E-Z-GO 4X4 Owner's Manual
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E-Z-GO 4X4 Owner's Manual

E-Z-GO 4X4 Owner's Manual

Off-road diesel utility vehicle
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Summary of Contents for E-Z-GO 4X4

  • Page 1 owner’s manual owner’s manual owner’s manual...
  • Page 3 FORWARD Thank you for choosing our off-road diesel utility vehicle. We are committed to provide the best quality products. It is strongly recommended for all customers and operators to read this owner’s manual thoroughly before using this vehicle 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.
  • 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 SAFETY PRECAUTIONS ....... 1-1 VEHICLE IDENTIFICATION NUMBER ..2-2 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...
  • Page 7 TABLE OF CONTENTS REFLEX REFLECTOR ..........4-7 CONTROLS..........4-20 SAFETY LAMP KIT (OPTIONAL) .......4-8 SHIFT LEVER............4-21 DIFFERENTIAL LOCK LEVER (REAR WHEEL) ..4-21 SWITCHES........... 4-9 2WD/4WD SHIFT LEVER.........4-23 KEY SWITCH .............4-9 BRAKE PEDAL............4-23 COMBINATION SWITCH ......... 4-11 PARKING BRAKE LEVER........4-24 HAZARD LAMP SWITCH (OPTIONAL) ....4-13 ACCELERATOR PEDAL ..........4-25 SPARE SWITCH PANEL ..........4-14 SEAT.................4-25...
  • Page 8 TABLE OF CONTENTS CARGO BED CONTROL LEVER (OPTIONAL) ..4-31 OPERATING PRINCIPLE OF PREHEAT SYSTEM ...5-6 REMOTE HYDRAULIC LEVER (OPTIONAL) ..4-32 STOPPING THE ENGINE ..........5-6 HAND THROTTLE LEVER (OPTIONAL) ....4-33 OPERATING THE VEHICLE ......5-7 CARGO BED EXTENSION (OPTIONAL)....4-33 WORKING LAMP (OPTIONAL)........4-34 HOW TO DRIVE ............5-7 FUEL TANK ..............4-34 WARMING UP ............5-10...
  • Page 9 TABLE OF CONTENTS TRANSPORTING .............5-24 DAILY INSPECTION........7-7 4WD OPERATION............5-25 ACCESS FOR SERVICE..........7-7 DIFFERENTIAL LOCK OPERATION......5-26 OPENING INSPECTION SHIELD (A) ......7-7 TAILGATE (BACK DOOR)........5-27 OPENING SEAT CUSHION (B)........7-8 REPLACEMENT PARTS ........ 6-1 RAISING CARGO BED (C) ........7-8 APPLYING GREASE (D) ..........7-9 ESSENTIAL REPLACEMENT PART....
  • Page 10 TABLE OF CONTENTS CHECKING SPARK ARRESTER OF EXHAUST USING BIODIESEL (AK) ..........7-41 PIPE (IF EQUIPPED) (R) .........7-25 ADJUSTING BELT TENSION (AL) ......7-42 CHECKING AND CHANGING GEARBOX OIL (S)...7-25 WASHING (AM)............7-43 CHECKING AND CHANGING FRONT AXLE OIL (T)...7-26 PROTECTING PLASTICAND PAINTED SURFACE(AO) ..7-43 CHECKING AND CHANGING REAR AXLE OIL (U) ...7-28 STROAGE AND DISPOSAL......
  • 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.
  • 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 Turn Signal Four-Wheel Drive-ON Reverse travel light...
  • 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

    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 1-19~22.
  • 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

    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- an enclosed building without the read this manual and all decals cle in an aggressive manner.
  • 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

    WHEN DRIVING THE VEHICLE UUVO133A UUVO122A KUVO158A T66O127A 10. Always activate the brake pedal 1. This is an off-road vehicle only, it 2. While turning the headlights on, before releasing the park brake. is illegal to drive a UTV on public dim them when meeting another roads.
  • Page 19 SAFETY PRECAUTIONS UUVO112A UUVO125A KUVO162A 3. Always slow the vehicle before 5. Do not apply the differential lock 8. When working in groups, always turning. Turning at high speed may while traveling at road speeds. As let the others know what you are tip the vehicle over or cause a loss the vehicle may run out of control.
  • Page 20 KUVO101A UUVO109A KUVO109A C56O164A 10. Watch where you are going at 12. For your safety ROPS with a seat 13. Watch front and rear to avoid ob- all times so that you are able to belt is recommended for all appli- stacles at row ends, near trees avoid obstacles that can cause cations.
  • Page 21 SAFETY PRECAUTIONS UUVO110A UUVO121A UUVO124A 16. Never drive the vehicle at ex- 14. Never try to get on or off a mov- 15. To minimize the risk of a rollover, ing vehicle. crash, be especially careful when cessive speeds. Always travel at obstacles and slopes are ahead speed proper for the terrain, visi- and when braking on hills or dur-...
  • Page 22 UUVO125A UUVO126A UUVO111A 20. Never drive in excessively rough, 17. Never attempt abrupt wheelies, 18. Always keep your both hands on jumps or other stunts. the steering wheel and your both slippery or loose terrain. feet on the floor of the vehicle 21.
  • Page 23 SAFETY PRECAUTIONS UUVO129A KUVO166A UUVO110A 22. Always follow proper procedures 23. When driving on a road inclined 25. Always be careful of skidding for climbing hills as described vertically or sideward, make sure or sliding. On slippery surfac- in this manual. Check the ter- to drive at a low speed.
  • Page 24 UUVO140A UUVO130A UUVO132A (1) Rear hitch receiver 27. Never exceed the stated load 26. Never operate your vehicle in 28. Pull only from the rear hitch re- fast-flowing water or in water capacity for this vehicle. Car- ceiver. Pulling from any other lo- deeper than that specified in this go should be properly distributed cation can cause the damage of...

  • Page 25: When Parking The Vehicle

    SAFETY PRECAUTIONS WHEN PARKING THE VEHICLE UUVO113A UUVO107A UUVO134A 1. Place all control levers in the neu- 2. Always remove the ignition key 4. Never park on a slope with only tral position, set the parking brake, when the vehicle is not in use to the transmission engaged.

  • Page 26: Safety Precautions During Servicing

    SAFETY PRECAUTIONS DURING SERVICING KUVO113A KUVO127A UUVO117A 1. In order to service your vehicle 2. D o n o t s m o k e w h i l e w o r k i n g 3. You must always stop the engine you must park it on a flat level sur- before refueling the vehicle.
  • Page 27 SAFETY PRECAUTIONS UUVO118A UUVO119A UUVO120A 4. It is recommended to keep a first 5. Do not remove the radiator cap 7. When working with your vehicles aid kit and fire extinguisher handy while the coolant is hot. When electrical components, you must first disconnect the battery cables.
  • Page 28 UUVO135A T66O130A UUVO104A 10. Tire mounting should be done by 13. Fluid escaping from pinholes may 14. No alterations should be made to qualified professionals, with the be invisible. Do not use hands to your vehicle. proper equipment. search for suspected leaks; 11.
  • Page 29 SAFETY PRECAUTIONS UUVO139A 15. Keep environmental pollution in 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

    SAFETY PRECAUTIONS WHEN USING THE ROPS UUVO104A UUVO141A 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 ...

  • Page 31: Safety Decal

    SAFETY PRECAUTIONS SAFETY DECAL MOUNTING LOCATION UUVO142C...

  • Page 32: Decals

    DECALS (1) Part No. : U3215-85611 (3) Part No. : U3215-85721 (4) Part No. : U3215-85681 ������� ������� ������� ���������������������������������� 1. The owner's manual and warning labels contain important information on ����������������������������������� safe operation of this vehicle. You must read and fully understand the ·Check the hood latches before operating the owner's manual and warning labels before operating this vehicle.
  • 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 (7) Part No. : U3215-85631 (10) Part No. : U3215-85641 ������� ������� ���������������������������������� ���������� ������������������ ������ � ������������������������������������������������� ���������������������������� ��������������������������������������������������������������� ���������������� �������������������������������������������������������� ����������������������������� U3215-85641 ���������������������������������������������������������� MAX 7.3 INCH �������������������� (185MM) �������������������������������������� U3215-85631 (8) Part No. : U3215-85661 (9) Part No. : U3215-85161 (11) Part No.
  • Page 35 SAFETY PRECAUTIONS (12) Part No. : U3215-85651 (13) Part No. : U3215-85691 ������� ������� ����������� ������������������������ ����������������������� ���� U3215-85691 (14) Part No. : U3215-85621 ������� ���������������������������������� · Never raise the bed/operate the dump mechanism while moving. · Operate on level ground only. ·...
  • Page 36 (15) Part No. : U3215-85701 (16) Part No. : U3215-85171 ������� ������� NEGATIVE FRAME GROUND 1. ALWAYS disconnect the negative battery cable before performing any type of maintenance. 2. TO PREVENT FIRE OR EXPLOSION, DO NOT contact the positive(+) battery post or cable to the frame or other ground. U3215-85701 TO PREVENT PERSONAL INJURY,...
  • Page 37 SAFETY PRECAUTIONS (18) Part No. : U3215-85191 (20) Part No. : U3215-85711 ������� ������� ����������������������������������� ������������������������������ · Do NOT Carry passengers/riders in the bed 1. The selective control valve lock is designed to · Haul unsecured cargo in the bed prevent accidental engagement of the hydraulic ·...

  • Page 38: Cautions For Decal Maintenance

    CAUTIONS FOR DECAL MAINTENANCE Safety decals are attached to the ve- IMPORTANT hicle for safe operation. Make sure  If a decal is damaged or lost, to follow the instruction on the decals contact your local dealer im- as well as the following instruction: mediately to install a new de- CAUTION cal.

  • Page 39: Precautions Before Operation

    PRECAUTIONS BEFORE OPERATION VEHICLE IDENTIFICATION NUMBER......2-2 VEHICLE SERIAL NUMBER ........2-2 ENGINE SERIAL NUMBER............2-2...

  • Page 40: Vehicle Identification Number

    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- al number and engine serial number should be submitted to the dealer during service.

  • Page 41: Specifications

    SPECIFICATIONS SPECIFICATION ............3-2 EXTERIOR DIMENSIONS............3-2 GENERAL SPECIFICATIONS .............3-3 OPTION LIST AND FEATURES ..........3-5...

  • Page 42: Specification

    SPECIFICATION EXTERIOR DIMENSIONS E, F UUVO301A in. (mm) Overall length Overall width Overall height Wheel base Front wheel tread Rear wheel tread Ground clearance 112.3 60.7 76.4 76.4 49.7 48.3 (2,852) (1,543) (1,940) (1,940) (1,262) (1,228) (304) Notes: The specifications are subject to change without notice. ※...

  • Page 43: General Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ITEMS REMARKS DESCRIPTION Model 3C100LWU Number of cylinders Total displacement cu.in(cc) 61.45 (1,007) Fuel Diesel Gross HP/KW 22/16.4 Rated speed 2,800 Engine oil U.S.Gal.(L) 0.85 (3.2) Fuel tank U.S.Gal.(L) 7.4 (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) Rear differential case oil U.S.Gal.(L)
  • Page 44 ITEMS REMARKS DESCRIPTION Front wheel 25 x 10-12(Worksite) 25 x 10-12(Turf) Rear wheel 25 x 10-12(Worksite) 25 x 10-12(Turf) Dimension (L x W x D) in.(mm) 38.5 x 56.2 x 11.5 (978 x1,427 x 293) Load capacity lbs(kg) 1,102 (500) Min.

  • Page 45: Option List And Features

    SPECIFICATIONS OPTION LIST AND FEATURES ITEM DESCRIPTION REMARKS Sun Canopy Kit Plastic moulding canopy Windshield Kit Acrylic windshield kit Front Hitch Receiver Kit 2 inch square type Remove lower screen of brush guard for installation Hydraulic cargo dumping kit with hydraulic pump, Hydraulic Dumping Kit oil tank, cylinder, valve, hoses and control lever Remote Hydraulic Kit...
  • Page 46 MEMO MEMO ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 47: Controls And Features

    CONTROLS AND FEATURES EXTERIOR VIEW ........4-3 COOLANT TEMPERATURE GAUGE .... 4-16 ENGINE OIL PRESSURE WARNING LAMP 4-17 HOOD ..............4-5 BATTERY CHARGING LAMP ....... 4-18 ELECTRIC COOLING FAN MOTOR ....4-5 HEAD LIGHT HIGH BEAM LAMP ....4-18 SUSPENSION ..........4-6 TURN SIGNAL LAMP ........

  • Page 48: Features And Controls

    FEATURES AND CONTROLS OUTSIDE REARVIEW MIRROR (OPTIONAL) .. 4-27 HAND THROTTLE LEVER (OPTIONAL) ..4-33 BRUSH GUARD ..........4-27 CARGO BED EXTENSION (OPTIONAL) ..4-33 SKID PLATES (OPTIONAL) ......4-28 WORKING LAMP (OPTIONAL) ..... 4-34 SUN CANOPY (OPTIONAL) ......4-28 FUEL TANK ...........4-34 WINDSHIELD (OPTIONAL) ......

  • Page 49: Exterior View

    FEATURES AND CONTROLS EXTERIOR VIEW [ STANDARD MODEL ] UUVO401A (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...
  • Page 50 EXTERIOR VIEW [ FULL OPTION MODEL ] UUVO461A (1) Front Working Lamp (5) Front Turn Signal Lamp (8) Tail Lamp (2) Sun Canopy (9) Fog Lamp (6) Windshield (3) Head Rest (10) Rear Screen (7) Cargo Bed Extension (4) Rear View Mirror...

  • Page 51: Hood

    CONTROLS AND FEATURES 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”...

  • Page 52: Suspension

    SUSPENSION HEADLAMP REAR HITCH RECEIVER UUVO404A UUVO405A UUVO406A (1) Front Axle (2) Rear Axle (1) Headlamp (RH) (2) Headlamp (LH) (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.

  • Page 53: Rear Wheel Mudguard

    CONTROLS AND FEATURES 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 54: Safety Lamp Kit (Optional)

    Safety laMp KIt (OptIONal) CAUTION always check that the reflex  reflector are clean before driv- ing. Driving with the dirty re- flective mirrors, especially in a cloudy weather or at night, can cause an accident. It is recommended to install ...

  • Page 55: Switches

    CONTROLS AND FEATURES SWITCHES Key SWItch UUVO411A (1) Key switch (A) Stop (B) ACC (C) ON (D) Heat (E) Start There are five positions for the ig- UUVO410A nition key switch as follow. The key can be removed from the key switch (1) Combination Switch (3) 12V Power Outlet (2) Spare Switch Panel...
  • Page 56 ACC (B) used in very cold weather to pre- CAUTION heat the engine manually for extra When the key switch is turned to Stop the engine immediately if period of time. Using this position  the position “B”, only electrical the oil pressure warning lamp for more than 30 seconds con- power outlet and brake lights can does not go off after the en-...

  • Page 57: Combination Switch

    CONTROLS AND FEATURES COMBINATION SWITCH HEADLAMP SWITCH NOTE The ignition key is not directional  and can be inserted in any direc- tion. Also, be careful not to leave the vehicle unattended with the key left in the ignition. UUVO412A UUVO413A Turn Signal Lamp Switch (1) Headlamp Switch...
  • Page 58 TURN SIGNAL LAMP SWITCH WARNING NOTE The turn signal lamp lever is not Driving with high beam head-   the self-return type. Therefore, lamps disturbs the approach- make sure to return the lever ing vehicle's visibility for safe manually after turning the vehi- driving.

  • Page 59: Hazard Lamp Switch (Optional)

    CONTROLS AND FEATURES hazaRD laMp SWItch (OptIONal) HORN SWITCH 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 of time while the engine is stopped, the battery can be discharged.

  • Page 60: Spare Switch Panel

    SPARE SWITCH PANEL 12V POWER OUTLET 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 ...

  • Page 61: Instrument Panel

    CONTROLS AND FEATURES INSTRUMENT PANEL SpeeDOMeteR / hOURMeteR UUVO418A (1) Speedometer (2) Hourmeter The speedmeter operates correctly when the specified tires with the cor- rect inflation pressure are installed. UUVO417A Refer to the chapter "Maintenance" for the correct tire inflation pressure. (1) Fuel Gauge (8) Preheating Indicator The hourmeter indicates the total us- (2) Speedometer (9) Hourmeter (3) Coolant Temperature Gauge...

  • Page 62: Fuel Gauge

    FUEL GAUGE COOLANT TEMPERATURE 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 to use only genuine ...

  • Page 63: Engine Oil Pressure Warning Lamp

    CONTROLS AND FEATURES ENGINE OIL PRESSURE WARNING LAMP Stop the vehicle or operation for a CAUTION while without stopping the engine un- If the oil level is below the  til the engine is cooled down. If the specified range, the engine engine temperature does not drop, can seize.

  • Page 64: Battery Charging Lamp

    BATTERY CHARGING LAMP HEAD LIGHT HIGH BEAM TURN SIGNAL LAMP LAMP UUVO420A UUVO421A UUVO422A This lamp is turned On when the key This lamp comes on in blue when the Operating the turn signal lamp switch switch is turned On before starting high beam head light is switched on.

  • Page 65: Glow Plug Indicator

    CONTROLS AND FEATURES GLOW PLUG INDICATOR paRKINg BRaKe INDIcatOR NEUTRAL INDICATOR UUVO423A UUVO424A UUVO425A This indicates the operating condi- If the shift lever is in neutral position, This lamp comes on in red when the tion of the preheat system. When the this lamp turns in green.

  • Page 66: Lower Fuel Level Warning Indicator

    CONTROLS LOWER FUEL LEVEL WARN- ING INDICATOR UUVO426A This lamp comes on when the fuel tank is approaching empty. When it UUVO427A comes on, you should add fuel as (1) Steering Wheel (4) 2WD/4WD Shift Lever soon as possible. Driving with the (2) Differential Lock Lever (5) Brake Pedal this lamp on or with the fuel level be-...

  • Page 67: Shift Lever

    CONTROLS AND FEATURES SHIFT LEVER DIffeReNtIal lOcK leVeR (ReaR Wheel) IMPORTANT this vehicle is equipped with  a cVt (continuous Variable transmission). Make sure to stop the vehi-  cle before moving the shift le- ver into the "h", "l" or "R" po- sition.
  • Page 68 to prevent this situation, this vehicle lSD Differential lock (front Wheel) CAUTION is equipped with the differential lock 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 ...

  • Page 69: 2Wd/4Wd Shift Lever

    CONTROLS AND FEATURES 2WD/4WD ShIft leVeR BRaKe peDal IMPORTANT Depress the brake pedal light-  ly for several times to dry the brake disc after driving over water or driving out of a mud- d y p i t s o t h a t t h e b r a k e i s properly operated when it is needed.

  • Page 70: Parking Brake Lever

    paRKINg BRaKe leVeR 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 71: Accelerator Pedal

    CONTROLS AND FEATURES ACCELERATOR PEDAL SEAT SEAT BELT UUVO433A UUVO434A UUVO435B (1) Accelerator Pedal (A) Depress (1) Seat Cushion (2) Seat Back (1) Seat Belt The accelerator pedal is located on This seat is a bench type and can The seat belts for a driver and pas- the right of the brake pedal.

  • Page 72: Headrest (Optional)

    heaDReSt (OptIONal) ROPS 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 73: Outside Rearview Mirror (Optional)

    CONTROLS AND FEATURES OUTSIDE REARVIEW MIRROR BRUSH GUARD (OptIONal) 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.

  • Page 74: Skid Plates (Optional)

    SKID plateS (OptIONal) SUN caNOpy (OptIONal) WINDShIelD (OptIONal) UUVO440A UUVO403A UUVO441A (1) Sun Canopy (1) Skid Plate 1 (2) Skid Plate 2 (1) Windshield The skid plates can be equipped as The sun canopy is available for this The transparent optional acrylic an option to protect the driving shaft, vehicle as an option.

  • Page 75: Rear Screen (Optional)

    CONTROLS AND FEATURES ReaR ScReeN (OptIONal) fRONt hItch ReceIVeR (Op- tIONal) WARNING Do not pile up cargo over the  height of the side frame of the cargo bed. the driver and passengers can be serious- ly injured by cargo in case of abrupt braking.

  • Page 76: Cup Holders And Storage Boxes

    CUP HOLDERS AND STORAGE CARGO BED CARGO BED CONTROL LEVER BOXES UUVO446C UUVO444A (1) Cup Holders (2) Glovebox (Driver Side) (1) Dumping Latch (2) Dumping Handle (3) Glovebox (Center) (A) Turn (B) Pull Up (4) Glovebox (Passenger Side) There are 2 cup holders, 1 for the To raise the cargo bed, pull up the driver and 1 for the passenger.

  • Page 77: Cargo Bed Control Lever (Optional)

    CONTROLS AND FEATURES CARGO BED CONTROL LEVER (OptIONal) WARNING When raising or lowering the  cargo bed, be careful not to let any part of your body, such as a hand or foot, stay between the cargo bed and cab frame. grip only the handle to prevent injuries.

  • Page 78: Remote Hydraulic Lever (Optional)

    REMOTE HYDRAULIC LEVER (OptIONal) CAUTION To operate the duping lever, remove Never drive your vehicle with  the lever lock bracket then pull the t h e c a r g o w e i g h t o v e r t h e lever to dump or raise the cargo bed specified max.

  • Page 79: Hand Throttle Lever (Optional)

    CONTROLS AND FEATURES HAND THROTTLE LEVER CARGO BED EXTENSION (OptIONal) (OptIONal) Use this lever to operate the hy- draulic implement or hydraulic mo- tor which is attached to the hydraulic couplers on the rear. Un-lock the le- ver lock bracket and pull the lever up to operate the implement or hydrau- lic motor.

  • Page 80: Working Lamp (Optional)

    WORKINg laMp (OptIONal) fUel taNK 2. Avoid using electrical devices, such as a cellular phone, during fueling. 3. The fuel is highly flammable and even explosive in certain condi- tions. Make sure to stop the en- gine and remove the key before fueling.

  • Page 81: 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.

  • Page 82: Coolant, Brake Fluid And Electrical Devices

    cOOlaNt, BRaKe flUID aND TIRE TIRE TREAD PATTERNS ELECTRICAL DEVICES 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.
  • Page 83 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 84: Proper Inflation Pressure

    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 12 PSI 28.9~33.3 lb . ft 4.0~4.6 kgf . m Front All terrain 25x10-12 12 PSI 28.9~33.3 lb . ft wheel 4.0~4.6 kgf .

  • Page 85: 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 AFTER DRIVING BACKWARD ......5-18 STARTING ENGINE ........5-5 DRIVING ON PATH ........5-19 OPERATING PRINCIPLE OF PREHEAT...

  • Page 86: Pre-Operation

    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.
  • Page 87 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 88 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 ...

  • Page 89: 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- ...

  • Page 90: Operating Principle Of Preheat System

    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 ...

  • Page 91: 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 turning off all the electri- hicle.
  • Page 92 UUVO503A UUVO506A UUVO505A (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" 3. Release the parking brake.
  • Page 93 OPERATION CAUTION IMPORTANT Avoid abrupt acceleration or Do not shift the gear when the   vehicle is moving or the en- braking for safe driving. When driving on a steep hill or gine is running at a high idling ...

  • Page 94: Warming Up

    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 95: 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 96: Stopping

    STOPPING PARKING Depress the brake pedal to control NOTE the driving speed. This vehicle does not have an  1. Release the accelerator pedal engine brake function. Always completely. check the brake function before 2. Depress the brake pedal evenly operating the vehicle.

  • Page 97: 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 loss of property from a ma- tomatic according to the accelerator equipped with separate disc and pad...

  • Page 98: Driving On Slippery Surfaces

    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...

  • Page 99: 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 100 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 101: 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 102: Driving Backward

    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...

  • Page 103: Driving On Path

    OPERATION DRIVING ON PATH 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 "Safety lamp kit"...
  • Page 104 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, not pile it over the side frame of abrupt starting-off or abrupt brak- the cargo bed.

  • Page 105: Unloading

    OPERATION UNLOADING 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 106: (If The Dumping Kit Is Installed)

    UNLOADING (IF THE DUMPING KIT IS INSTALLED) 1. Open the tailgate first before WARNING dumping the cargo bed. Make sure to check the ground  2. Pull the duping lever slowly after condition before driving back- removing lever lock bracket. wards to unload.

  • Page 107: Towing Trailer

    OPERATION 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 bed or your waist can 1.

  • Page 108: Transporting

    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 109: 4Wd Operation

    OPERATION 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- belts.

  • Page 110: Differential Lock 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 111: Tailgate (Back Door)

    OPERATION 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 112 MEMO MEMO ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 113: 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 114: Essential Replacement Part

    ESSENTIAL REPLACEMENT PART OIL AND FLUID FILTERS U.S.Gal.(L ITEM SPECIFICATION CAPACITY Engine SAE 15W40 8.45 (3.0) 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 SAE multifunc- Grease A little tional...

  • Page 115: 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. Continuous use of a belt, hose or 2350-69571 Headlight Bulb boot in poor condition can result in...
  • Page 116 MEMO MEMO ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 117 MAINTENANCE MAINTENANCE CHECK LIST ....7-3 CHECKING INJECTION NOZZLE AND FUEL INJECTION PUMP (N) .....7-20 DAILY CHECK CHART.........7-3 CLEANING RADIATOR CORE (O) ....7-20 MAINTENANCE INTERVAL TABLE .....7-4 CHECKING COOLANT IN AUXILIARY COOLANT TANK (P) ........7-21 LUBRICANTS ........7-6 CHANGING COOLANT (Q)......7-22 CHECKING SPARK ARRESTER OF DAILY INSPECTION ......7-7 EXHAUST PIPE (IF EQUIPPED) (R) ..7-25 ACCESS FOR SERVICE......7-7...

  • Page 118: Maintenance

    MAINTENANCE ABSORBER (AC) ........7-35 BATTERY (SEALED) (AD)......7-35 REPLACING HEADLAMP BULB (AE)..7-37 CHECKING AND REPLACING FUSE (AF) ...7-38 MAIN FUSE (SLOW-BLOW FUSE) (AG) ..7-39 ALIGNING WHEEL AND CHECKING WHEEL NUT (AH) ........7-39 CHECKING DIFFERENTIAL LOCK CABLE (AI) ..........7-40 CHECKING SHIFT AND 4WD CABLES (AJ) ..7-41 USING BIODIESEL (AK) ......7-41 ADJUSTING BELT TENSION (AL) .....7-42 WASHING (AM)..........7-43...

  • Page 119: 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 120: Maintenance Interval Table

    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 121 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 122: Lubricants

    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) SAE 15W40 Gear Box Oil...

  • Page 123: 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 124: Opening Seat Cushion (B)

    OPENING SEAT CUSHION (B) RAISING CARGO BED (C) MANUAL TYPE UUVO446C UUVO703A UUVO704A (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 IF EQUIPPED the holes and then push down the cushion gently.

  • Page 125: Applying Grease (D)

    MAINTENANCE APPLYING GREASE (D) KUVO706A UUVO707B UUVO775A (1) Grease fitting (Rear axle drive shaft) (1) Grease fitting (Front wheel hubstrut) (1) Hydraulic Cylinder It is possible to check the gearbox oil, There are four greasing points. Two The other two are located on the CVT, muffler, air filter, fuel strainer, of them are located on both ends of front wheel knuckle.

  • Page 126: Checking Engine Oil Level (E)

    CHECKING ENGINE OIL LEVEL (E) UUVO708A H11O606A UUVO776A (1) Oil dipstick (1) Oil dipstick (1) Grease Fitting(Front Axle Drive Shaft Around (A) MAX limit (B) MIN limit Gear Box) It is located on the spline area of 1. Park the vehicle on level ground 6.

  • Page 127: Changing Engine Oil And Filter (F)

    MAINTENANCE CHANGING ENGINE OIL AND FILTER (F) 1. Warm up the engine oil by operat- IMPORTANT ing the engine for approx. 10 min- T h e e n g i n e o i l s h o u l d b e ...

  • Page 128: Dust Valve (G)

    DUST VALVE (G) 12. Stop the engine and wait for ap- It is necessary to remove dust from prox. 5 minutes. Then, check the the anti-dust valve of the air filter fre- oil level and add oil as neces- quently. sary.

  • Page 129: Replacing Air Filter (H)

    MAINTENANCE REPLACING AIR FILTER (H) CHECKING AIR HOSE AND CLAMP(I) 4. Check if the anti-dust valve is torn If there is a tiny gap caused by a or damaged and replace it as nec- loose connecting clamp on the air essary.

  • Page 130: Checking Cvt Belt (J)

    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 UUVO714A (1) Clamp 1 (2) Clamp 2 (1) Battery...
  • Page 131 MAINTENANCE UUVO718A UUVO719A UUVO717A (1) Heat shield cover 1 (1) Exhaust pipe (2) Muffler (1) Air hose 1 (2) Air hose 2 (2) Heat shield cover 2 4. Remove the heat shield covers (1 5. Remove the exhaust pipe, but 6.
  • Page 132 NOTE The width of a new belt is 29 mm  (1 9/64 in.). Its max. speed re- duction ratio is 3.55 while its min. speed reduction ratio is 0.68. As- suming that its width is reduced to 1 in. due to wear, the speed reduction ratio would be 3.22 and 0.76 respectively.

  • Page 133: Checking Cvt Driven Pulley Clutch Buttons(K)

    MAINTENANCE CHECKING FUEL FILTER(L) CHECKING CVT DRIVEN PUL- LEY CLUTCH BUTTONS(K) 1. Remove the relevant parts such 3. Check for any water or foreign ma- NOTE as the CVT cover by following the terials on the bottom of the fuel fil- It is recommended to start servic- same procedure as for the CVT belt ...
  • Page 134 5. Remove any water or foreign ma- terials or replace the filter as nec- essary. At this time, be careful not to let any foreign materials enter the strainer. 6. Install the filter cup to its original position after checking that the fil- ter, spring and O-ring are located in their proper positions.

  • Page 135: Bleeding Fuel Line (M)

    MAINTENANCE BLEEDING FUEL LINE (M) The fuel line for the engine is de- 4. If there is air in the fuel strainer, turn its fuel cock to the AIR side and wait signed to be bled automatically. If the for a moment. When the fuel tank is fully filled, the fuel strainer can be filled engine still cannot be started even with fuel by natural pressure.

  • Page 136: Checking Injection Nozzle And Fuel Injection Pump (N)

    CHECKING INJECTION NOZZLE CLEANING RADIATOR CORE (O) AND FUEL INJECTION PUMP (N) 6. Unscrew the bleeding bolt (1) The injection nozzle and injection 1. Park the vehicle on level ground slightly and crank the engine. pump can be inspected only by a qual- and apply the parking brake firmly.

  • Page 137: Checking Coolant In Auxiliary Coolant Tank (P)

    MAINTENANCE CHECKING COOLANT IN AUX- ILIARY COOLANT TANK (P) When the coolant in the radiator ex- IMPORTANT pands by heat, it overflows into the Driving with the radiator core auxiliary coolant tank. On the other  clogged by foreign materials hand, when the coolant temperature can deteriorate heat radiation in the radiator decreases, the radi-...

  • Page 138: Changing Coolant (Q)

    CHANGING COOLANT (Q) 1. Park the vehicle on level ground IMPORTANT WARNING and apply the parking brake firmly. Do not remove the radiator cap If you have to keep adding   2. Check the coolant level through while the engine is hot. You water to the auxiliary cool- the sight glass of the auxiliary can get burnt by hot steam.
  • Page 139 MAINTENANCE 4. After confirming the radiator cap is not hot, unscrew it counterclock- wise slowly pressing it down. Un- screw it in several steps to remove any inner pressure safely. 5. Remove the cap after the inner pressure is removed. UUVO731A UUVO732A (1) Coolant Drain Plug Of Radiator...
  • Page 140 13. Make sure to install the drain 1.7 U.S Gal. (6.3 L) Coolant plugs for radiator and engine be- Water+Ethylene glycol Capacity fore filling new coolant. 50:50 14. Fill the tank with water and an- ti-freeze (Ethylene glycol) in ratio 20.

  • Page 141: Checking Spark Arrester Of Exhaust Pipe (If Equipped) (R)

    MAINTENANCE CHECKING SPARK ARRESTER OF CHECKING AND CHANGING EXHAUST PIPE (IF EQUIPPED) (R) GEARBOX OIL (S) 1. Park the vehicle on level ground 1. Park the vehicle on level ground 6. If the color or viscosity of the oil is and apply the parking brake firmly.

  • Page 142: Checking And Changing Front Axle Oil (T)

    CHECKING AND CHANGING FRONT AXLE OIL (T) 1. Park the vehicle on level ground WARNING and apply the parking brake firmly. You can get burnt badly by  2. Stop the engine and let the engine hot oil. Make sure to work on cooled down sufficiently.
  • Page 143 MAINTENANCE 6. If the color or viscosity of the oil is 11. Wipe the differential case and its not normal or it is at the oil change surrounding with a rag thorough- interval, change the oil. 12. Test drive the vehicle for 5 to 10 minutes to check for leakage.

  • Page 144: Checking And Changing Rear Axle Oil (U)

    CHECKING AND CHANGING REAR AXLE OIL (U) 1. Park the vehicle on level ground 5. 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. 2.

  • Page 145: Checking Drive Shaft And Cv Boots (V)

    MAINTENANCE CHECKING DRIVE SHAFT AND CV BOOTS (V) 10. 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. 11. Test drive the vehicle for 5 to 10 minutes to check for leakage.

  • Page 146: Checking Steering Rack Boots And Ball Joint (W)

    CHECKING STEERING RACK BOOTS AND BALL JOINT (W) 1. Park the vehicle on level ground IMPORTANT and apply the parking brake firmly. The components related to  2. Stop the engine. the steering operation direct- 3. Open the hood and support it. ly affect your safety.

  • Page 147: Checking Brake Fluid (X)

    MAINTENANCE CHECKING BRAKE FLUID (X) CHECKING BRAKE PEDAL FREE PLAY (Y) 1. Park the vehicle on level ground The master cylinder rod of the vehi- Brake fluid DOT 3 and apply the parking brake firmly. cle is adjusted so that the brake ped- al free play is 0.59 ~ 0.79 in.

  • Page 148: Checking Brake Pad (Z)

    CHECKING BRAKE PAD (Z) 1. Park the vehicle on level ground 5. If any of the brake pads on either and apply the parking brake firmly. side of the disc is too thin, close to 0.04 in. (1 mm), both pads for that disc as well as the pads for the wheel on the other side should be replaced.

  • Page 149: Checking Parking Brake (Aa)

    MAINTENANCE CHECKING PARKING BRAKE (AA) NOTE The vehicle should be stopped  on a slope (up to 10 degrees) when the parking brake is ful- ly applied. With cargo loaded. When driving the vehicle downhill without depressing the accelera- tor pedal, there should be no fric- tion resistance.

  • Page 150: Adjusting Suspension (Ab)

    ADJUSTING SUSPENSION (AB) 7. If the parking brake pads should The rear suspension equipped on 4. Unscrew the wheel nuts complete- be replaced with new ones or ab- this vehicle is adjustable, to allow for ly to remove the wheel. normal wear is found on the disc, ride quality and weight hauling.

  • Page 151: Checking Suspension Shock Absorber (Ac)

    MAINTENANCE CHECKING SUSPENSION BATTERY (SEALED) (AD) SHOCK ABSORBER (AC) INSPECTION 6. After adjustment, install the wheel If the shock absorber is malfunc- Never open or service the battery and tighten the wheel nuts firmly. tioning, your riding comfort can be and never add electrolyte to the bat- harmed.
  • Page 152 REPLACEMENT 1. Park the vehicle on level ground IMPORTANT and apply the parking brake firmly. The battery discharges natu-  2. Stop the engine. rally if the vehicle is stored for an extended period of time. When storing the vehicle for a long period of time, run the engine for approx.

  • Page 153: Replacing Headlamp Bulb (Ae)

    MAINTENANCE REPLACING HEADLAMP BULB (AE) 1. Park the vehicle on level ground WARNING CALIFORNIA BATTERY WARNING and apply the parking brake firmly. The battery terminals and ca- The battery gas is dangerous   2. Stop the engine, open the hood bles contains lead.

  • Page 154: Checking And Replacing Fuse (Af)

    CHECKING AND REPLACING FUSE (AF) 1. Park the vehicle on level ground and apply the parking brake firmly. 2. Stop the engine, open the hood and support the hood. UUVO774B UUVO755A (1) Bulb (2) Rubber Cover (A) Pull Out 4. Hold and pull the socket section to UUVO756A pull out the bulb.

  • Page 155: Main Fuse (Slow-Blow Fuse) (Ag)

    MAINTENANCE MAIN FUSE (SLOW-BLOW FUSE) (AG) ALIGNING WHEEL AND CHECKING WHEEL NUT (AH) 4. Wrap the fuse with insulation tape 1. Park the vehicle on level ground after replacement. Make sure that and apply the parking brake firmly. the inspection shield is visible. 5.

  • Page 156: Checking Differential Lock Cable (Ai)

    CHECKING DIFFERENTIAL LOCK CABLE (AI) WARNING WARNING Driving with loose wheel nuts You can get burnt by touching   is very dangerous and can hot parts, such as the muffler. lead to overturn and collision. Make sure the vehicle is not Make sure that they are firmly hot before starting servicing.

  • Page 157: Checking Shift And 4Wd Cables (Aj)

    MAINTENANCE CHECKING SHIFT AND 4WD USING BIODIESEL (AK) CABLES (AJ) 3. Unscrew nut 1 and adjust the 1. It is allowed to use 5% biodiesel length of the shift cable. fuel. If biodiesel fuel of higher ratio is used, the engine can be dam- 4.

  • Page 158: Adjusting Belt Tension (Al)

    ADJUSTING BELT TENSION (AL) The engine belt drives the alterna- 3. Loosen the adjusting bolt on the tor and coolant pump. If the tension top of the alternator as well as the of this belt is below the specification, hinge bolt on the bottom of the al- the alternator efficiency decreases, ternator.

  • Page 159: Washing (Am)

    MAINTENANCE PROTECTING PLASTIC AND WASHING (AM) PAINTED SURFACE(AO) It is recommended to wash your ve- Do not wipe any plastic parts if they hicle with water of moderate pres- are not washed. sure and with or without soap. When Spraying insecticide can damage the washing your vehicle in a car wash, plastic and painted surface.
  • Page 160 MEMO MEMO ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 162   9. Apply grease to every grease fit  necessary, drain and flush it, and 4. Inflate the tires to a pressure a lit...
  • Page 163 and inflate the tires if they are low. diesel and fill the standard diesel  4. Check all fluid levels, including the  leading to a fire. and brake fluid.  points, and grease fitting as need  ...
  • Page 166 This troubleshooting chart summarizes simple service items for users who are familiar with mechanical systems. For more detailed service items, contact your local dealer.    Hard to start the engine  Insufficient preheating    Insufficient fuel ...
  • Page 167  No operation of solenoid valve   Too high viscosity of engine oil (improper type of oil)   Improper valve clearance  3. Engine power is insufficient Excessive engine oil (overfilling, water or hydraulic oil mixed with engi ...
  • Page 168 3. Engine power is insufficient  (knocking, vibration, smoke) Improper valve clearance  4. Engine is overheated  Insufficient or leaking coolant (loose hose connection)  Broken cooling fan         ...
  • Page 169 4. Engine is overheated Insufficient engine oil  Insufficient fuel or clogged filter and hose   Seizure due to overheated engine  Engine oil leakage  Coolant leakage    6. Electrical device is malfunc    ...
  • Page 170 Electrical devices (headlamps, work lamps, turn signal lamps, etc) left "ON"    Frequent repetition of engine start and stop (lack of time to charge)  Excessive electricity use from external device  (additionally attached device, such as implement) Prolonged cranking in severe condition ...
  • Page 171 Differential lock system malfunction (improperly adjusted differential lock cable)  11. Power is insufficient to drive Shift lever not in "L" position      13. Braking force is insufficient Wet brake  Insufficient brake fluid  Air in brake line ...
  • Page 172 15. Parking brake is malfunc Improperly adjusted parking brake cable  (vehicle rolls down on slope) Worn parking brake pad  16. Steering wheel feels heavy Insufficient inflation pressure of front tires  Insufficient lubrication and contamination due to torn steering rack boots ...

  • Page 175: Index

    INDEX...
  • Page 177 INDEX...
  • Page 180 (800) 241-5855 I Fax (706) 796-4540 I www.ezgo.com (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. e-mail: ezgo@textron.com I ©2011 E-Z-GO Division of Textron Inc. e-mail: ezgo@textron.com I ©2011 E-Z-GO Division of Textron Inc.

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