Cushman 646442 User manual

hauler 4x4 diesel
2 passenger
owner’s manual
646442

UTV-EZGO-Hauler 4X4 Diesel-00.in2 2 2015-05-26 오전 8:58:20

FOREWORD
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.
Thespecicationsinthismanualaresubjecttochangewithoutnotice.
< NOTE >
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,explana-
tionforoperations,maintenanceinterval,simplemaintenanceguide,troubleshootingsandetc.
Ifyouhaveanyquestionabouttheproductormanual,pleasefeelfreetocontactus.Wearealwaystryingto
deliver ultimate satisfaction and safety to customers.
UTV-EZGO-Hauler 4X4 Diesel-00.in1 1 2015-05-26 오전 8:58:20

UTV-EZGO-Hauler 4X4 Diesel-00.in2 2 2015-05-26 오전 8:58:20

SAFETY PRECAUTIONS ................................
VEHICLE IDENTIFICATIONS ..........................
SPECIFICATIONS ............................................
CONTROLS AND FEATURES .........................
OPERATION ....................................................
REPLACEMENT PARTS .................................
MAINTENANCE ...............................................
STORAGE AND DISPOSAL ............................
TROUBLESHOOTING .....................................
INDEX ...............................................................
SECTION
1
2
3
4
5
6
7
8
9
10
TABLE OF CONTENTS
UTV-EZGO-Hauler 4X4 Diesel-00.in3 3 2015-05-26 오전 8:58:20

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 ................................1-6
WHEN PARKING THE VEHICLE .............................1-13
SAFETY PRECAUTIONS DURING SERVICING ... 1-14
SAFETY PRECAUTIONS WHEN
USING THE ROPS ................................... 1-18
SAFETY DECAL ........................................ 1-19
MOUNTING LOCATION ...........................................1-19
DECALS ...................................................................1-20
CAUTIONS FOR DECAL MAINTENANCE ..............1-26
PRECAUTIONS BEFORE OPERATION ........ 2-1
VEHICLE IDENTIFICATION NUMBER........ 2-2
VEHICLE SERIAL NUMBER ......................................2-2
ENGINE SERIAL NUMBER........................................2-2
SPECIFICATIONS........................................... 3-1
SPECIFICATION .......................................... 3-2
EXTERIOR DIMENSIONS..........................................3-2
GENERAL SPECIFICATIONS ....................................3-3
OPTION LIST AND FEATURES .................................3-6
FEATURES AND CONTROLS........................ 4-1
EXTERIOR VIEW ......................................... 4-3
HOOD.........................................................................4-5
ELECTRIC COOLING FAN MOTOR ..........................4-5
SUSPENSION ............................................................4-6
HEADLAMP................................................................4-6
REAR HITCH RECEIVER ..........................................4-6
REAR WHEEL MUDGUARD......................................4-7
REFLEX REFLECTOR ...............................................4-7
UTV-EZGO-Hauler 4X4 Diesel-00.in4 4 2015-05-26 오전 8:58:20

TABLE OF CONTENTS
ENGINE CHECK WARNING LAMP ........................4-20
ERROR INDICATOR ................................................4-21
CONTROLS................................................ 4-24
SHIFT LEVER...........................................................4-25
DIFFERENTIAL LOCK LEVER (REAR WHEEL) .....4-25
2WD/4WD SHIFT LEVER.........................................4-27
BRAKE PEDAL.........................................................4-27
PARKING BRAKE LEVER........................................4-28
ACCELERATOR PEDAL ..........................................4-29
SEAT.........................................................................4-29
SEAT BELT ...............................................................4-29
HEADREST (OPTIONAL).........................................4-30
ROPS .......................................................................4-30
OUTSIDE REARVIEW MIRROR (OPTIONAL) ........4-31
BRUSH GUARD .......................................................4-31
SKID PLATES (OPTIONAL) .....................................4-32
SUN CANOPY (OPTIONAL) ....................................4-32
WINDSHIELD (OPTIONAL)......................................4-32
REAR SCREEN (OPTIONAL) ..................................4-33
FRONT HITCH RECEIVER (OPTIONAL) ................4-33
SAFETY LAMP KIT (OPTIONAL)...............................4-8
SWITCHES................................................... 4-9
KEY SWITCH .............................................................4-9
COMBINATION SWITCH .........................................4-11
HAZARD LAMP SWITCH (OPTIONAL) ...................4-13
SPARE SWITCH PANEL ..........................................4-14
12V POWER OUTLET..............................................4-14
INSTRUMENT PANEL ............................... 4-15
SPEEDOMETER / HOURMETER............................4-15
FUEL GAUGE...........................................................4-16
COOLANT TEMPERATURE GAUGE.......................4-16
ENGINE OIL PRESSURE WARNING LAMP ...........4-17
BATTERY CHARGING LAMP ..................................4-18
HEAD LIGHT HIGH BEAM LAMP ............................4-18
TURN SIGNAL LAMP...............................................4-18
GLOW PLUG INDICATOR .......................................4-19
PARKING BRAKE INDICATOR ................................4-19
NEUTRAL INDICATOR ............................................4-19
LOWER FUEL LEVEL WARNING INDICATOR .......4-20
UTV-EZGO-Hauler 4X4 Diesel-00.in5 5 2015-05-26 오전 8:58:20

CUP HOLDERS AND STORAGE BOXES ...............4-34
CARGO BED ............................................................4-34
CARGO BED CONTROL LEVER.............................4-34
CARGO BED CONTROL LEVER (OPTIONAL) .......4-35
REMOTE HYDRAULIC LEVER (OPTIONAL) ..........4-36
HAND THROTTLE LEVER (OPTIONAL) .................4-37
CARGO BED EXTENSION (OPTIONAL).................4-37
WORKING LAMP (OPTIONAL)................................4-38
FUEL TANK ..............................................................4-38
FUEL REQUIREMENTS...........................................4-39
ENGINE INSPECTION.............................................4-39
COOLANT, BRAKE FLUID AND ELECTRICAL
DEVICES...............................................................4-40
TIRE..........................................................................4-40
TIRE TREAD PATTERNS.........................................4-40
PROPER INFLATION PRESSURE ..........................4-42
OPERATION ................................................... 5-1
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
OPERATING PRINCIPLE OF PREHEAT SYSTEM ...5-6
STOPPING THE ENGINE ..........................................5-6
OPERATING THE VEHICLE........................ 5-7
HOW TO DRIVE .........................................................5-7
WARMING UP ..........................................................5-10
JUMP START............................................................5-11
STOPPING ...............................................................5-12
PARKING..................................................................5-12
SHIFTING.................................................................5-13
DRIVING ON SLIPPERY SURFACES .....................5-14
TURNING .................................................................5-15
DRIVING ON SLOPE ...............................................5-15
DRIVING IN FOREST...............................................5-17
DRIVING THROUGH WATER ..................................5-17
DRIVING BACKWARD .............................................5-18
DRIVING ON ROAD.................................................5-19
TABLE OF CONTENTS
UTV-EZGO-Hauler 4X4 Diesel-00.in6 6 2015-05-26 오전 8:58:20

TRANSPORTING CARGO .......................................5-19
UNLOADING ............................................................5-21
UNLOADING (IF THE DUMPING KIT IS INSTALLED)...5-22
TOWING TRAILER...................................................5-23
TRANSPORTING .....................................................5-24
4WD OPERATION....................................................5-25
DIFFERENTIAL LOCK OPERATION........................5-26
TAILGATE (BACK DOOR)........................................5-27
REPLACEMENT PARTS ................................ 6-1
ESSENTIAL REPLACEMENT PART........... 6-2
OIL AND FLUID ..........................................................6-2
FILTERS .....................................................................6-2
BELTS AND RUBBER PARTS....................................6-3
ELECTRIC PARTS ....................................................6-3
MAINTENANCE.............................................. 7-1
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............................................7-7
OPENING INSPECTION SHIELD (A) ........................7-7
OPENING SEAT CUSHION (B)..................................7-8
RAISING CARGO BED (C) ........................................7-8
APPLYING GREASE (D) ............................................7-9
CHECKING ENGINE OIL LEVEL (E) .......................7-11
CHANGING ENGINE OIL AND FILTER (F)..............7-12
DUST VALVE (G)......................................................7-13
REPLACING AIR FILTER (H) ...................................7-14
CHECKING AIR HOSE AND CLAMP( I )..................7-14
CHECKING CVT BELT (J)........................................7-15
CHECKING CVT DRIVEN PULLEY CLUTCH
BUTTONS(K).........................................................7-17
CHECKING FUEL FILTER(L) ...................................7-18
BLEEDING FUEL LINE (M) ......................................7-20
CHECKING INJECTION NOZZLE AND FUEL
INJECTION PUMP (N) ..........................................7-21
CLEANING RADIATOR CORE (O) ..........................7-21
TABLE OF CONTENTS
UTV-EZGO-Hauler 4X4 Diesel-00.in7 7 2015-05-26 오전 8:58:20

TABLE OF CONTENTS
CHECKING COOLANT IN AUXILIARY
COOLANT TANK (P) .............................................7-22
CHANGING COOLANT (Q)......................................7-23
CHECKING SPARK ARRESTER OF
EXHAUST PIPE (IF EQUIPPED) (R) ....................7-26
CHECKING AND CHANGING GEARBOX OIL (S)...7-26
CHECKING AND CHANGING FRONT AXLE OIL (T).....7-27
CHECKING AND CHANGING REAR AXLE OIL (U) ...7-29
CHECKING DRIVE SHAFT AND CV BOOTS (V) ....7-30
CHECKING STEERING RACK BOOTS AND
BALL JOINT (W) ....................................................7-31
CHECKING BRAKE FLUID (X) ................................7-32
CHECKING BRAKE PEDAL FREE PLAY (Y)...........7-32
CHECKING BRAKE PAD (Z)....................................7-33
CHECKING PARKING BRAKE (AA) ........................7-34
ADJUSTING SUSPENSION (AB).............................7-35
CHECKING SUSPENSION SHOCK ABSORBER (AC)....7-36
BATTERY (SEALED) (AD)........................................7-36
REPLACING HEADLAMP BULB (AE)......................7-38
CHECKING AND REPLACING FUSE (AF) ..............7-39
MAIN FUSE (SLOW-BLOW FUSE) (AG) ................7-40
ALIGNING WHEEL AND CHECKING WHEEL NUT (AH) ....7-40
CHECKING DIFFERENTIAL LOCK CABLE (AI)......7-41
CHECKING SHIFT AND 4WD CABLES (AJ) ...........7-42
USING BIODIESEL (AK) ..........................................7-42
ADJUSTING BELT TENSION (AL)...........................7-43
WASHING (AM)........................................................7-44
PROTECTING PLASTIC AND PAINTED
SURFACE(AO) .....................................................7-44
STROAGE AND DISPOSAL.......................... 8-1
VEHICLE STORAGE ................................... 8-2
DAILY STORAGE .......................................................8-2
LONG-TERM STORAGE............................................8-2
USING VEHICLE AFTER LONG-TERM STORAGE ..8-3
DISPOSAL ................................................... 8-4
TROUBLESHOOTING.................................... 9-1
VEHICLE TROUBLESHOOTING ...............................9-2
INDEX............................................................ 10-1
INDEX.......................................................................10-2
UTV-EZGO-Hauler 4X4 Diesel-00.in8 8 2015-05-26 오전 8:58:20