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  4. 4X4
  5. Owner's Manual

E-Z-GO 4X4 Owner's Manual

Manual is about: E-Z-GO off-road diesel utility vehicle owner's manual

Summary of 4X4

  • Page 1

    4x4 owner’s manual.

  • Page 2

    Utv-미국향-oem용-00.Indd 2 2011-03-21 오후 1:14:04.

  • Page 3: Forward

    Forward make sure to read this manual carefully and keep it handy for future reference. When leasing or transferring this vehicle, deliver this manual together with the vehicle. Thespecificationsinthismanualaresubjecttochangewithoutnotice. Thank you for choosing our off-road diesel utility vehicle. ...

  • Page 4

    Utv-미국향-oem용-00.Indd 2 2011-03-21 오후 1:14:04.

  • Page 5: Section

    Safety precautions ................................ Vehicle identifications .......................... Specifications ............................................ Controls and features ......................... Operation .................................................... Replacement parts ...........

  • Page 6: Table of Contents

    Table of contents safety precautions ............................... 1-1 precautions before operation ...... 1-2 general precautions........................................1-2 precautions during operation....... 1-4 when starting the engine...............................1-4 when driving the vehicle ...

  • Page 7: Table of Contents

    Table of contents controls................................................ 4-20 shift lever...........................................................4-21 differential lock lever (rear wheel) .....4-21 2wd/4wd shift lever.........................................4-23 brake pedal.........................

  • Page 8: Table of Contents

    Cargo bed control lever (optional) .......4-31 remote hydraulic lever (optional) ..........4-32 hand throttle lever (optional) .................4-33 cargo bed extension (optional).................4-33 working lamp (optional)................................4-34 fuel tank ................................

  • Page 9: Table of Contents

    Transporting .....................................................5-24 4wd operation....................................................5-25 differential lock operation........................5-26 tailgate (back door)........................................5-27 replacement parts .......................

  • Page 10: Table of Contents

    Table of contents checking spark arrester of exhaust pipe (if equipped) (r) .........................................7-25 checking and changing gearbox oil (s)...7-25 checking and changing front axle oil (t)...7-26 checking and changing rear axle oil (u)...7-28 checking drive shaft and cv boots (v) ...

  • Page 11

    This manual includes information titled as warning, caution, important and note. These titles indicate the following: safety and vehicle damage warning this indicates that interesting or helpful information is being provided. Note warning this indicates that a condition may result in harm, serious i...

  • Page 12: Universal Symbols

    Variousuniversalsymbolshavebeenusedontheinstrumentsandcontrolsofyourvehicle.Belowisalistof theuniversalsymbolsandtheirmeanings. Universal symbols fuel-level low parking brake battery charging condition engine oil-pressure turn signal differential lock hazard warning lights headlight-low beam headlig...

  • Page 13: Safety Precautions

    Safety precautions 1 1 precautions before operation ...................... 1-2 general precautions.........................................................1-2 precautions during operation ....................... 1-4 when starting the engine ................................................1-4 when dr...

  • Page 14

    1 - 2 1. It is recommended that you read and understand this entire manual before operation of your new vehi- cle. Failure to do so could result in accidents or injury. 2. Only persons who are properly trained should be allowed to oper- ate the vehicle. 3. Read and follow all warning labels and deca...

  • Page 15

    Safety precautions 1 - 3 1 uuvo102a 6. Never operate this vehicle or any other agricultural equipment while under the influence of alcohol, drugs or while fatigued. 7. While working in cooperation with other vehicles always communi- cate your intentions. 8. This vehicle should be driven only by a dr...

  • Page 16

    1 - 4 10. Never allow anyone to operate this vehicle unless person has read this manual and all decals thoroughly. Uuvo116a 11. It is recommended to wear a hel- met whenever driving this vehi- cle in an aggressive manner. Eye protection is recommended at all times. Uuvo123a precautions during op- er...

  • Page 17

    Safety precautions 1 - 5 1 2. When starting the vehicle make sure your path is clear of people to avoid accidents caused by sudden movements. 3. Before starting your vehicle you should make sure that all shift le- vers are in the neutral position and parking brake is applied. Uuvo103a 7. Make sure t...

  • Page 18

    1 - 6 10. Always activate the brake pedal before releasing the park brake. Uuvo133a when driving the vehicle kuvo158a 2. While turning the headlights on, dim them when meeting another vehicle. T66o127a 1. This is an off-road vehicle only, it is illegal to drive a utv on public roads. Uuvo122a utv-미국...

  • Page 19

    Safety precautions 1 - 7 1 3. Always slow the vehicle before turning. Turning at high speed may tip the vehicle over or cause a loss of control. 4. Drive at speeds that allow you to maintain control at all times. Uuvo112a 5. Do not apply the differential lock while traveling at road speeds. As the v...

  • Page 20

    1 - 8 12. For your safety rops with a seat belt is recommended for all appli- cations. 13. Watch front and rear to avoid ob- stacles at row ends, near trees and around other obstructions. Uuvo109a 10. Watch where you are going at all times so that you are able to avoid obstacles that can cause injur...

  • Page 21

    Safety precautions 1 - 9 1 14. Never try to get on or off a mov- ing vehicle. Uuvo110a 15. To minimize the risk of a rollover, crash, be especially careful when obstacles and slopes are ahead and when braking on hills or dur- ing turns. Uuvo121a 16. Never drive the vehicle at ex- cessive speeds. Alw...

  • Page 22

    1 - 10 17. Never attempt abrupt wheelies, jumps or other stunts. Uuvo125a 18. Always keep your both hands on the steering wheel and your both feet on the floor of the vehicle during operation. 19. Always keep arms and legs in- side the cab frame while the ve- hicle is in motion. Uuvo126a 20. Never d...

  • Page 23

    Safety precautions 1 - 11 1 22. Always follow proper procedures for climbing hills as described in this manual. Check the ter- rain carefully before attempting to climb any hill. Never climb hills with excessively slippery or loose surfaces. Never open the throttle suddenly or make sudden gear chang...

  • Page 24

    1 - 12 26. Never operate your vehicle in fast-flowing water or in water deeper than that specified in this manual. Wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them light- ly several times to let friction dry out the pads. Uuvo130a 27. Never...

  • Page 25

    Safety precautions 1 - 13 1 1. Place all control levers in the neu- tral position, set the parking brake, stop the engine. When parking the vehicle uuvo113a uuvo134a 2. Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or acci- dental starting. 3. Never leave ...

  • Page 26

    1 - 14 safety precautions during servicing 1. In order to service your vehicle you must park it on a flat level sur- face, set the parking brake, place the gear shift lever in neutral and stop the engine. Kuvo127a 2. D o n o t s m o k e w h i l e w o r k i n g around the battery or when refuel- ing ...

  • Page 27

    Safety precautions 1 - 15 1 uuvo118a 4. It is recommended to keep a first aid kit and fire extinguisher handy at all times. 5. Do not remove the radiator cap while the coolant is hot. When cool, slowly rotate the cap to the first stop and allow sufficient time for excess pressure to escape. Af- ter ...

  • Page 28

    1 - 16 10. Tire mounting should be done by qualified professionals, with the proper equipment. 11. Maintaining correct tire pres- sure is important for the life of your tires. Do not inflate the tires above the recommended pres- sure specified in the owner ’s manual. 12. Securely support the vehicle...

  • Page 29

    Safety precautions 1 - 17 1 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. Uuvo139a utv-미국향-oem용-01.Indd 17 201...

  • Page 30

    1 - 18 safety precautions when using the rops 1. Rops (roll over protective struc- ture) is equipped to protect driver and passengers when the vehicle is rolled over. Always fasten your seat belt. Failure to fasten your seat belt can invalidate rops. (1) rops uuvo141a rops, sun canopy or cabin are n...

  • Page 31

    Safety precautions 1 - 19 1 safety decal mounting location uuvo142c utv-미국향-oem용-01.Indd 19 2011-03-21 오후 5:29:46.

  • Page 32

    1 - 20 decals (5) part no. : u3215-85562 1. Never drive this utility vehicle unless you're 16 or older or have a driver's license. 2. This machine is designed for off-road use only. Never drive on public roads and avoid paved surfaces as the handling characteristics of the machine may be adversely a...

  • Page 33

    Safety precautions 1 - 21 1 (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 · fasten seat belts · securely fasten all cargo ·...

  • Page 34

    1 - 22 (8) part no. : u3215-85661 u3215-85661 (7) part no. : u3215-85631 max 7.3 inch (185mm) ...

  • Page 35

    Safety precautions 1 - 23 1 (12) part no. : u3215-85651 u3215-85651 (13) part no. : u3215-85691 u3215-85691 (14) part no. : u3215-85621 · never raise the bed/operate the dump mechanis...

  • Page 36

    1 - 24 (16) part no. : u3215-85171 u3215-85171 to prevent personal injury, 1. Always wear your seat belt. In the event of a rollover, press your feet firmly against the floor board and keep hands on the steering wheel or hand holds. 2. Do not remove the rops for any reason. 3. Never modify o...

  • Page 37

    Safety precautions 1 - 25 1 (18) part no. : u3215-85191 riders · do not carry passengers/riders in the bed · haul unsecured cargo in the bed · do not travel with the cargo bed in the raised position · do not exceed the rated bed capacity of 1,100 pounds (500 kg) · do not place hands behind the seat ...

  • Page 38

    1 - 26 cautions for decal maintenance safety decals are attached to the ve- hicle for safe operation. Make sure to follow the instruction on the decals as well as the following instruction: keep the decals clean and in- tact. If any decal is dirty, wash it with soap and dry with a soft cloth. Never ...

  • Page 39: Precautions Before Operation

    2 precautions before operation 2 vehicle identification number......................... 2-2 vehicle serial number........................................ 2-2 engine serial number.........................................................2-2 precautions before operation ........ 2-1 vehicle identificat...

  • Page 40

    Precautions before operation 2 - pb 2 - 2 the engine serial number is stamped on the engine cylinder block where the injection pump is installed. (1) vehicle serial number this vehicle serial number is located on the structure frame where the bat- tery is installed. (1) engine serial number vehicle ...

  • Page 41: Specifications

    Specifications specification ........................................................... 3-2 exterior dimensions...........................................................3-2 general specifications.....................................................3-3 option list and features ........................

  • Page 42

    3 - 2 specification exterior dimensions in. (mm) overall length (a) overall width (b) overall height (c) wheel base (d) front wheel tread (e) rear wheel tread (f) ground clearance (g) 112.3 (2,852) 60.7 (1,543) 76.4 (1,940) 76.4 (1,940) 49.7 (1,262) 48.3 (1,228) 12 (304) d a e, f b c g c uuvo301a ※ ...

  • Page 43

    Specifications 3 - 3 3 general specifications items description remarks engine model 3c100lwu number of cylinders 3 total displacement cu.In(cc) 61.45 (1,007) fuel diesel gross hp/kw 22/16.4 rated speed rpm 2,800 capacity engine oil u.S.Gal.(l) 0.85 (3.2) fuel tank u.S.Gal.(l) 7.4 (28.0) gear box oi...

  • Page 44

    3 - 4 items description remarks t ire front wheel 25 x 10-12(worksite) 25 x 10-12(turf) rear wheel 25 x 10-12(worksite) 25 x 10-12(turf) cargo bed 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. Turning radius ft(m) 13 (3.96) gross weight lb...

  • Page 45

    Specifications 3 - 5 3 item description remarks canopy & w/s sun canopy kit plastic moulding canopy windshield kit acrylic windshield kit hitch front hitch receiver kit 2 inch square type remove lower screen of brush guard for installation hydraulics hydraulic dumping kit hydraulic cargo dumping kit...

  • Page 46

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  • Page 47: Controls And Features

    Controls and features 4 4 exterior view................................... 4-3 hood ..............................................................4-5 electric cooling fan motor ...............4-5 suspension .................................................4-6 headlamp ..................................

  • Page 48: Features And Controls

    Features and controls outside rearview mirror (optional) ..4-27 brush guard ............................................4-27 skid plates (optional) ..........................4-28 sun canopy (optional) .........................4-28 windshield (optional) ...........................4-28 rear screen (op...

  • Page 49

    4 - 3 features and controls 4 exterior view (1) seat back (2) seat (3) dumping handle (4) dumping latch (5) fuel tank cap (6) rops (7) steering handle (8) hood (9) headlamp (10) brush guard (11) rearreflexreflector (12) cargo bed (13) rear hitch receiver (14) rear wheel mudguard uuvo401a [ standard ...

  • Page 50

    4 -4 exterior view (1) front working lamp (2) sun canopy (3) head rest (4) rear view mirror (5) front turn signal lamp (6) windshield (7)cargobedextension uuvo461a [ full option model ] (8) tail lamp (9) fog lamp (10) rear screen utv-미국향-oem용-04.Indd 4 2011-03-21 오후 7:10:20

  • Page 51

    4 -5 controls and features 4 hood the hood has two rubber hooks to secure itself into the place. Always checkthattheyarefirmlyengaged. Make sure that the hood is firmly closed and engaged be- fore driving. If not, it may open during driving, resulting in an accident. Warning (1) hood (a) hook make s...

  • Page 52

    4 -6 headlamp the headlamps consist of halogen lamps for high beam and low beam. Their reflective mirrors are chrome- plated and have black bezel covers, featuringrefineddesign. (1) headlamp (rh) (2) headlamp (lh) driving with high beam head- lamps disturbs the approach- ing vehicle’s visibility for...

  • Page 53

    4 -7 controls and features 4 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 the driving speed of 16 km/h (10 mph). Remember that the stopping distance becomes longer whil...

  • Page 54

    4 -8 safety lamp kit (optional) (1) brake lamp & tail lamp (2) turn signal lamp & hazard lamps the brake lamps, turn signal lamps, horn and hazard switch are supplied as the "safety lamp kit" (optional). It is strongly recommended to install this if you drive at night frequently. Uuvo409a there is n...

  • Page 55

    4 -9 controls and features 4 switches (1) combination switch (2) spare switch panel uuvo410a (3) 12v power outlet key switch (1) key switch (a) stop (b) acc (c) on (d) heat (e) start (a) when the key switch is in position “a”, the engine and all electrical devicesinthevehiclestopexcept horn, hazard ...

  • Page 56

    4 -10 acc ( b) when the key switch is turned to the position “b”, only electrical power outlet and brake lights can be operated. (c) the position “c” indicates the “on” position.As soon as the key switch is turned to this position, the oil pressure warning lamp and bat- tery charge warning lamp come...

  • Page 57

    4 -11 controls and features 4 combination switch (1) turn signal lamp switch (2) headlamp switch (3) horn switch 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. Note uuvo412a the combi...

  • Page 58

    4 -12 driving with high beam head- lamps disturbs the approach- ing vehicle's visibility for safe driving. Use the high beam headlamps only if necessary. Warning turn signal lamp switch (1) turn signal lamp switch (a) : turn signal lamps on pulling the lever up blinks the right turn signal lamp whil...

  • Page 59

    4 -13 controls and features 4 (1) hornswitch the horn switch can be operated without the key in the key switch. Pressing this switch sounds the horn. Horn switch this horn switch can be operated when the optional horn which is included in optional "safety lamp kit" is installed in the vehicle. Make ...

  • Page 60

    4 -14 12v power outlet (1) 12v power outlet this 12 v power outlet operates with the key in the “acc” or "on" posi- tion. Usingthepoweroutletforanextend- ed period of time with the engine off or connecting an electric device with its capacity over the limit into the power outlet can discharge the ba...

  • Page 61

    4 -15 controls and features 4 instrument panel uuvo417a (1) fuel gauge (2) speedometer (3) coolant temperature gauge (4) turn signal indicator (lh) (5) neutral indicator (6) high beam indicator (7) lower fuel level warning indicator (8) preheating indicator (9) hourmeter (10) battery charge warning ...

  • Page 62

    4 -16 t46o568a (1) fuel gauge “e”: empty “f”: full this indicates the remaining fuel lev- el after the key switch is turned to the “on” position. F:fueliscompletelyfilled. E : replenish the fuel tank. If driving is continued with the nee- dle below the position "e", the warn- ing lamp of out of fuel...

  • Page 63

    4 -17 controls and features 4 coolant temperature gauge make sure to control the work load so that the pointer is not in the red zone. If the pointer stays in the red zone, do not stop the engine immediately. Instead, reduce the work load to cool down the engine before stopping the en- gine. Make su...

  • Page 64

    4 -18 battery charging lamp this lamp is turned on when the key switch is turned on before starting the engine but turned off after start- ing the engine. If this warning lamp comes on while driving, the charging system, such as the alternator, is malfunctioning. Therefore, turn off all electrical d...

  • Page 65

    4 -19 controls and features 4 this indicates the operating condi- tion of the preheat system. When the key switch is turned to the "on" po- sition, this indicator comes on for ap- prox.9seconds.Itisrecommended to start the engine as soon as this in- dicator goes off for best starting per- formance. ...

  • Page 66

    4 -20 lower fuel level warn- ing indicator this lamp comes on when the fuel tank is approaching empty. When it comes on, you should add fuel as soon as possible. Driving with the this lamp on or with the fuel level be- low “e” can cause the engine to mis- fireanddamagetheengineparts. If the air ente...

  • Page 67

    4 -21 controls and features 4 the shift lever has four positions; "h" (high speed), "l" (low speed), "n" (neutral) and "r" (reverse). This vehicle is equipped with the in- line type shift lever system for conve- nient control. Also, there is a stopper between the "h" and "n" positions to ensure safe...

  • Page 68

    4 -22 [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. To prevent this situation, this vehicle is equipp...

  • Page 69

    4 -23 controls and features 4 2wd/4wd shift lever (1) 2wd/4wd shift lever (2) lock (a) 2wd position (b) 4wd position the 2wd/4wd shift lever is equipped with a lock which should be pulled up byafingerinordertooperatethele- ver. (so does diff. Lock lever) the 4wd should be used only on a slippery sur...

  • Page 70

    4 -24 parking brake lever (1) parking brake lever (a) down to release with pushing (b) pull up to set button. The parking brake lever is similar to the one installed to cars. Make sure that the parking brake is released be- fore driving. Uuvo432a an unauthorized person or child can move or operate t...

  • Page 71

    4 -25 controls and features 4 the accelerator pedal is located on the right of the brake pedal. Make sure not to depress the brake pedal instead of the accelerator pedal and vice versa by mistake. Accelerator pedal (1) accelerator pedal (a) depress uuvo433a this seat is a bench type and can accommod...

  • Page 72

    4 -26 (1) adjustable headrest headrest (optional) the headrest can be installed on the driver and passenger positions on the rear frame. It height of headrest can be adjust- able with two steps. Uuvo436a the rops (roll over protective structure) is a unit made of robust metal tubes in order to prote...

  • Page 73

    4 -27 controls and features 4 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. Warning note rops: roll over protective structure fops: fal...

  • Page 74

    4 -28 sun canopy (optional) the sun canopy is available for this vehicle as an option. This is to im- prove the driver's comfort in rain or sunlight. Also, its curved design adds luxurytothevehicleexterior. (1) sun canopy when entering a garage, make sure that the vehicle does not hit the ceiling or...

  • Page 75

    4 -29 controls and features 4 the rear screen helps protect the passengers and driver against the falling objects from cargo to rider`s head by abrupt braking. (1) rear screen rear screen (optional) do not pile up cargo over the height of the side frame of the cargo bed. The driver and passengers ca...

  • Page 76

    4 -30 cargo bed (1) door (2) latch handle (3) wire rope (a) close (b) open to open the back door of the cargo bed, rotate and pull the handles on the both sides simultaneously. Also, make sure the latch handles are securely locked after closing the back door. Uuvo445a never drive your vehicle with t...

  • Page 77

    4 -31 controls and features 4 never let anyone ride on the cargo bed during driving. He/ she can fall off the bed and be seriously injured. It is dangerous to drive with the cargo bed raised. Make sure to lower the cargo bed to its original position and en- gage the latch before driving. Warning uuv...

  • Page 78

    4 -32 remote hydraulic lever (optional) (1)remotehydrauliclever(2)lockbracket (a)pulltoon (b)returntooff uuvo464b (1)outport (2)inport (a)in (b)out uuvse07a uuvo466a never drive your vehicle with the cargo weight over the specified max. Load limit. Caution max.Load:500kg(1,102lbs) always lock the le...

  • Page 79

    4 -33 controls and features 4 cargo bed extension (optional) (1)cargobedextender thecargobedextenderismadeof metal tubes and can be attached to the sides of the cargo bed to load bigger objects. Never exceed the specified max. Load limit even with the cargo bed extender installed. Caution max.Load:5...

  • Page 80

    4 -34 (1) fuel tank fuel tank the fuel tank is installed under the right side of the cargo bed and its ca- pacity is 7.4 gallons (28 liters). Since this vehicle is equipped with the die- sel engine make sure to fill the fuel tank with clean diesel fuel for optimal performance. Make sure to keep the ...

  • Page 81

    4 -35 controls and features 4 make sure to use high quality diesel fuel for durability and performance of the engine. The cetane number of the fuel should be at least 40 (astm d975) in any circumstance. It is rec- ommended to use fuel with higher cetane number when driving in cold weather or at an a...

  • Page 82

    4 -36 t56o530a tire though the tire inflation pressure is factory-set to the prescribed level, it naturally drops slowly in the course of time. Thus, check it everyday and inflateasnecessary. (a)insufficient (b)standard (c)excessive uuvo456a all terrain (recreational) uuvo460a tire tread patterns wo...

  • Page 83

    4 -37 controls and features 4 1. Always check the tire inflation pressure before driving. It is possi- bletochecktheinflationpressure roughly by checking the tires visu- ally and tapping them (refer to the figureabove). 2.Check if the wheel nuts are firm- ly tightened and tighten them as necessary b...

  • Page 84

    4 -38 alwaysmaintainthepropertireinflationpressure.Makesurethetirepressure doesnotexceedthepressurerecommendedinthemanual. Proper inflation pressure iftireswithadifferentsizefromtheonesspecifiedareinstalled,contact the dealer for the front/rear wheel speed ratio. Improper front/rear wheel speedratio...

  • Page 85: Operation

    Operation 5 5 pre-operation .............................. 5-2 daily inspection...................................5-2 operating the engine ............... 5-2 starting the engine...........................5-2 checking warning lamps after starting engine ...................................5-5 operati...

  • Page 86

    5 -2 it is a good practice to know the con- dition of your vehicle before you start it. You should do routine check be- fore each use. Stop the vehicle on level ground, stop the engine and apply the parking brake before checking or servicing the vehi- cle. For refueling, refer to the chap- ter "main...

  • Page 87

    5 -3 operation 5 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. The parking brake indicator on the instrument panel comes on while the parking brake is en- gaged. It goes off when the park- ing brak...

  • Page 88

    5 -4 4. Insert the key into the key switch and turn it to the "on" position. 7. When the engine is started, re- lease the key. The key switch is automatically returned to the "on" position. 8. After the engine is started, let the engine run for approx. 3 to 4 min- utes (10 minutes in cold weath- er)...

  • Page 89

    5 -5 operation 5 the engine can be severely damaged if it is run with the oil pressure warning lamp on. Warning checking warning lamps after starting engine 2. If the charge warning lamp does not go off in 4 to 5 seconds after the engine is properly started, it means that the battery is not being pr...

  • Page 90

    5 -6 stopping the engine never touch the muffler or heat shield until the engine is suffi- ciently cooled down. Failure to do so could result in serious injury or burns. Warning apply the parking brake and remove the key from the key switch before leaving your ve- hicle. An unauthorized person or ch...

  • Page 91

    5 -7 operation 5 when leaving the vehicle, make sure to remove the key after turning off all the electri- cal systems. Also, be careful not to leave the utility vehicle unattended as the same key is used for all vehicles. It can be stolen. The horn, turn signal lamps and hazard warning lamps can be ...

  • Page 92

    5 -8 2. Start the engine after checking that the shift lever is in the neutral position. (1) shift lever (1) parking brake (a) push (b) release 3.Releasetheparkingbrake. Uuvo503a uuvo505a 4. Place the shift lever to the "h" (high speed) or "l" (low speed). 5. Depress the accelerator pedal gradually ...

  • Page 93

    5 -9 operation 5 avoid abrupt acceleration or braking for safe driving. When driving on a steep hill or loading or unloading the vehi- cle from the transportation ve- hicle, set the shift lever into the "l" position or the 4wd/ 2wd lever into the "4wd" po- sition in advance. Practice starting and st...

  • Page 94

    5 -10 it is recommended always to warm up the engine before driving in order to maintain the durability of the en- gine and prevent malfunction of the engine. Warming up the engine can ensure that each part in the engine is prop- erly lubricated and each hydraulic part is in a perfect condition in o...

  • Page 95

    5 -11 operation 5 (1) battery if the battery is discharged and the engine cannot be started, it is possi- ble to start the engine by connecting the discharged battery to a battery from another vehicle or other extra battery. 1. Check that the voltage of the dis- charged battery is the same as the vo...

  • Page 96

    5 -12 depress the brake pedal to control the driving speed. 1. Release the accelerator pedal completely. 2. Depress the brake pedal evenly and firmly. Stopping this vehicle does not have an engine brake function. Always check the brake function before operating the vehicle. This vehicle is equipped ...

  • Page 97

    5 -13 operation 5 never park on a slope with only the transmission en- gaged. The vehicle may roll down, leading to an accident. If it is unavoidable to park on a slope and leave the vehicle, apply the parking brake and chock the wheels. Never park the vehicle on a steep slope. A serious acci- dent ...

  • Page 98

    5 -14 abrupt braking or acceleration in the 2wd operation on a slip- pery surface can make the rear wheels slide to one side, re- sulting in the vehicle skidding. Make sure to use the 4wd in advance in this case. When the vehicle starts to skid with the rear wheels spin- ning, release the accelerato...

  • Page 99

    5 -15 operation 5 driving on slope uphill and downhill 1. Move the shift lever into the "l" position before driving uphill. Also, select the 4wd as necessary de- pending on road surface condi- tions. 2. Avoid driving on a slope of 15° or more. Drive the vehicle at a low speed so that the engine is n...

  • Page 100

    5 -16 3. It is hard to steer the vehicle and the front section of the ve- hicle can be lifted off the ground when driving on a slope with ex- cessive cargo loaded in the vehi- cle. In the worst case, the vehicle may roll over down the hill. There- fore, avoid carrying excessive load when driving on ...

  • Page 101

    5 -17 operation 5 driving in forest driving through water driving through water without knowing depth, speed and bot- tom condition of waterflow is very dangerous and can lead to a drowning accident. If driving on a slope or at a high speed with the brake wet after driving through water, the brake s...

  • Page 102

    5 -18 it is required to service the vehi- cle after driving through water. Pay special attention to the en- gine oil, transmission fluid, front/ rear differential gear cases and grease fittings. Salty water corrodes paint and exterior parts of the vehicle. Make sure to wash the vehicle thoroughly wi...

  • Page 103

    5 -19 operation 5 observe the following when driving on a road: 1. It is recommended to attach the "safety lamp kit" (optional) from dealer when driving on a public road. 2. If the vehicle is equipped with the turn signal lamps, use them during driving. If not, inform other driv- ers of your intende...

  • Page 104

    5 -20 if loading cargo excessive- ly or unevenly, you can lose steerability and braking con- trol, resulting in a severe acci- dent. Make sure to keep under the specified load limit and ob- serve relevant regulations. Avoid overspeed driving, abrupt acceleration and abrupt starting-off in order to p...

  • Page 105

    5 -21 operation 5 1. Open the tailgate with both hands. Be careful as the tailgate can open abruptly due to cargo on the cargo bed. 2. To raise the cargo bed, pull up the handle with one hand while turn- ing the latch lever with the other hand. 3. Never apply excessive force to raise the cargo bed a...

  • Page 106

    5 -22 unloading (if the dumping kit is installed) 1. Open the tailgate first before dumping the cargo bed. 2. Pull the duping lever slowly after removing lever lock bracket. 3. After duping the cargo, push the dumping lever back to lower down the cargo bed. (1)hydrauliclever (2) leverlockbracket (a)...

  • Page 107

    5 -23 operation 5 uuvo517a towing trailer this vehicle is equipped with a 2-inch square hitch receiver in the back as standard. Be careful of the following when towing a trailer 1. This vehicle can tow a trailer and cargo with their weight of up to 590 kg (1300 lbs). You can lose control of the vehi...

  • Page 108

    5 -24 [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. Transporting 1. Check the width of the cargo bed of a trans...

  • Page 109

    5 -25 operation 5 5. After getting onto the transporting vehicle, apply the parking brake firmly and secure the vehicle onto the body frame or bracket of the transporting vehicle with chains or belts. 6. When transporting the vehicle on a road, set applicable decals to keep local regulations. 7. Alw...

  • Page 110

    5 -26 2. When moving the 2wd/4wd le- ver, push up the detent knob with a finger and then move the lever. 3. To operate the shift lever, depress the brake pedal and stop the ve- hicle completely. It is hard to shift when the vehicle is moving or the engine is running at a high idling speed. Moreover,...

  • Page 111

    5 -27 operation 5 [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. 2. Keep your feet as far as possible ...

  • Page 112

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  • Page 113: Replacement Parts

    Replacement parts 6 essential replacement part ........................... 6-2 oil and fluid ...........................................................................6-2 filters ......................................................................................6-2 belts and rubber parts...........

  • Page 114

    Replacement parts 6 - 3 6 - 2 replacement parts 6 - 3 6 - 2 there are various types of oil and flu- ids used in this vehicle for the opera- tion, lubrication, cooling and anti-cor- rosion of the vehicle. If any oil or fluid is insufficient, de- graded or contaminated, it can cause incorrect operatio...

  • Page 115

    Replacement parts 6 - 3 6 - 2 replacement parts 6 - 3 6 - 2 6 rubber belts, hoses and boots get tender and cracked as they age. Continuous use of a belt, hose or boot in poor condition can result in part should be part failure, caus- ing a serious problem to the vehi- cle. Make sure to replace such ...

  • Page 116

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  • Page 117: Maintenance

    Maintenance 7 maintenance check list ............7-3 daily check chart.................................7-3 maintenance interval table .............7-4 lubricants ......................................7-6 daily inspection ............................7-7 access for service................................

  • 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) .............

  • Page 119

    7 -3 maintenance 7 maintenance check list daily check chart ※ for detailed information about maintenance codes, refer to the corresponding section in each chapter. Service schedule maintenance codes item service required engine cooling system clean debris from radiator, screen and grills. Check cool...

  • Page 120

    7 -4 maintenance interval table no interval check item run hour run age maintenance codes 10 50 100 200 400 800 1000 1year 2year 1 engine oil and filter replace ⊙ ○ f 2 fuel filter replace ○ l 3 fuel line and hose connection check ⊙ ○ m 4 fuel tank and its filler cap check ○ l, m 5 air cleaner filte...

  • Page 121

    7 -5 maintenance 7 no interval check item run hour run age maintenance codes 10 50 100 200 400 800 1000 1year 2year 15 hydraulic oil (if equipped with hydraulic kit) replace ⊙ ○ s 16 pump, cylinder, levers, oil tank and hoses related to hydraulic kit (if equipped) check ○ 17 brake fluid level check ...

  • Page 122

    7 -6 lubricants to prevent serious equipment damage, use only indicated fluids, oils and greases, or equivalents. Check the oil level regularly. Correct the oil level, if needed, before operating. Always check and add oil with the vehicle on a flat, level surface. Warning no. Item capacity [ u.S. Ga...

  • Page 123

    7 -7 maintenance 7 daily inspection access for service (1) inspection shield (1) engine oil dipstick (2) oil filter it is possible to check the engine oil dipstick, oil filter, fan belt tension, start motor power connection, etc. After opening the inspection shield. This vehicle is designed so that ...

  • Page 124

    7 -8 raising cargo bed (c) opening seat cushion (b) uuvo703a to open the seat cushion, lift its rear side slightly and then raise both sides with both hands as shown in the figure. (1) seat uuvo704a to close the seat cushion, align the pins under the cushion with the holes and then push down the cus...

  • Page 125

    7 -9 maintenance 7 (1) hydraulic cylinder kuvo706a it is possible to check the gearbox oil, cvt, muffler, air filter, fuel strainer, parking brake pad for wear and play, shift lever cable and differential lock cable play by raising the cargo bed. Also, most of the service items can be inspected by l...

  • Page 126

    7 -10 6. If the oil level is below the min lim- it, add some oil. If the oil level is above the max limit, drain some oil through the drain plug. 7. Insert the dipstick to its end and close the inspection shield. H11o606a (1) oil dipstick (a) max limit (b) min limit checking engine oil level (e) 1. ...

  • Page 127

    7 -11 maintenance 7 the engine oil should be checked regularly. Driving without sufficient engine oil can lead to severe engine dam- age. It is recommended to inspect the engine when it is cold be- fore starting it. The oil level should always be between the max and min lim- its. Be sure to stop the...

  • Page 128

    7 -12 (1) filler cap 8. Open the filler cap and slowly add new oil. 9. The engine oil capacity for this ve- hicle is as follow. Oil capacity 0.85 u.S.Gal. (3.2 l) 10. Install the filler cap. 11. Start the engine and run it at a low speed without load. Then, check if any oil has leaked. Uuvo711a 12. ...

  • Page 129

    7 -13 maintenance 7 do not operate the engine without the anti-dust valve or air filter. The engine can be damaged. Important 4. Check if the anti-dust valve is torn or damaged and replace it as nec- essary. Replacing air filter (h) 1. Park the vehicle on level ground and apply the parking brake fir...

  • Page 130

    7 -14 (1) clamp 1 (2) clamp 2 1. Park the vehicle on level ground and apply the parking brake firmly. 2. Stop the engine, remove the seat cushion and raise the cargo bed. (in case the hydraulic dumping kit is installed, raise the cargo bed before stopping the engine.) 3. Check if the clamps (1 and 2...

  • Page 131

    7 -15 maintenance 7 4. Remove the heat shield covers (1 and 2). (1) heat shield cover 1 (2) heat shield cover 2 uuvo717a 5. Remove the exhaust pipe, but leave the muffler in place. (1) exhaust pipe (2) muffler uuvo718a 6. Remove the air hoses (1 and 2) from the cvt cover. (1) air hose 1 (2) air hose...

  • Page 132

    7 -16 7. Remove the cvt cover. (1) cvt cover uuvo720a 8. Measure the width of the cvt belt. Replace it with a new one if it has been used for more than 800 hours or its width is 1 in. (25 mm) or less. For replacement, contact your dealer. (1) cvt belt uuvo721a the width of a new belt is 29 mm (1 9/6...

  • Page 133

    7 -17 maintenance 7 checking cvt driven pul- ley clutch buttons(k) 1. Remove the relevant parts such as the cvt cover by following the same procedure as for the cvt belt service (see "checking cvt belt"). 2. Check the cvt driven pulley clutch buttons (1 and 2) for wear. 3. If they should need replac...

  • Page 134

    7 -18 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 posi...

  • Page 135

    7 -19 maintenance 7 bleeding fuel line (m) 1. Park the vehicle on level ground and apply the parking brake firmly. 2. Stop the engine, raise the car- go bed, and then remove the seat cushion. 3. Make sure that the fuel is suffi- cient in the fuel tank. If necessary, fill the fuel tank with fuel. The...

  • Page 136

    7 -20 6. Unscrew the bleeding bolt (1) slightly and crank the engine. Check that air comes out of the gap. 7. When air bubbles are not seen any more in the drained fuel, screw the bleeding bolt and try to start the engine 2~3 times again. 8. If the engine still cannot be start- ed, unscrew the nozzl...

  • Page 137

    7 -21 maintenance 7 driving with the radiator core clogged by foreign materials can deteriorate heat radiation performance, resulting in the overheated engine. If the distorted or clogged area of the radiator core is over 30% of its total area, it is recommend- ed to replace it with a new one. For r...

  • Page 138

    7 -22 1. Park the vehicle on level ground and apply the parking brake firmly. 2. Stop the engine and let the engine cooled down sufficiently. 3. Open the hood. 1. Park the vehicle on level ground and apply the parking brake firmly. 2. Check the coolant level through the sight glass of the auxiliary ...

  • Page 139

    7 -23 maintenance 7 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. (1) brush guard (upper) (2) brush guard (middle) (3) b...

  • Page 140

    7 -24 20. If a different type of anti-freeze is to be used, fill the cooling sys- tem with clean water, run the en- gine for approx. 5 minutes and drain the water. Repeat this 2 to 3 times before adding new anti- freeze. Coolant capacity 1.7 u.S gal. (6.3 l) water+ethylene glycol 50:50 uuvo733a 9. L...

  • Page 141

    7 -25 maintenance 7 checking spark arrester of exhaust pipe (if equipped) (r) 1. Park the vehicle on level ground and apply the parking brake firmly. 2. Stop the engine and let the engine cooled down sufficiently. 3. Raise the cargo bed and support it with the support rod. Checking and changing gear...

  • Page 142

    7 -26 10. Check the oil level by performing the step 5 in the previous page. If the oil level is normal, install the filler plug. 11. Wipe the gearbox and is sur- rounding with a rag thoroughly. 12. Test drive the vehicle for 5 to 10 minutes to check for leakage. 1. Park the vehicle on level ground ...

  • Page 143

    7 -27 maintenance 7 10. Check the oil level by performing the step 5 in the previous page. If the oil level is normal, install the filler plug. You can get burnt badly by hot oil. Make sure to work on it after it is sufficiently cooled down. Warning 9. When adding new oil, add it through a long hose...

  • Page 144

    7 -28 1. Park the vehicle on level ground and apply the parking brake firmly. 2. Stop the engine and let the engine cooled down sufficiently. Checking and changing rear axle oil (u) 3. Clean around filler plug, then re- move the filler plug. 4. Check that the differential case surface is not hot. Th...

  • Page 145

    7 -29 maintenance 7 1. Park the vehicle on level ground and apply the parking brake firmly. 2. Stop the engine. Checking drive shaft and cv boots (v) (1) cv boots (front wheel) 3. Check if the cv boots of the drive shaft for the front wheels are torn or have a sign of leakage. (1) cv boots (rear whe...

  • Page 146

    7 -30 1. Park the vehicle on level ground and apply the parking brake firmly. 2. Stop the engine. 3. Open the hood and support it. Checking steering rack boots and ball joint (w) (1) steering rack boot 4. Check the steering rack boots, to see if torn or have a sign of leak- age. (1) tie rod end 5. T...

  • Page 147

    7 -31 maintenance 7 1. Park the vehicle on level ground and apply the parking brake firmly. 2. Stop the engine, open the hood and support the hood. Checking brake fluid (x) (1) brake fluid tank (a) max limit (b) min limit 3. Clean the brake fluid tank and its surrounding thoroughly. 4. Check the bra...

  • Page 148

    7 -32 checking brake pad (z) 1. Park the vehicle on level ground and apply the parking brake firmly. 2. Unscrew the nuts of the wheel to be checked only 1 turn. 3. Lift the vehicle with a hydraulic jack and then support the vehicle with the safety stand. Then, lower the hydraulic jack so that the ve...

  • Page 149

    7 -33 maintenance 7 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. In order to keep the parking brake in ...

  • Page 150

    7 -34 7. If the parking brake pads should be replaced with new ones or ab- normal wear is found on the disc, contact your dealer. Adjusting suspension (ab) 1. Park the vehicle on level ground and apply the parking brake firmly. 2. Unscrew the nuts of one of the rear wheels only 1 turn. 3. Lift the v...

  • Page 151

    7 -35 maintenance 7 6. After adjustment, install the wheel and tighten the wheel nuts firmly. Driving with loose wheel nuts is very dangerous and can lead to overturn and collision. Make sure that the nuts are firmly tightened. Checking suspension shock absorber (ac) 3. Check for any sign of oil lea...

  • Page 152

    7 -36 replacement 1. Park the vehicle on level ground and apply the parking brake firmly. 2. Stop the engine. (1) side cover 3. Remove the side cover (lh). (1) battery cover (a) positive (+) cable (b) negative (-) cable 4. Remove the battery cover and dis- connect the negative battery ca- ble. 5. Di...

  • Page 153

    7 -37 maintenance 7 replacing headlamp bulb (ae) 3. Remove the rubber cover. Then, remove the mounting screws with a phillip’s head screwdriver. 1. Park the vehicle on level ground and apply the parking brake firmly. 2. Stop the engine, open the hood and support the hood. (1) connector (2) rubber co...

  • Page 154

    7 -38 4. Hold and pull the socket section to pull out the bulb. 5. When installing a new bulb, be careful not to touch its glass. Du- rability of a bulb can be deteriorat- ed. 6. Tighten the mounting screws and install the rubber cover firmly. (1) bulb (2) rubber cover (a) pull out checking and repl...

  • Page 155

    7 -39 maintenance 7 main fuse (slow-blow fuse) (ag) (1) slow-blow fuse if the start motor and all electrical de- vices do not operate at all when turn- ing the key the switch to the "start" position, the first thing to inspect is the main fuse. 1. Remove the engine inspection shield. 2. Check if the...

  • Page 156

    7 -40 checking differential lock cable (ai) (1) differential lock cable (2) nut 1. Park the vehicle on level ground and apply the parking brake firmly. 2. Stop the engine, raise the cargo bed and support it with the support rod. (in case the hydraulic dump- ing kit is installed, raise the cargo bed ...

  • Page 157

    7 -41 maintenance 7 checking shift and 4wd cables (aj) (1) shift cable (2) nut 1 (3) 4wd cable (4) nut 2 1. Park the vehicle on level ground and apply the parking brake firmly. 2. Stop the engine, raise the cargo bed and support it. 3. Unscrew nut 1 and adjust the length of the shift cable. 4. Unscr...

  • Page 158

    7 -42 adjusting belt tension (al) the engine belt drives the alterna- tor and coolant pump. If the tension of this belt is below the specification, the alternator efficiency decreases, resulting in insufficient battery charge level and low coolant circulation effi- ciency. If the tension of this bel...

  • Page 159

    7 -43 maintenance 7 do not wipe any plastic parts if they are not washed. Spraying insecticide can damage the plastic and painted surface. Never spray insecticide near the vehicle. Do not spill the brake fluid on the vehicle parts. It can damage the painted surface. If the brake fluid is spilled, wi...

  • Page 160

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  • Page 161

    Utv-미국향-oem용-08.Indd 1 2011-03-21 오후 5:07:14.

  • Page 162

    4.Inflatethetirestoapressurealit 9.Applygreasetoeverygreasefit necessary,drainandflushit,and utv-미국향-oem용-08.Indd 2 2011-03-21 오후 5:07:15.

  • Page 163

    Andinflatethetiresiftheyarelow. 4.Checkallfluidlevels,includingthe andbrakefluid. Points,andgreasefittingasneed leading to a fire. Dieselandfillthestandarddiesel utv-미국향-oem용-08.Indd 3 2011-03-21 오후 5:07:15.

  • Page 164

    Utv-미국향-oem용-08.Indd 4 2011-03-21 오후 5:07:15.

  • Page 165

    Utv-미국향-oem용-09.Indd 1 2011-03-21 오후 5:07:32.

  • Page 166

    Hard to start the engine insufficient preheating insufficient fuel clogged fuel filter or fuel hose, blocked fuel filter valve this troubleshooting chart summarizes simple service items for users who are familiar with mechanical systems. For more detailed service items, contact your local dealer. Ut...

  • 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 (knocking, vibration, smoke) excessive engine oil (overfilling, water or hydraulic oil mixed with engi overheated engine restricted fuel supply (clogged fil...

  • 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 utv-미국향-oem용-09.Indd 4 2011-03-21 오후 5:07:32.

  • 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 utv-미국향-oem용-09.Indd 5 2011-03-21 오후 5:07:32.

  • 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 8. Vehicle cannot...

  • 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 excessively worn brake pad when braking wet brake pads on one s...

  • Page 172

    15. Parking brake is malfunc (vehicle rolls down on slope) improperly adjusted parking brake cable 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 faulty steering knuckle e...

  • Page 173

    Utv-미국향-oem용-10.Indd 1 2011-03-21 오후 5:07:47.

  • Page 174

    Utv-미국향-oem용-10.Indd 2 2011-03-21 오후 5:07:47.

  • Page 175

    Index utv-미국향-oem용-10.Indd 3 2011-03-21 오후 5:07:47.

  • Page 176

    Utv-미국향-oem용-10.Indd 4 2011-03-21 오후 5:07:47.

  • Page 177

    Index utv-미국향-oem용-10.Indd 5 2011-03-21 오후 5:07:47.

  • Page 178

    Utv-미국향-oem용-10.Indd 6 2011-03-21 오후 5:07:48.

  • Page 179

    Utv-미국향-oem용-00.Indd 2 2011-03-21 오후 1:14:04.

  • Page 180

    1451 marvin griffin road, augusta, ga 30906 (800) 241-5855 i fax (706) 796-4540 i www.Ezgo.Com e-mail: ezgo@textron.Com i ©2011 e-z-go division of textron inc. Read all this manual to become thoroughly familiar with this vehicle. Pay particular attention to all notes, cautions and warnings. E-mail: ...