ctv cover 5. remove the exhaust pipe, but 6. remove the air hoses (1 and 2) 7. remove the cvt cover. leave the muffler in place. from the cvt cover.

  • Page 122: Checking Cvt Driven Pulley Clutch Buttons(K)

    1600xD4 ChECkING CVT DRIVEN pUl- lEy ClUTCh BUTToNs(k) 1. remove the relevant parts such NoTE as the cvt cover by following the the width of a new belt is 29 mm same procedure as for the cvt belt  (1 9/64 in.). its max. speed re- service (see "checking cvt belt").

  • Page 123: Checking Fuel Filter(L)

    MaiNteNaNce ChECkING fUEl fIlTER(l) BlEEDING fUEl lINE (M) REplACING fUEl fIlTER 1. Wipe the surface of the fuel filter clean. 2. 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.
  • Page 124 1600xD4 CAUTIoN IMpoRTANT CAUTIoN Do not operate the start motor To protect the catalyst filter, Never bleed the fuel system   while the engine is hot. for more than 5 seconds con- keep the followings: tinuously. Instead, operate it Make sure to use only genuine ...

  • Page 125: Checking Injection Nozzle And Fuel Injection Pump (N)

    MaiNteNaNce ChECkING INJECTIoN NozzlE ClEANING RADIAToR CoRE (o) AND fUEl INJECTIoN pUMp (N) the injection nozzle and injection 1. park the vehicle on level ground pump can be inspected only by a and apply the parking brake firmly. qualified service personnel. for de- 2.

  • Page 126: Checking Coolant In Auxiliary Coolant Tank (P)

    1600xD4 ChECkING CoolANT IN AUX- IlIARy CoolANT TANk (p) When the coolant in the radiator ex- 1. park the vehicle on level ground IMpoRTANT pands by heat, it overflows into the and apply the parking brake firmly. Driving with the radiator core auxiliary coolant tank.

  • Page 127: Changing Coolant (Q)

    MaiNteNaNce ChANGING CoolANT (Q) 4. After confirming the radiator cap is IMpoRTANT WARNING not hot, unscrew it counterclock- If you have to keep adding Do not remove the radiator cap wise slowly pressing it down. un-   while the engine is hot. you water to the auxiliary cool- screw it in several steps to remove can get burnt by hot steam.
  • Page 128 1600xD4 UUVO731A UUVO732A U12O733A (1) coolant Drain plug of radiator (1) engine coolant Drain plug (1) air bleeder bolt (2) engine oil filter 7. place a container with wide open- 8. Now drain the coolant from the en- 9. loosen the air bleeder bolt for...

  • Page 129: Checking Spark Arrester Of Exhaust Pipe (If Equipped) (R)

    MaiNteNaNce 13. Make sure to install the drain 1.7 u.s gal. (6.3 l) Coolant plugs for radiator and engine be- ChECkING spARk ARREsTER of Water+ethylene glycol Capacity fore filling new coolant. EXhAUsT pIpE (If EQUIppED) (R) 50:50 1. park the vehicle on level ground 14.

  • Page 130: Checking And Changing Gearbox Oil (S)

    1600xD4 ChECkING AND ChANGING GEARBoX oIl (s) 1. park the vehicle on level ground 6. if the color or viscosity of the oil is and apply the parking brake firmly. not normal or it is at the oil change interval, change the oil.

  • Page 131: Checking And Changing Front Axle Oil (T)

    MaiNteNaNce ChECkING AND ChANGING fRoNT AXlE oIl (T) 1. park the vehicle on level ground 6. if the color or viscosity of the oil is WARNING and apply the parking brake firmly. not normal or it is at the oil change you can get burnt badly by interval, change the oil.

  • Page 132: Checking And Changing Rear Axle Oil (U)

    1600xD4 ChECkING AND ChANGING REAR AXlE oIl (U) 11. Wipe the differential case and its 1. park the vehicle on level ground surrounding with a rag thorough- and apply the parking brake firmly. 2. stop the engine and let the engine 12.
  • Page 133 MaiNteNaNce 5. if the color or viscosity of the oil is 10. Wipe the differential case and its not normal or it is at the oil change surrounding with a rag thorough- interval, change the oil. 11. test drive the vehicle for 5 to 10 minutes to check for leakage.

  • Page 134: Checking Drive Shaft And Cv Boots (V)

    1600xD4 ChECkING DRIVE shAfT AND ChECkING sTEERING RACk CV BooTs (V) BooTs AND BAll JoINT (W) 1. park the vehicle on level ground 1. park the vehicle on level ground and apply the parking brake firmly. and apply the parking brake firmly.

  • Page 135: Checking Brake Fluid (X)

    MaiNteNaNce IMpoRTANT ChECkING BRAkE flUID (X) The components related to  the steering operation direct- 1. park the vehicle on level ground ly affect your safety. If a condi- and apply the parking brake firmly. tion of such components is in 2.

  • Page 136: Checking Brake Pedal Free Play (Y)

    1600xD4 ChECkING BRAkE pAD (z) ChECkING BRAkE pEDAl fREE plAy (y) the master cylinder rod of the vehi- 1. park the vehicle on level ground Brake fluid Dot 3 cle is adjusted so that the brake ped- and apply the parking brake firmly.

  • Page 137: Checking Parking Brake (Aa)

    MaiNteNaNce ChECkING pARkING BRAkE (AA) 5. if any of the brake pads on either NoTE side of the disc is too thin, close to the vehicle should be stopped  0.04 in. (1 mm), both pads for that on a slope (up to 10 degrees) disc as well as the pads for the when the parking brake is ful- wheel on the other side should be...
  • Page 138 1600xD4 7. if the parking brake pads should be replaced with new ones or ab- normal wear is found on the disc, contact your Dealer. UUVO748A UUVO749A (1) parking brake cable (1) Disc pad 3. adjust the length of the parking 4.

  • Page 139: Adjusting Suspension (Ab)

    MaiNteNaNce ADJUsTING sUspENsIoN (AB) the rear suspension equipped on 4. unscrew the wheel nuts complete- 6. after adjustment, install the wheel this vehicle is adjustable, to allow for ly to remove the wheel. and tighten the wheel nuts firmly. ride quality and weight hauling. to WARNING adjust the suspension, perform the following steps:...

  • Page 140: Checking Suspension

    1600xD4 ChECkING sUspENsIoN BATTERy (sEAlED) (AD) shoCk ABsoRBER (AC) INspECTIoN REplACEMENT if the shock absorber is malfunc- Never open or service the battery IMpoRTANT tioning, your riding comfort can be and never add electrolyte to the bat- The battery discharges natu- harmed.
  • Page 141 MaiNteNaNce 1. park the vehicle on level ground CAlIfoRNIA BATTERy WARNING and apply the parking brake firmly. The battery terminals and ca-  2. stop the engine. bles contains lead. The body accumulates lead which can cause cancer. Make sure to wash your hands after han- dling these parts.

  • Page 142: Replacing Headlamp Bulb (Ae)

    1600xD4 REplACING hEADlAMp BUlB (AE) 1. park the vehicle on level ground WARNING and apply the parking brake firmly. The battery gas is dangerous  2. stop the engine, open the hood enough to cause explosion. and support the hood.

  • Page 143: Checking And Replacing Fuse (Af)

    MaiNteNaNce ChECkING AND REplACING MAIN fUsE (sloW-BloW fUsE) (AG) fUsE (Af) 1. park the vehicle on level ground and apply the parking brake firmly. ALTER- ENGINE DISPLAY HEAD NATOR / RADIATOR 2. stop the engine, open the hood STOP UNIT LAMP LAMP HOLD COIL...

  • Page 144: Aligning Wheel And Checking Wheel Nut (Ah)

    1600xD4 AlIGNING WhEEl AND ChECkING WhEEl NUT (Ah) 4. Wrap the fuse with insulation tape 1. park the vehicle on level ground WARNING after replacement. Make sure that and apply the parking brake firmly. Driving with loose wheel nuts the inspection shield is visible.

  • Page 145: Checking Differential Lock Cable (Ai)

    MaiNteNaNce ChECkING DIffERENTIAl ChECkING shIfT AND 4WD loCk CABlE (AI) CABlEs (AJ) WARNING you can get burnt by touching  hot parts, such as the muffler. Make sure the vehicle is not hot before starting servicing. 3. unscrew the nut and adjust the cable length.

  • Page 146: Using Biodiesel (Ak)

    1600xD4 UsING BIoDIEsEl (Ak) ADJUsTING BElT TENsIoN (Al) 3. unscrew nut 1 and adjust the 1. it is allowed to use 5% biodiesel the engine belt drives the alterna- length of the shift cable. fuel. if biodiesel fuel of higher ratio tor and coolant pump.

  • Page 147: Washing (Am)

    MaiNteNaNce WAshING (AM) 3. loosen the adjusting bolt on the it is recommended to wash your ve- top of the alternator as well as the hicle with water of moderate pres- hinge bolt on the bottom of the al- sure and with or without soap. When ternator.

  • Page 148: Protecting Plastic And Painted Surface(Ao)

    1600xD4 pRoTECTING plAsTIC AND pAINTED sURfACE(Ao) Do not wipe any plastic parts if they are not washed. spraying insecticide can damage the plastic and painted surface. Never spray insecticide near the vehicle. Do not spill the brake fluid on the vehicle parts.

  • Page 149: Stroage And Disposal

    STROAGE AND DISPOSAL vEhIcLE STORAGE ............ 8-2 daily storage ............. 8-2 long-term storage ..........8-2 Using vehicle after long-term storage ..8-3 DISPOSAL ..............8-4...

  • Page 150: Vehicle Storage

    1600Xd4 vEhIcLE STORAGE DAILy STORAGE LONG-TERm STORAGE 1. Keep the vehicle clean when it is follow the instructions below if the 6. Keep the vehicle in a dry place stored. make sure to wash it after vehicle is not to be used for a long where the vehicle is sheltered work.

  • Page 151: Using Vehicle After Long-Term Storage

    stroage and disPosal USING vEhIcLE AfTER LONG- TERm STORAGE 14. if the machine is being operat- 1. check the tire inflation pressure 9. stop the engine and check for oil ed with Bio-diesel, drain the bio- and inflate the tires if they are low. leakage. repair the vehicle as diesel and fill the standard diesel necessary.

  • Page 152: Disposal

    1600Xd4 DISPOSAL in order to protect the environment, use and dispose of the vehicle keep- ing the following in mind: 1. 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.

  • Page 153: Troubleshooting

    TROUBLESHOOTING vEHIcLE TROUBLESHOOTING ......... 9-2...

  • Page 154: Vehicle Troubleshooting

    1600XD4 This troubleshooting chart summarizes simple service items for users who are familiar with mechanical systems. For more detailed service items, contact your local Dealer. vEHIcLE TROUBLESHOOTING Problem check item Maintenance code 1. Start motor cannot run Blown main fuse (slow-blow fuse: near start motor cable) ...
  • Page 155 TROUBLESHOOTING Problem check item Maintenance code 2. Engine is hard to start Fuel with low cetane used  (with start motor running) No operation of solenoid valve  Injection pump malfunctioning  Too high viscosity of engine oil (improper type of oil) ...
  • Page 156 1600XD4 Problem check item Maintenance code 3. Engine power is insufficient Poor injection nozzle condition or carbon accumulated onto it  (knocking, vibration, smoke) Improper valve clearance  4. Engine is overheated Clogged radiator grille and core  Insufficient or leaking coolant (loose hose connection) ...
  • Page 157 TROUBLESHOOTING Problem check item Maintenance code 4. Engine is overheated Insufficient engine oil  5. Engine stops abruptly during Insufficient fuel or clogged filter and hose  operation Air in fuel line or contaminated fuel  Seizure due to overheated engine ...
  • Page 158 1600XD4 Problem check item Maintenance code 7. Battery is discharged Electrical devices (headlamps, work lamps, turn signal lamps, etc) left "ON"  Natural discharge due to no operation for a long period of time  No charging due to faulty alternator, faulty alternator wiring connection ...
  • Page 159 TROUBLESHOOTING Problem check item Maintenance code 10. Vehicle cannot escape a pit Differential lock system malfunction (improperly adjusted differential lock cable)  or rough road 11. Power is insufficient to drive Shift lever not in "L" position  uphill 4WD not used ...
  • Page 160 1600XD4 Problem check item Maintenance code 15. Parking brake is malfunc Improperly adjusted parking brake cable  tioning (vehicle rolls down on slope) Worn parking brake pad  16. Steering wheel feels heavy Insufficient inflation pressure of front tires ...

  • Page 161: Index

    INDEX index................10-2...
  • Page 162 1600XD4 nUMeRiCAL cautions for Decal maintenance ......1-23 12V power outlet ............4-12 changing coolant (Q) ..........7-21 2wD/4wD shift leVer ............4-21 changing engine oil anD filter (f) ......7-11 4wD operation ..............5-24 check item .................5-2 checking air hose anD clamp(i) .......7-13 checking anD changing front aXle oil (t) ..7-25 accelerator peDal ............4-23...
  • Page 163 inDeX checking steering rack boots anD ball joint (w) ..7-28 DriVing on slope ............5-15 checking suspension shock absorber (ac) ..7-34 DriVing through water ..........5-17 checking warning lamps after starting engine ..5-5 Dust ValVe (g)..............7-12 cleaning raDiator core (o) ........7-19 combination switch ............4-9 controls ................4-19 electric cooling fan motor ........4-4 controls anD features ..........4-1...
  • Page 164 1600XD4 general specifications ..........3-3 long-term storage ............8-2 glow plug inDicator ...........4-17 lower fuel leVel warning inDicator ....4-18 lubricants .................7-6 haZarD lamp switch ............. 4-11 heaD light high beam lamp ........4-16 main fuse (slow-blow fuse) (ag) ......7-37 heaDlamp ................4-5 maintenance ..............7-1 heaDlamp switch ............4-10...
  • Page 165 inDeX safety Decal ..............1-19 parking ................5-12 safety precautions ............1-1 parking brake inDicator ..........4-17 safety precautions During serVicing ....1-14 parking brake leVer ............4-22 safety precautions when using the rops ..1-18 precautions before operation ........1-2 seat ..................4-24 precautions before operation ........2-1 seat belt ................4-24 precautions During operation ........1-4 shift leVer ..............4-19 pre-operation ..............5-2...
  • Page 166 1600XD4 using Vehicle after long-term storage ....8-3 tire treaD patterns .............4-30 towing trailer ...............5-22 transporting ..............5-23 Vehicle iDentification number ........2-2 transporting cargo ...........5-19 Vehicle serial number ..........2-2 troubleshooting ............9-1 Vehicle storage ..............8-2 turf ..................4-31 Vehicle troubleshooting ...........9-2 turn signal lamp ............4-17 turn signal lamp switch ..........4-10...
  • Page 168 Read all this manual to become thoroughly familiar with this vehicle. Pay particular attention to all notes, cautions and warnings. 1451 Marvin Gri n Road, Augusta, GA 30906 (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.

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