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
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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

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 in-
jury or death to you or other persons if the warning is not hee-
ded. Follow the advice provided with the warning.
!
CAUTION
This indicates that a condition may result in damage to your
vehicle or its equipment if the caution is not heeded. Follow
the advice provided with the caution.
This mark indicates emphasis on notable characteristics of
working procedures, and information about technology for
easier operation.
IMPORTANT
UTV-EZGO-Hauler 4X4 Diesel-00.in9 9 2015-05-26 오전 8:58:20

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.
UNIVERSAL SYMBOLS
Fuel-Level low
Parking Brake
Battery Charging Condition
Engine Oil-Pressure
Turn Signal
Differential Lock
Hazard Warning Lights
Headlight-Low Beam
Headlight-High Beam
Four-Wheel Drive-ON
H
L
Preheat
Neutral Position
High speed travel light
Low speed travel light
Reverse travel light
N
R
UTV-EZGO-Hauler 4X4 Diesel-00.in10 10 2015-05-26 오전 8:58:20

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
UTV-EZGO-Hauler 4X4 Diesel-01.in1 1 2015-05-26 오전 8:53:56

HAULER 4X4 DIESEL
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 decals afxed to the vehicle.
T66O101a
PRECAUTIONS BEFORE OPERATION
GENERAL PRECAUTIONS
A careful operator is the best oper-
ator. Most accidents can be avoid-
ed by observing certain precautions.
To help prevent accidents, use these
safety precautions, and pay attention
to the job at hand. If you can prevent
an accident, your time will have been
well spent.
4. Replace any missing or damaged
decals as soon as it is practical.
A list of decals is shown on page
1-19 ~ 1-25.
5. Keep safety decals clean of dirt
and debris.
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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 driver with a valid driver’s li-
cense.
driver's license
UUVO114a
9. Never let anyone under 5 years of
age ride in the vehicle. If it is un-
avoidable, such child should be
secured with special restraints
which are not available with this
vehicle. Both driver and passen-
gers should wear their seat belts
at all times.
UUVO115a
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HAULER 4X4 DIESEL
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-
ERATION
WHEN STARTING THE ENGINE
1. Do not operate your vehicle in
an enclosed building without the
proper ventilation. Inhalation of
carbon monoxide can cause seri-
ous injury or death.
UUVO108a
UTV-EZGO-Hauler 4X4 Diesel-01.in4 4 2015-05-26 오전 8:53:57

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 that wheel nuts have
been tightened to the specified
torque.
8. Always check the tire pressure be-
fore start engine. For more infor-
mation about tire pressure, see
chapter 4.
9. Make sure that all pressure lines
are tight before starting the vehi-
cle.
UUVO131a
C56O164a
UUVO105a
4. Never start the engine while not
seated.
5. Keep bystanders away from the
vehicle while in operation.
6. Be sure to scrape off mud or soil
from your shoes before riding in
the vehicle.
UTV-EZGO-Hauler 4X4 Diesel-01.in5 5 2015-05-26 오전 8:53:57

HAULER 4X4 DIESEL
1
-6
10. Always activate the brake pedal
before releasing the park brake.
UUVO133a
WHEN DRIVING THE VEHICLE
2. When driving on a public road,
make sure to install the "Safety
lamp kit" supplied by dealer and
observe the applicable regula-
tions and laws. If the vehicle is not
equipped with the "Safety lamp
kit", there will be no brake lamps,
turn signal lamps and tail lamps
on the vehicle. In this condition,
it is very dangerous to drive on a
public road.
KUVO157a
T66O127a
1. In some countries or states, it is
illegal to drive a UTV on public
roads. Be aware of trafc laws be-
fore driving.
UUVO122a
UTV-EZGO-Hauler 4X4 Diesel-01.in6 6 2015-05-26 오전 8:53:57

SAFETY PRECAUTIONS 1
-
7
1
4. Always slow the vehicle before
turning. Turning at high speed may
tip the vehicle over or cause a loss
of control.
5. Drive at speeds that allow you to
maintain control at all times.
UUVO112aKUVO158a
6. Do not apply the differential lock
while traveling at road speeds. As
the vehicle may run out of control.
7. Do not use 4WD while traveling at
road speeds in a normal road con-
dition.
8. Avoid sudden movements of the
steering wheel as this can cause a
loss of control of the vehicle. This
risk is especially great when trav-
eling at road speeds.
3. While turning the headlights on,
dim them when meeting another
vehicle.
UUVO125a
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HAULER 4X4 DIESEL
1
-8
13. For your safety ROPS with a seat
belt is recommended for all appli-
cations.
9. When working in groups, always
let the others know what you are
going to do before you do it.
10. Do not operate near ditches,
holes, embankments, or other
terrain features which may col-
lapse under the vehicle's weight.
The risk of vehicle upset is even
higher when the ground is loose
or wet.
KUVO162a
11. Watch where you are going at
all times so that you are able to
avoid obstacles that can cause
injury or damage to your vehicle.
12. Before making reverse move-
ments with your vehicle, you
should always check to see that
the path is clear.
KUVO101a C56O164a
KUVO109a
UTV-EZGO-Hauler 4X4 Diesel-01.in8 8 2015-05-26 오전 8:53:57