User Manuals: Ezgo 1600xd Utility Vehicle

Manuals and User Guides for Ezgo 1600xd Utility Vehicle. We have 1 Ezgo 1600xd Utility Vehicle manual available for free PDF download: Repair Manual

Ezgo 1600xd Repair Manual

Ezgo 1600xd Repair Manual (416 pages)

4x4

Brand: Ezgo | Category: Utility Vehicle | Size: 38 MB

Table of Contents

Safety First

7
- Table of Contents
  7
- CHAPTER 1 Alert Symbols
  8
- Safety Decals
  8
- Safety Tips
  9
  - Safety Gear
    9
  - Workplace
    9
    
    Illumination
    9
    
    Keeping Your Work Area Clean
    9
    
    Safe Workplace
    9
    
    Safety Equipment
    9
    
    Ventilating System
    9
    
    Fire
    10
    
    Safety Instructions When Preparing Tractor
    10
    
    Cautions for High Pressure Hoses
    11
    
    Cautions When Handling the Battery
    11
    
    Handling of Hazardous Materials
    12
    
    Use of Appropriate Tools and Equipment
    12
    
    Handling of Rotating Shaft and Driving Belt
    13
  - Scald Prevention
    13
  - Disposal of Environmental Waste
    14
  - Cautions When Handling Tires
    14
General

19
- Description for Symbols and Abbreviations
  20
- Serial Number
  21
  - Utv Serial Number Location
    21
  - Engine Serial Number Location
    22
  - Others Location
    22
- Utv Appearance
  21
- Dimensions
  23
- Specifications
  24
- Gear Arrangement and Driving Speed
  25
- Maintenance
  28
  - Maintenance Schedule Chart
    28
  - Lubrication and Replenishment
    30
- Chapter 2
  31
- Speciﬁ Ed Inﬂ Ation Pressure
  31
- Tightening Torque for Wheel
  31
- Tire Maintenance
  31
- Tightening Torques
  32
- Part Number Assignment Standard for Daedong Bolts and Nuts
  34
  - Bolts
    34
  - Nuts
    35
- How to Install Spring Pin and Snap Ring
  36
  - Spring Pin Installation
    36
  - Snap Ring Assembly
    36
- Unit Conversion Table
  37
Engine

39
- General Information
  41
  - Engine Views
    41
  - Engine Identiﬁ Cation
    41
- Specifications
  42
  - Engine Dimensions
    42
  - General Speciﬁ Cations
    43
  - Service Speciﬁ Cations
    44
    
    Cylinder Head
    44
    
    Valve Springs
    44
    
    Valves
    44
    
    Camshaft
    45
    
    Piston Rings
    45
    
    Valve Rocker Arms
    45
    
    Crankshaft
    46
    
    Pistons
    46
    
    Fanbelt
    47
    
    Injection Pump
    47
    
    Oil Pump
    47
    
    Radiator
    47
    
    Thermostat
    47
    
    Tightening Torque
    48
- Structure and Function
  49
  - Body and Power Train
    49
    
    Cylinder Block
    49
    
    Cylinder Head
    49
    
    Connecting Rods
    50
    
    Crankshaft
    50
    
    Camshaft and Fuel Camshaft
    51
    
    Inlet and Exhaust Valves
    51
    
    Rocker Arm Assembly
    51
    
    Flywheel
    52
    
    Timing Gears
    52
  - Lubrication System
    54
    
    Engine Oil Fl Ow
    55
    
    Oil Pressure Switch
    56
    
    Relief Valve
    56
    
    Oil Pump
    57
  - Cooling System
    57
    
    Thermostat
    58
    
    Water Pump
    58
    
    Radiator
    59
    
    Radiator Cap
    59
  - Fuel System
    60
    
    Bleeding the Fuel System
    60
    
    Flow of Fuel
    60
    
    Fuel Fi Lter and Bleeding
    60
    
    Fuel Feed Pump
    61
    
    Fuel Injection Pump
    61
  - Governor System
    65
    
    Disassembled View
    65
    
    Basic Principle of Governor System
    66
    
    Operation of Governor
    67
  - Intake and Exhaust System
    68
    
    Air Cleaner
    68
    
    Flow of Intake Air and Exhaust Gas
    68
    
    Mufﬂ er
    68
    
    Pcv Valve
    69
- CHAPTER 3 MLS Cylinder Head Gasket
  53
- Troubleshooting
  70
- Inspection and Adjustment
  72
  - Fan Belt Tension Adjustment
    72
  - Measuring the Piston Compression Pressure
    72
  - Checking and Adjusting the Injection Timing
    73
  - Engine Oil Pressure
    74
  - Injection Nozzle Inspection
    75
  - Bubble Test for Radiator
    75
  - Intake and Exhaust Valves
    76
    
    Clearance Adjustment
    76
    
    (Length, Tension and Squareness)
    77
    
    Valve Spring Inspection
    77
    
    Valve Spring Squareness (Tilt)
    77
  - Rocker Arm Assembly Check
    78
  - Cylinder Head Check
    78
    
    Cylinder Head Surface Fl Atness
    78
    
    Cylinder Bore Check
    79
    
    Cylinder Head Valve Recess
    79
- Piston Check
  80
  - Piston Pin Bore
    80
  - Clearance between Piston Pin and Bushing
    80
  - Piston Ring End Gap
    81
  - Piston Ring Clearance
    81
- Crankshaft Check
  82
  - Crankshaft Deﬂ Ection
    82
  - Oil Clearance between Crankshaft
    82
    
    Journal and Bearing 1
    82
    
    Oil Clearance between Crank Pin and Connecting Rod Big End Bearing
    83
    
    Oil Clearance between Crankshaft
    83
- Timing Gear
  84
- Flywheel Deﬂ Ection and Crankshaft End Play Check
  88
- Oil Pump Check
  88
- Disassembly, Service and Assembly
  90
  - Engine Removal
    90
  - Engine Component Disassembly and Assembly
    96
    
    Cylinder Head
    96
    
    Fuel Injection Pump
    98
    
    Speed Control Lever Plate and Governor Spring
    99
    
    Fuel Camshaft (Gear Case)
    100
    
    Valve Camshaft
    102
    
    Idle Gear Shaft, Oil Pump and Oil Pan
    103
    
    Piston, Fl Ywheel and Crankshaft
    104
  - Engine Component Disassembly and Assembly
    108
    
    Intake and Exhaust Valves
    108
    
    Rocker Arm
    108
    
    Injection Nozzle
    109
    
    Piston Assembly
    110
    
    Thermostat
    111
    
    Water Pump
    112
    
    Main Bearing Case Assembly
    113
    
    (Fuel Camshaft Gear)
    114
    
    Engine Oil Relief Valve
    114
    
    Njection Pump Gear Assembly
    114
  - Cylinder Head Gasket Replacement
    115
  - Gear Case Disassembly and Reassembly (Gear Case Gasket, Crankshaft Oil Seal and Oil Pump Replacement)
    117
- Engine Exploded View
  120
  - E010 Cylinder Block
    120
  - E020 Oil Pan
    121
  - E030 Cylinder Head
    122
  - E040 Gear Case
    123
  - E050 Main Bearing Case
    124
  - E080 Valve Rocker Arm
    125
  - E090 Cylinder Head Cover
    126
  - E100 Camshaft
    127
  - E110 Piston & Crank Shaft
    128
- E120 Flywheel
  129
- E130 Nozzle, Holder
  130
- E140 Fuel Camshaft
  131
- E150 Speed Control Plate
  132
- E160 Engine Stop Lever
  133
- E170 Governor
  134
- E190 Water Hose
  135
- E200 Dynamo
  136
- E220 Mainfold
  137
Table of Contents

139
- Specifications
  140
  - General Speciﬁ Cations
    140
  - Tightening Torque
    140
  - Sealant and Adhesive
    140
- Structure and Operating Principle
  141
- Troubleshooting
  146
- Inspection and Adjustment
  147
  - Adjusting Distance between Shafts for Pulleys
    147
  - Check and Replacement for CVT Belt
    148
- Chapter 4 Disassembly, Service and Assembly
  149
- CVT Disassembly
  149
- CVT Assembly
  151
- Drive Pulley Assembly Components Disassembly and Assembly
  153
- Driven Pulley Assembly Components Disassembly and Assembly
  155
- Components for Cvt
  156
  - U060A Cvt
    156
  - U0287A Clutch Cover
    157
Transmission

159
- Specifications
  160
  - General Speciﬁ Cations
    160
  - Tightening Torque
    160
  - Sealant and Adhesive
    161
- Structure and Operating Principle
  162
  - Transmission Structure
    162
  - Speed Control System
    163
  - Shift System
    164
  - Wheel Drive System
    165
- Troubleshooting
  166
- Inspection and Adjustment
  167
- Chapter 5 Disassembly, Service and Assembly
  171
- Transmission Removal
  171
- Transmission Components Disassembly and Assembly
  172
- Axle Drive Shaft Disassembly and Assembly
  176
- Gear Shift System Disassembly and Assembly
  180
- Front Wheel Drive System Disassembly and Assembly
  182
- Components
  183
  - U120A Transmission Case
    183
  - U130A Shaft 1
    184
  - U140A Bevel Pinion Gear
    185
  - U150A Shaft 2
    186
  - U160A Propeller Shaft
    187
Chassis

189
- Specifications
  190
  - Tire
    190
- Inspection and Adjustment
  191
  - Installation Direction of Front/Rear Tires
    191
  - Routes for Various Cables
    192
    
    Differential Lock Cable
    192
    
    Shift Selector Cable
    192
    
    Front Wheel Drive Cable
    193
    
    Parking Brake Cable
    193
    
    Accelerator Pedal Cable
    194
- Disassembly, Service and Assembly
  194
  - Cargo Bed Removal
    194
  - Seat and Fender Removal
    195
  - Hood, Panel, Fl Oor and Radiator Removal
    197
  - Hand Throttle Disassembly
    199
- Chapter 6 Components
  201
- U030A Accelerator Pedal
  201
- U0912A Hood
  202
- U0200A Structure
  203
- U630A Lever
  204
- U0900A Molding
  205
- U670A Engine Mounting
  206
- U0922A Deck
  207
- U1000A Gas Cylinder
  208
- U0225A Rops
  209
- U0811A Seat
  210
Rear Axle

211
- Specifications
  212
  - Rear Axle Case Oil
    212
  - Tightening Torque
    212
  - Suspension
    212
- Structure and Function
  213
- Troubleshooting
  218
- Inspection and Adjustment
  219
  - Differential System Assembly
    219
  - Differential Lock Cable Length
    224
- Chapter 7 Disassembly, Service and Assembly
  224
- Rear Axle Case Removal (Rear Axle Disassembly)
  224
- Rear Axle Case Disassembly and Assembly
  227
- Rear Differential System Disassembly and Assembly
  230
- Rear Axle Replacement
  232
- CV Joint Boot Replacement
  233
- Suspension Assembly Removal
  236
- Rear Carrier Replacement
  237
- Rear Propeller Shaft Replacement
  238
- Components
  240
  - U200A Rear Axle Drive Shaft
    240
  - U210A Rear Differential System
    241
  - U680A Rear Differential
    242
  - U0510A Rear Suspension
    243
Brake

245
- Specifications
  246
  - General Speciﬁ Cations
    246
  - Tightening Torque
    246
- Structure and Function
  247
  - Front and Rear Wheel Brakes
    247
  - Parking Brake
    248
- Troubleshooting
  249
- Inspection and Adjustment
  250
- Chapter 8 Disassembly, Service and Assembly
  253
- Rear Wheel Brake Removal (Brake Pad and Disc Replacement)
  253
- Front Wheel Brake Removal (Brake Pad and Disc Replacement)
  255
- Brake Master Cylinder Disassembly
  256
- Bleeding Brake Line
  257
- Parking Brake Disassembly and Assembly (Parking Brake Pad Replacement)
  259
- Components
  261
  - U300A Front Brake
    261
  - U0431A Packing Backe
    262
Front Axle

263
- Specifications
  264
  - General Speciﬁ Cations
    264
  - Tightening Torque
    265
  - Sealant and Adhesive
    265
- Structure and Function
  266
  - Front Axle Power Transfer Diagram
    266
  - LSD (Limited Slip Device)
    268
- Troubleshooting
  269
- Inspection and Adjustment
  270
- Chapter 9 Disassembly, Service and Assembly
  275
- Components
  289
  - U100A Front Axle Drive
    289
  - U110A Front Diff. Case
    290
  - U0500A Front Suspension
    291
Steering System

293
- Specifications
  294
  - Steering Gearbox
    294
  - Tightening Torque
    294
- Structure and Function
  295
  - Operating System Diagram
    295
  - Structure in Steering Gearbox
    296
  - Steering Gearbox Components
    297
- Troubleshooting
  298
- Inspection and Adjustment
  299
  - Tie-Rod Length Adjustment
    299
  - Toe-In Adjustment
    299
- Chapter 10 Disassembly, Service and Assembly
  300
- Steering Gearbox Removal
  300
- Steering Column Removal and Installation
  301
- Components
  304
  - U250A Steering
    304
Hydraulic System

305
- Specifications
  306
- Operating Principle
  307
  - Hydraulic Component Layout
    307
  - Hydraulic Circuit
    309
  - Hydraulic Line
    310
    
    Dumping Operation
    310
    
    External Hydraulic Oil Operation
    312
  - Gear Pump
    314
  - Dumping Cylinder
    316
  - Front Block (Dumping Valve)
    318
  - Auxiliary Hydraulic Valve
    320
- Troubleshooting
  322
- Inspection and Adjustment
  323
  - Main Relief Valve Pressure
    323
- Disassembly, Service and Assembly
  324
  - Gear Pump Disassembly and Assembly
    324
    
    Gear Pump Disassembly
    324
    
    Gear Pump Removal
    324
  - Valve Removal
    325
  - Auxiliary Hydraulic Valve Disassembly
    327
  - Dumping Valve Disassembly
    330
  - Front Block (Relief Valve) Disassembly
    333
- CHAPTER 11 Auxiliary Hydraulic Valve, Dumping Valve and Front Block (Relief Valve) Disassembly and Assembly
  325
- Dumping Cylinder Disassembly and Assembly
  334
  - Dumping Cylinder Removal
    334
  - Dumping Cylinder Disassembly
    335
- Exploded View
  336
- U1300A Hydraulic Dumping
  336
- U1310A Auxiliary Hydraulic Valve
  337
Electric System

339
- Specification
  341
- Circuit Diagram
  342
  - Color Code of Wire
    342
  - Cross Section of Wire
    342
  - Symbols for Electric Components
    343
- Operating Principle
  347
- Electrical Components
  354
  - Display Unit
    354
    
    External Wiring Diagram for Display Unit
    355
  - Cooling Fan Motor
    356
  - Headlamp
    358
- Chapter 12
  359
- Glow Plug
  359
- Slow-Blow Fuse
  359
- Engine Stop Solenoid
  360
- Parking Brake Switch
  361
- Safety Start Switch
  362
- Coolant Temperature Sensor
  363
- Engine Oil Pressure Switch
  363
- Fuel Sender
  365
- Alternator
  366
- Speed Sensor
  368
- Key Switch
  370
- Combination Switch
  371
- Engine Stop Relay (5P)
  373
- Flasher Unit (Optional)
  373
- Preheat Relay (4P)
  374
- Instrument Panel
  376
- Fan Motor Relay (5P)
  382
- Start Relay (5P)
  382
- Twin Relay (High/Low Beam)
  383
- Twin Relay (Work/Fog Lamp) (Optional)
  383
- Fuse Box
  384
- Power Outlet
  384
- Brake Lamp Switch (Optional)
  385
- Wiring Configuration
  386
  - Wiring Diagram
    386
- Diagnosis and Troubleshooting
  387
  - General Troubleshooting
    387
    
    Battery
    387
    
    Wiring
    388
    
    General
    390
  - Troubleshooting
    393
    
    When the Engine Cannot be Started
    393
    
    When the System Is Not Charged
    395
    
    Check the Charge Warning Lamp for Malfunction
    396
    
    When the System Is Not Preheated Manually
    397
    
    When the System Is Not Preheated Automatically
    398
    
    When High and Low Beams Cannot be Operated
    400
    
    Speedometer Operation with the Engine Running
    401
    
    Fuel Gauge Operation
    402
    
    Hour Meter Operation
    403
    
    Exploded View for the Components
    404
    
    U500A Light
    404

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