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Husqvarna HUV 4421 4421-D/DX/DXL User Manual

Huv 4421 series gas and diesel utility vehicles
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HUV 4421 Owner's Manual
4421-G/GX/GXL Gas and
4421-D/DX/DXL Diesel Utility Vehicles
[Refer to back cover for applicable build code range]

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  Summary of Contents for Husqvarna HUV 4421 4421-D/DX/DXL

  • Page 1 HUV 4421 Owner’s Manual 4421-G/GX/GXL Gas and 4421-D/DX/DXL Diesel Utility Vehicles [Refer to back cover for applicable build code range]...
  • Page 3 Your authorized representative checked the vehicle before it was delivered to you and will provide you a copy of the completed vehicle warranty registration form. Husqvarna is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual.
  • Page 4 We hope you will consider this owner’s manual a permanent part of your Husqvarna vehicle. If you sell the vehicle, please include the manual so that the next owner will have the important operating, safety, and maintenance information it contains.
  • Page 5: Table Of Contents

    TABLE OF CONTENTS Safety Decal and Feature Identification ... 5 Practice Safety ... 10 Proposition 65 – State of California ... 10 Safety Details ...11 General Warnings...11 General Information ... 14 Model Identification... 14 Controls and Indicators ... 15 Roll-Over Protective Structure and Seat Belts... 20 Seat Latch and Adjustment ...
  • Page 6 Vehicle Specifications ... 56 Warranties... 59 Page 4 HUV 4421 Owner’s Manual...
  • Page 7: Safety Decal And Feature Identification

    Safety Decal and Feature Identification SAFETY DECAL AND FEATURE IDENTIFICATION The following pages contain safety decal and feature identification information. For detailed information on specific features, read the appropriate section in this manual. HUV 4421 Owner’s Manual Page 5...
  • Page 8 Safety Decal and Feature Identification ALL HUV 4421 TWO PASSENGER MODELS Decal, Gasoline Fuel Warning (at fuel fill or on 101547601 frame, near fuel tank) Decal, Winch Safety Warning (on vehicle body, 102231601 below seat) Decal, Hot Pressurized Fluid Warning (on coolant 102427501 reserve tank cap, under hood) Decal, Hot Surface Warning (on coolant pipes and...
  • Page 9 ALL HUV 4421 TWO PASSENGER MODELS Decal, Trailer Hitch Tongue Weight Notice (on 1011553 trailer/receiver hitch) Decal, Crush Area Warning (behind seat, near 101609401 cargo bed) 102224001 Decal, Rotating Parts Warning (on frame) Decal, Bed Latch Warning (on vehicle body, below 102459301 bed latch) 102459401...
  • Page 10 Safety Decal and Feature Identification ALL HUV 4421 FOUR PASSENGER MODELS Decal, Gasoline Fuel Warning (at fuel fill or on 101547601 frame, near fuel tank) Decal, Winch Safety Warning (on vehicle body, 102231601 below seat) Decal, Hot Pressurized Fluid Warning (on coolant 102427501 reserve tank cap, under hood) Decal, Hot Surface Warning (on coolant pipes and...
  • Page 11 ALL HUV 4421 FOUR PASSENGER MODELS Decal, Trailer Hitch Tongue Weight Notice (on 1011553 trailer/receiver hitch) Decal, Crush Area Warning (behind seat, near 101609401 cargo bed) 102224001 Decal, Rotating Parts Warning (on frame) Decal, Bed Latch Warning (on vehicle body, below 102459301 bed latch) 102459401...
  • Page 12: Practice Safety

    Practice Safety PRACTICE SAFETY Figure 1 Practice Safety Safety signs like you see above may at first seem shocking, but their impact is mild compared with the reality of severe personal injury. Your safety and satisfaction are of the utmost importance to us. That is why before operating the vehicle, we urge you to review the information in this manual.
  • Page 13: Safety Details

    SAFETY DETAILS WARNING • This owner’s manual should be read completely before attempting to drive or service the vehicle. Failure to follow the instructions in this manual could result in property damage, severe personal injury, or death. It is important to note that some vital statements throughout this manual and on the decals affixed to the vehicle are preceded by the words DANGER, WARNING, or CAUTION.
  • Page 14 General Warnings WARNING • Follow the procedures exactly as stated in this manual, and heed all DANGER, WARNING, and CAUTION statements in this manual as well as those on the vehicle. • Do not leave children unattended on vehicle. • Children requiring a child safety seat must not ride on the vehicle. Comply with state and local laws pertaining to child safety.
  • Page 15 Please contact your nearest Husqvarna dealer or distributor for information on how to properly recycle your batteries. Figure 3 All-Wheel Drive Warning HUV 4421 Owner’s Manual...
  • Page 16: General Information

    General Information 1403 Figure 4 Dispose of Lead-acid Batteries Properly GENERAL INFORMATION This manual includes operating procedures, maintenance, and regular servicing information for all gasoline and diesel HUV 4421-G and HUV 4421-D vehicles. GXP and DXP models have been renamed GX and DX, respectively. All operating procedures, maintenance, and regular servicing are identical unless otherwise noted.
  • Page 17: Controls And Indicators

    1400 Figure 5 Serial Number Decal CONTROLS AND INDICATORS See General Warnings on page 11. WARNING • Before allowing anyone to drive the vehicle, make sure the driver is familiar with all controls and operating procedures. • Do not tamper with the high idle speed setting on the diesel vehicle. Doing so will void the warranty, as well as damage the engine and other components, and could result in property damage, personal injury, or death due to unsafe speeds.
  • Page 18 Controls and Indicators Page 16 HUV 4421 Owner’s Manual Figure 6 Instrument Panel – Gasoline Vehicles Figure 7 Instrument Panel – Diesel Vehicles...
  • Page 19 KEY SWITCH – GASOLINE VEHICLES The key switch (7) is mounted on the instrument panel to the right of the steering column (Figure 6). It has three positions: OFF, ON, and START. To start the vehicle, place the Forward/Reverse handle in the NEUTRAL position and turn the key to the START position, and hold it there until the engine starts.
  • Page 20 Controls and Indicators BRAKE PEDAL The brake pedal (2) is located to the immediate left of the accelerator pedal (Figure 6 and Figure 7). To slow or stop the vehicle, press the brake pedal. PARK BRAKE The park brake pedal (3) is located to the left of the brake pedal (Figure 6 and Figure 7). To engage the park brake, first apply pressure to the brake pedal, then firmly press the park brake pedal until it latches into place.
  • Page 21 12-VOLT ACCESSORY OUTLET The 12-volt accessory outlet (11) is located to the right of the key switch (Figure 6 and Figure 7). It provides a constant 12VDC with the key switch in the ON or OFF position. See following NOTE. NOTE: Extended use of this accessory outlet can cause the battery to become heavily discharged.
  • Page 22: Roll-Over Protective Structure And Seat Belts

    See following WARNING. WARNING • The ROPS must be properly installed before operating the vehicle. Husqvarna strongly urges that the vehicle’s occupants be properly restrained at all times with the seat belts provided. Pregnant woman: Consult your doctor for specific recommendations. The safety belt should be worn securely and as low as possible over the hips and not on the waist.
  • Page 23: Seat Latch And Adjustment

    WARNING • Do not operate the vehicle with the ROPS removed. Doing so could result in property damage, personal injury, or death. • Do not remove or modify any component of the ROPS structure. Doing so will result in voiding the ROPS certification and could weaken the ROPS, resulting in serious injury or death.
  • Page 24: Pre-Operation And Daily Safety Checklist

    Pre-Operation and Daily Safety Checklist WARNING • Do not adjust the driver-side seat while the vehicle is in motion. To adjust the passenger-side seat Remove the seat from the vehicle. Remove the four bolts and washers from the bottom of the seat mounting plate. Align the mounting plate holes with holes in the seat to achieve the desired seat position.
  • Page 25: Driving Instructions

    PERFORMANCE INSPECTION After you have familiarized yourself with the vehicle controls and have read and understood the driving instructions, take the vehicle for a test drive. Use the following list, in addition to the Pre-Operation and Daily Safety Checklist, as a guide to inspect the vehicle daily for proper operation.
  • Page 26 Driving Instructions WARNING • Stop the vehicle before shifting the Forward/Reverse handle. Engine must be at idle before shifting the Forward/Reverse handle. Failure to do so may result in injury to inattentive passengers and (or) damage to the vehicle. • To help avoid being struck, do not stand in front of or behind the vehicle. •...
  • Page 27 Press and hold the brake pedal. To start the vehicle 8.1. Gasoline vehicles: Turn the key to the START position and hold it there until the engine starts. Activate the choke as necessary. If the engine does not start after 10-15 seconds, release the key and repeat the procedure.
  • Page 28: Bed Latch And Prop Rod

    Bed Latch and Prop Rod WARNING • Reduced steering control can occur if the front differential becomes locked. To help prevent this condition, avoid extremely hard braking in reverse. STOPPING THE VEHICLE To stop the vehicle, release the accelerator pedal and press the brake pedal until the vehicle comes to a complete stop. See following WARNING and CAUTION.
  • Page 29: Loading And Unloading Cargo

    WARNING persons are clear of cargo bed area. Keep hands clear of all crush areas. Do not drop cargo bed; lower gently and keep entire body clear. Failure to heed this warning could result in severe personal injury or death. NOTE: HUV 4421 gas and diesel vehicles are equipped with an automatically engaging prop rod (Figure 11), unless equipped with the electric bed lift accessory.
  • Page 30: Vehicle Load Capacities

    Vehicle Load Capacities WARNING • Unload cargo bed before raising vehicle with a lift, hoist, or jack. • Avoid stopping on a hill when loaded. If you must stop on a hill, avoid sudden starts, or rolling backwards and stopping suddenly. Failure to heed this warning may cause vehicle to overturn, possibly resulting in severe personal injury.
  • Page 31: Towing With The Vehicle

    Figure 12 Vehicle Load Capacity – Two-Passenger Vehicles TOWING WITH THE VEHICLE WARNING • Do not tow a vehicle or trailer on public streets or highways. • Normal vehicle operating speed should be reduced when towing. • Extreme caution should be used when towing. •...
  • Page 32: Storage

    Storage WARNING • Avoid stopping on a hill when towing. If you must stop on a hill, avoid sudden starts, or rolling backwards and stopping suddenly. Failure to heed this warning could cause the vehicle to overturn, possibly resulting in severe personal injury. •...
  • Page 33 4.3. Disconnect the fuel vent line from the fuel tank vent nipple (Figure 34). 4.4. Plug the fuel tank vent nipple so that it is air tight. Husqvarna recommends using a slip-on vinyl cap. Remove both spark plugs, and pour 1/2 ounce (14.2 mL) of SAE 10 weight oil through each of the two spark plug holes.
  • Page 34: Maintenance

    Maintenance Disconnect battery and spark plug (Gas only) wires. See Disconnecting the Battery – Gasoline/Diesel Vehicle on page 13. The battery should be clean and free of corrosion. Wash the battery top and terminals with a solution of baking soda and water (1 cup (237 mL) baking soda per 1 gallon (3.8 L) of water). Rinse the solution off the battery. Do not allow this solution to enter the battery.
  • Page 35: Periodic Service Schedule

    WARNING • If any problems are found during scheduled inspection or service, do not operate vehicle until repairs are made. Failure to make necessary repairs could result in fire, property damage, severe personal injury, or death. • Do not wear loose clothing or jewelry such as rings, watches, chains, etc., when servicing the vehicle. •...
  • Page 36 Periodic Service Schedule PERIODIC SERVICE SCHEDULE REGULAR INTERVAL Daily service by owner Daily service by owner or trained technician Monthly service by owner or trained technician Semiannual service by trained technician only (or every 50 hours of operation, whichever comes first) Page 34 HUV 4421 Owner’s Manual SERVICE...
  • Page 37 PERIODIC SERVICE SCHEDULE REGULAR INTERVAL Annual service by trained technician only (or every 100 hours of operation, whichever comes first) WARNING • If any problems are found during scheduled inspection or service, do not operate vehicle until repairs are made. Failure to make necessary repairs could result in fire, property damage, severe personal injury, or death.
  • Page 38: Periodic Lubrication Schedule

    Periodic Lubrication Schedule PERIODIC LUBRICATION SCHEDULE PERIODIC LUBRICATION SCHEDULE REGULAR INTERVAL SERVICE Gasoline vehicle: Kawasaki engine- First change 10 hours Diesel vehicle: First change 50 hours Change engine oil and oil filter Additional change for all engines every 100 hours of operation or annually, whichever comes first.
  • Page 39 Periodic Lubrication Schedule Figure 15 Lubrication Points – Gasoline Vehicles Figure 16 Lubrication Points – Diesel Vehicles HUV 4421 Owner’s Manual Page 37...
  • Page 40: Brake Fluid Reservoir

    Brake Fluid Reservoir BRAKE FLUID RESERVOIR Figure 17 Brake Fluid and Coolant Access (diesel vehicle shown) The brake fluid reservoir (1) is located under the hood (Figure 17). Raise the hood to check the brake fluid level. During the brake fluid level inspection, also inspect the following: •...
  • Page 41: Engine Oil

    ENGINE OIL Even though the low oil warning light on the instrument panel should illuminate if the oil level becomes low, the engine oil level should be checked daily. The vehicle should be on a level surface when the oil is checked. Do not overfill the engine with oil.
  • Page 42 Engine Oil 1. Full Level 2. Safe Level 3. Low Level Figure 19 Engine Oil Level Check – Kawasaki Gasoline Vehicles ENGINE OIL AND FILTER CHANGE The engine oil and oil filter should be changed at the following intervals: • Kawasaki gasoline engine: after the first 10 hours of operation. •...
  • Page 43 Use a socket or wrench to replace the oil drain plug (1) (Figure 21 or Figure 22). Turn the plug clockwise and tighten to 61 in-lb (6.9 N·m) for Kawasaki gas vehicles with plastic drain plugs, 14.5 ft-lb (20 N·m) for Kawasaki gas vehicles with metal drain plugs, or 31 ft-lb (42 Nm) for diesel vehicles.
  • Page 44 Engine Oil NOTE: An oil drip guard (1) can be used to prevent excess oil from dripping onto the engine base plate (Figure 24). Use an empty quart (one liter) container and cut the bottom off at an angle, then slide the open area of the container up and under the oil filter (2) before removal.
  • Page 45 Figure 26 Add Engine Oil – Gasoline Vehicles Engine Oil Filling Add engine oil (Figure 26 or Figure 27). With filter change, the engine requires the following amounts: – Kawasaki gasoline engines: 1 qt. and 19 oz. (1.5 L) of oil per change. –...
  • Page 46: Gearcase Lubrication

    Gearcase Lubrication NOTE: Use engine oil with API classification SJ for gasoline engines and CF for diesel engines. Using multi-grade oils (5W-20, 10W-30, and 10W-40) may increase oil consumption. If multi-grade oil is used, check the oil level more frequently. Figure 28 Oil Viscosity Chart –...
  • Page 47 Gearcase Lubrication Figure 30 Front Differential Lubrication Level Figure 31 Transmission Lubrication Level Transmission: Clean and install the drain plug (2) before filling the transmission with new lubricant (Figure 31). Tighten the drain plug to 96 in-lb (11 N·m). Remove the fill plug from the top of the transmission case and use a funnel to fill the transmission with lubricant.
  • Page 48: Engine Coolant - Diesel Vehicles

    Engine Coolant – Diesel Vehicles Figure 32 Rear Differential Lubrication Level ENGINE COOLANT – DIESEL VEHICLES ENGINE COOLANT LEVEL CHECK The coolant reserve tank (2) is located under the hood on the passenger side (Figure 17). Raise the hood to check the coolant level before every operation.
  • Page 49: Air Intake System

    Remove the air filter cartridge (1). See following NOTE. NOTE: The air filter cartridge is specifically designed for this engine. It only fits into the canister one way. Use only the Husqvarna part (P/N 603 00 00-10) designed for this engine. Figure 33 Air Filter Cartridge Air Filter Installation Push the new air filter cartridge onto the nozzle inside the canister.
  • Page 50: Fueling Instructions

    Fueling Instructions FUELING INSTRUCTIONS See General Warnings on page 11. DANGER • Turn the key switch to the OFF position before fueling. • Do not pour fuel into the fuel tank when the engine is hot or while it is running. •...
  • Page 51 Biodiesel is an excellent medium for microbial growth and contamination. Microbial contamination can cause corrosion of the fuel system and prematurely plugged fuel filters. See following NOTE. NOTE: Use of biodiesel may result in premature failure of fuel system components. Kubota has documented problems such as plugged fuel filters and deteriorated fuel lines during testing of biodiesel.
  • Page 52: Battery

    Battery WARNING • Clean up spilled fuel. Keep sparks and flames away from the vehicle and service area. Failure to heed this warning could result in an explosion or fire, resulting in severe personal injury or death. Close the valve by rotating it counterclockwise until the valve is firmly sealed. To resupply the filter with fuel, turn the key switch to the ON position for 10 seconds.
  • Page 53 DANGER – Eyes: Flush with water for 15 minutes. Call a physician immediately. • Tools, wires, and metal objects can cause sparks when shorted across a battery. WARNING • Wear safety glasses or approved eye protection when servicing the vehicle. •...
  • Page 54: Using A Booster Battery (Jump Starting)

    Using A Booster Battery (Jump Starting) WARNING • Wear safety glasses or approved eye protection when servicing the vehicle. Wear a full face shield and rubber gloves when working on or near batteries. Carefully check the electrolyte level and add distilled water if necessary. Do not fill the battery cells above the designated fill line.
  • Page 55: Cleaning The Vehicle

    CAUTION • The alternator can be damaged if the following actions occur: – Engine is operated with battery cables disconnected. – Booster cables are connected wrong. Figure 39 Jump Starting CLEANING THE VEHICLE Each vehicle is equipped with hand-washable front and rear bodies. The vehicle has a powder-coated steel cargo bed (or optional aluminum flat bed).
  • Page 56: Accessories

    Accessories ACCESSORIES There is a complete line of accessory equipment available from our dealers/distributors. Care should be taken that these accessories are properly installed by trained technicians and that they are used in the manner for which they were designed. See following WARNING and CAUTION. WARNING •...
  • Page 57: Subsequent Owner Registration

    In the event a vehicle is bought as a used vehicle, we strongly urge the new owner to register the vehicle with Husqvarna. This will enable us to contact you if the need arises. Please send your name, address, and serial number of the vehicle to Husqvarna, 7349 Statesville Rd., Charlotte, NC 28269, Attention: Vehicle Registration.
  • Page 58: Vehicle Specifications

    Vehicle Specifications VEHICLE SPECIFICATIONS SPECIFICATIONS POWER SOURCE Engine: (Kawasaki) 4-cycle OHV, 675 cc, 23.0 maximum HP @3600 RPM (per SAE J 1940/1349), twin-cylinder, air-cooled, with pressure lubrication system Engine: 4-cycle OHV, 719 cc, 20.0 maximum HP @3600 RPM (per SAE J 1940/1349), three-cylinder, liquid-cooled, with pressure lubrication system Fuel system: Side-draft carburetor with float bowl, fixed jets, fuel filters, and impulse fuel pump...
  • Page 59 SPECIFICATIONS Overall width: without mirror with mirror *Overall height (with ROPS): with mud tires with all-terrain tires Wheelbase Ground clearance: under differential Front and rear wheel tread *Weight: 2-passenger gasoline with electric bed lift, mud tires, and without brush guard 2-passenger diesel with electric bed lift, mud tires, and brush guard 4-passenger gasoline with all-terrain tires 4-passenger diesel with all-terrain tires...
  • Page 60 Vehicle Specifications SPECIFICATIONS Rear differential: Mobil 424, Exxon Hydraul 560, or Esso Hydraul 56 lubricant Transmission: Mobil 424, Exxon Hydraul 560, or Esso Hydraul 56 lubricant Engine coolant: mixture of 55% propylene glycol and 45% water Brake fluid: DOT 5 (silicone) brake fluid Fuel tank: unleaded gasoline Fuel tank: diesel grade no.2 with cetane rating of 45 or higher TIRE PRESSURE...
  • Page 61 Portable Refreshment Center, and all other original equipment options and accessories supplied by Husqvarna are warranted with respect to parts and labor against defects in material and workmanship for a period of one year or 1000 hours of operation, whichever first occurs, from the date of purchase.
  • Page 62 (“SORE”) must be designed, built and equipped to meet the State’s stringent anti-smog standards. HUSQVARNA shall warrant the emission control system on the vehicle engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your small off-road engine.
  • Page 63 - As the vehicle engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. HUSQVARNA recommends that you retain all receipts covering maintenance on your vehicle engine, but HUSQVARNA cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
  • Page 64 MANNER OR SHOWS INDICATIONS THAT IT HAS BEEN ALTERED IN ANY WAY, INCLUDING, BUT NOT LIMITED TO, MODIFICATION OF THE SPEED GOVERNOR, BRAKING SYSTEM, STEERING, TRANSAXLE, OR OTHER OPERATING SYSTEMS OF THE VEHICLE TO CAUSE IT TO PERFORM OUTSIDE HUSQVARNA SPECIFICATIONS. 4. HOW TO MAKE A WARRANTY CLAIM:...
  • Page 68 BC55503 Publication Part Number 103472526 Edition Code 0708D1010C This manual is valid for vehicles built during the 2009 model year. It is also valid for vehicles with build codes between 54699 and the one indicated at the top of this page.