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Husqvarna HUV 4421-G / GXP Owner's Manual

Husqvarna utility vehicle user manual.
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2007
Utility Vehicles
Gasoline and Diesel
Owner's Manual
HUV 4421-G / GXP
HUV 4421-D / DXP

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   Summary of Contents for Husqvarna HUV 4421-G / GXP

  • Page 1

    2007 Utility Vehicles Gasoline and Diesel Owner’s Manual HUV 4421-G / GXP HUV 4421-D / DXP...

  • 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

    Husqvarna representative perform them. For the name and address of the Husqvarna representative nearest you, logon to our web site at www.usa.husqvarna.com. If you would prefer to write to us, direct your letter to: Husqvarna, Attention: Marketing Services, 7349 Statesville Rd., Charlotte, NC 28269 USA. Your local autho- rized Husqvarna representative can also provide technical advice, parts, and service manuals.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Safety Details ... General Warnings ... General Information ... 10 Model Identification ... 10 Controls and Indicators ... 10 Roll-Over Protective Structure and Safety Belts ... 15 Seat Latch and Adjustment ... 16 Pre-Operation and Daily Safety Checklist ... 17 Performance Inspection ...

  • Page 6

    Vehicle Feature Identification ALL HUV 4421 MODELS DIESEL WARNING DECAL (DIESEL VEHICLES ONLY, GASOLINE WARNING DECAL ON PASSENGER-SIDE SEAT SUPPORT) (GASOLINE VEHICLES ONLY, ON PASSENGER-SIDE SEAT SUPPORT) OPERATING INSTRUCTIONS (ON INSTRUMENT PANEL) HOT MANIFOLD WARNING DECAL (ON ENGINE VALVE COVER) WINCH CABLE WARNING DECAL (FOR VEHICLES WITH WINCH ACCESSORY) FRAME GROUND WARNING DECAL...

  • Page 7: Vehicle Feature Identification

    ALL HUV 4421 MODELS DRIVER/PASSENGER WARNING DECAL ROTATING PARTS DECAL - DIESEL (UNDER SEAT ON DRIVER-SIDE FRAME) SERIAL NUMBER DECAL CRUSH AREA DECAL (ON DRIVER SIDE AND PASSENGER SIDE) VEHICLE LOADING DECAL (STANDARD VEHICLE) (HIGH-CAPACITY OPTION) 2007 HUV 4421 Gasoline and Diesel Vehicle Owner’s Manual Vehicle Feature Identification UNDERAGE WARNING DECAL...

  • Page 8

    Vehicle Feature Identification Page 6 2007 HUV 4421 Gasoline and Diesel Vehicle Owner’s Manual...

  • Page 9: Safety Details

    SAFETY DETAILS ý 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 vehi- cle are preceded by the words DANGER, WARNING, or CAUTION.

  • Page 10: General Warnings

    GENERAL WARNINGS The following safety statements must be heeded whenever the vehicle is being operated, repaired, or ser- viced. Safety decal identification information is also included beginning on page 4. Other specific safety state- ments appear throughout this manual and on the vehicle. ý...

  • Page 11

    ý WARNING • Only trained technicians should service or repair the vehicle. Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair. The appropriate instructions must be used when performing maintenance, service, or accessory installation.

  • Page 12: General Information

    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. All operating procedures, maintenance, and regular ser- vicing are identical unless otherwise noted. MODEL IDENTIFICATION The serial number of each vehicle is printed on a bar code decal mounted on the frame above the brake pedal (Example: RC0601-123456) (Figure 3).

  • Page 13

    OPERATING INSTRUCTIONS Figure 4 Instrument Panel – Gasoline Vehicles OPERATING INSTRUCTIONS Figure 5 Instrument Panel – Diesel Vehicles 2007 HUV 4421 Gasoline and Diesel Vehicle Owner’s Manual Controls and Indicators START PREHEAT START Page 11...

  • Page 14: Accelerator Pedal

    KEY SWITCH – GASOLINE VEHICLES The key switch (7) is mounted on the instrument panel to the right of the steering column (Figure 4, Page 11). 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 15: Brake Pedal

    BRAKE PEDAL The brake pedal (2) is located to the immediate left of the accelerator pedal (Figure 4 and Figure 5, Page 11). 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 4 and Figure 5, Page 11). 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 16: Low Oil Warning Light

    LOW OIL WARNING LIGHT The low oil warning light (9) is located on the instrument panel just to the left of the steering column (Figure 4 and Figure 5, Page 11). If the warning light lights up, oil should be checked and added to the engine as nec- essary before vehicle use continues.

  • Page 17: Roll-over Protective Structure And Safety Belts

    ý 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 safety 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 18: Seat Latch And Adjustment

    ý WARNING • After inserting the tab, make sure the tab and buckle are locked and that the belt is not twisted. • Loose fitting safety belts could increase the chance of injury due to sliding under the belt if sudden braking should occur.

  • Page 19: Pre-operation And Daily Safety Checklist

    To adjust the passenger-side seat 1. Remove the seat from the vehicle. 2. Remove the four bolts and washers from the bottom of the seat mounting plate. 3. Align the mounting plate holes with holes in the seat to achieve the desired seat position. 4.

  • Page 20: Performance Inspection

    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 21: Starting The Vehicle

    ý WARNING - Be sure all passengers are capable of securing themselves in a moving vehicle before allowing them to ride in one. - Be sure all persons can properly operate the vehicle prior to allowing them to drive the vehicle.

  • Page 22

    5. Make sure wheels are turned in desired direction and nothing is in your path. 6. Make sure the Forward/Reverse handle is in the NEUTRAL position. 7. Press and hold the brake pedal. 8. 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.

  • Page 23: Bed Latch And Prop Rod

    Under most circumstances the driver will not need to do anything to engage the AWD system; however, the front differential may become locked (rotate at the same speed regardless of the terrain) under certain condi- tions. If the front differential becomes locked, drive slowly in reverse for at least 10 feet (3 meters), then brake gently.

  • Page 24: Loading And Unloading Cargo

    ý WARNING • For vehicles with cargo beds, remove all cargo before raising the bed or servicing the vehicle. If the vehicle is equipped with a prop rod, ensure that it is securely engaged. Do not close bed until all persons are clear of cargo bed area. Keep hands clear of all crush areas. Do not drop cargo bed;...

  • Page 25: Vehicle Load Capacities

    ý WARNING • Reduce speed and avoid sudden stops when backing up. Failure to do so may cause the vehicle to overturn or flip over backwards. • Maximum cargo load must be reduced by the weight of optional equipment. Center and secure cargo as far forward as possible in the cargo bed. Do not overload the vehicle. See Vehi- cle Load Capacities on page 23 for vehicle capacities.

  • Page 26: Towing With The Vehicle

    Figure 10 Vehicle Load Capacity – Two-Passenger Vehicles TOWING WITH THE VEHICLE ý 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 27: Storage

    ý WARNING • For use on public roads, the trailer must meet all federal, state, and local requirements such as taillights, brake lights, etc. • Never tow a vehicle behind a passenger vehicle or truck on a public road unless it is on an approved trailer.

  • Page 28: Preparing The Vehicle For Extended Storage

    ý CAUT ION • Batteries in a low state of charge will freeze at low temperatures. CLOSED (OFF) POSITION (SELECTOR IS ALIGNED WITH OFF MARKINGS ON THE SIDES OF VALVE) VIEWED FROM SELECTOR SIDE OF VALVE Figure 11 Fuel Shut-off Valve – Closed Position FULL OPEN (ON) POSITION VIEWED FROM SELECTOR...

  • Page 29: Returning The Stored Vehicle To Service

    4.3. Disconnect the fuel vent line from the fuel tank vent nipple (Figure 36, Page 44). 4.4. Plug the fuel tank vent nipple so that it is air tight. Husqvarna recommends using a slip-on vinyl cap. 5. 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 30: Maintenance

    5. Place the Forward/Reverse handle in the NEUTRAL position. Crank the engine until fuel is pumped into the carburetor (gasoline vehicles) and the fuel lines (all vehicles) and the engine starts. Turn the engine off. See following NOTE. NOTE: Due to the oil added to the gasoline engine in preparation for storage, the engine may smoke excessively for a short time when it is run for the first time after storage.

  • Page 31: Periodic Service Schedule

    ý WARNING - Gasoline vehicles only: Disconnect the spark plug wires from the spark plugs. • If wires are removed or replaced make sure wiring and wire harness are properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury, or death.

  • Page 32

    PERIODIC SERVICE SCHEDULE REGULAR INTERVAL Monthly service by owner or trained technician First adjustment after 20 hours, additional every 100 hours of operation Semiannual service by trained technician only (or every 50 hours of operation, whichever comes first) Periodic Service Schedule continued on next page... Page 30 2007 HUV 4421 Gasoline and Diesel Vehicle Owner’s Manual SERVICE...

  • Page 33

    PERIODIC SERVICE SCHEDULE REGULAR INTERVAL Annual service by trained technician only (or every 100 hours of operation, whichever comes first) ý 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 34: Periodic Lubrication Schedule

    PERIODIC LUBRICATION SCHEDULE PERIODIC LUBRICATION SCHEDULE REGULAR INTERVAL SERVICE Gasoline vehicle: Honda engine-First change 20 hours Kawasaki engine- First change 10 hours Diesel vehicle: Change engine oil and oil filter First change 50 hours Additional change for all engines every 100 hours of operation or annually, whichever comes first.

  • Page 35

    Periodic Lubrication Schedule Figure 14 Lubrication Points – Gasoline Vehicles Figure 15 Lubrication Points – Diesel Vehicles 2007 HUV 4421 Gasoline and Diesel Vehicle Owner’s Manual Page 33...

  • Page 36: Brake Fluid Reservoir

    BRAKE FLUID RESERVOIR Figure 16 Brake Fluid and Coolant Access (diesel vehicle shown) The brake fluid reservoir (1) is located under the hood (Figure 16). Raise the hood to check the brake fluid level. During the brake fluid level inspection, also inspect the following: •...

  • Page 37

    NOTE: The normal oil pressure value stated in the Honda engine manual is 28 psi at idle; however, the remote filter design causes oil pressure to be 18 psi, which is normal for this type of oil circulation design. Kawasaki engine: The Kawasaki gasoline engine has an oil filter that is mounted on a bracket between and in front of the engine and transmission.

  • Page 38

    Figure 20 Engine Oil Level Check – Diesel Vehicles With Driver-side Dipstick ENGINE OIL AND FILTER CHANGE Engine oil and oil filter should be changed: • Kawasaki gasoline engine after the first 10 hours of operation. • Honda gasoline engine after the first 20 hours of operation. •...

  • Page 39

    7. Use a socket or wrench to replace the oil drain plug (1) (Figure 22 or Figure 23). Turn the plug clockwise and tighten to 29 ft-lb (40 N·m) for Honda gas vehicles, 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 40

    NOTE: An oil drip guard (1) can be used to prevent excess oil from dripping onto the engine base plate (Figure 26). 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. Position the port of the plastic container so oil will be directed into the oil pan (3).

  • Page 41

    Figure 28 Add Engine Oil – Gasoline Vehicles (Honda Shown) Engine Oil Filling 1. Add engine oil; use a funnel or pour spout to direct the oil into the opening (Figure 28 or Figure 29). With filter change, the engine requires: •...

  • Page 42: 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. SAE 10W-30 SAE 5W-30 Figure 30 Oil Viscosity Chart –...

  • Page 43

    the lubricant level indicator hole (1). See Periodic Lubrication Schedule on page 32. Tighten the level indi- cator plug to 10 ft-lb (14 N·m). Figure 32 Front Differential Lubrication Level Transmission: Clean and install the drain plug (2) before filling the transmission with new lubricant (Figure 33). Tighten the drain plug to 8 ft-lb (11 N·m).

  • Page 44: Engine Coolant - Diesel Vehicles

    Figure 34 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 16). Raise the hood to check the coolant level before every operation. 1.

  • Page 45: Fueling Instructions

    4. Remove the air filter cartridge (1). See following NOTE. NOTE: The air filter cartridge is specifically designed for this engine. It only fits into the canister one way. Use only the Husqvarna part (P/N 603 00 00-10) designed for this engine. Figure 35 Air Filter Cartridge Air Filter Installation 1.

  • Page 46

    NOTE: Gasoline vehicles: Use unleaded gasoline only. Whenever possible, avoid using oxygenated fuels and fuels that are blended with alcohol. Diesel vehicles: Use only diesel fuel grade no. 2 with a cetane rating of 45 or higher. 2. Replace the fuel cap. Ensure that the cap is tightened securely. 3.

  • Page 47

    If biodiesel is used, be sure to apply the following guidelines: • Ensure the fuel tank is as full as possible at all times to prevent moisture from collecting. • Ensure that the fuel tank cap is securely tightened to prevent water from entering the fuel tank. •...

  • Page 48: Battery

    Figure 38 Fuel Filter BATTERY See General Warnings on page 8. ý DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries.

  • Page 49

    The battery in this vehicle is a 12-volt, low-maintenance battery that requires infrequent checks (Figure 39). Electrolyte level should be checked semiannually. FRONT OF VEHICLE Figure 39 Battery 1. Turn the key switch to the OFF position and remove the key. Place the Forward/Reverse handle in the NEUTRAL position.

  • Page 50: Using A Booster Battery (jump Starting)

    USING A BOOSTER BATTERY (JUMP STARTING) ý 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. • When jumping from a booster battery make final connection (negative) at engine frame. •...

  • Page 51: Cleaning The Vehicle

    CLEANING THE VEHICLE Each vehicle is equipped with hand wash-washable front and rear bodies. The vehicle has a powder-coated steel cargo bed (or optional aluminum flat bed). Use commercial automotive cleaning solutions with a sponge or soft cloth for normal cleaning. A garden hose at normal residential water pressure is adequate. To remove oxidation or discoloration from aluminum, use a commercially available aluminum cleaner paste and fine grade (No.

  • Page 52: 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 Registra-...

  • Page 53: Vehicle Specifications

    VEHICLE SPECIFICATIONS SPECIFICATIONS POWER SOURCE Engine: (Honda) 4-cycle OHV, 614 cc, 20.0 maximum HP @3600 rpm (per SAE J 1940/ 1349), twin-cylinder, air-cooled, with pressure lubrication system 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...

  • Page 54: Specifications

    SPECIFICATIONS BODY/CHASSIS, CONTINUED Side and rear body: Plastic Cargo bed: Powder-coated steel or aluminum Front body: Geloy XTWM206 Tires: All Terrain: 25 x 10.5 – 12 front and rear; tubeless, 4-ply rated load range Mud: 25 x 11 – 12 front and rear; tubeless, 4-ply rated load range DIMENSIONS/WEIGHT NOTE: Items marked with an asterisk (*) indicate approximate values.

  • Page 55

    Vehicle Specifications SPECIFICATIONS HUV 4421 HUV 4421 2 gal. Engine coolant: mixture of 55% propylene glycol and 45% water (7.8 L) Brake fluid: DOT 5 (silicone) brake fluid 8 oz. (240 ml) 6.5 gallons Fuel tank: unleaded gasoline (24.6 L) 6.5 gallons Fuel tank: diesel grade no.2 with cetane rating of 45 or higher (24.6 L)

  • Page 56

    Repair shall mean remedying a defect in the vehicle or component thereof at no cost to the purchaser during the applicable limited warranty period. If Husqvarna elects to repair the vehicle, it may provide factory-reconditioned parts or components.

  • Page 57

    6. DISCLAIMER: THIS LIMITED WARRANTY IS EXCLUSIVE. HUSQVARNA MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY HUSQVARNA AND EXCLUDED FROM THIS WARRANTY.

  • Page 58

    TECHNICAL & CONSUMER INFORMATION (GASOLINE ENGINES) Carburetor Modification for High Altitude Operation At high altitude, the standard carburetor air-fuel mixture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. Operation at an altitude that differs from that at which this engine was certified, for extended periods of time, may increase emissions.

  • Page 59

    The emission control systems on your Honda engine were designed, built, and certified to conform with EPA and California emission regulations. We recommend replacement parts be purchased from Husqvarna, Inc.. These original-design replacement parts are manufactured to the same standards as the original parts, so you can be confident of their performance.

  • Page 60: California Emission Control Warranty Statement

    Husqvarna cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. - As the vehicle engine owner, you should however be aware that Husqvarna may deny you warranty coverage if vehicle engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

  • Page 64

    Husqvarna Part Number 531 30 81-86 Edition Code 0706C0307B CCI P/N 103218307...

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