Ezgo 1600xd Operating instructions

ISSUED APRIL 2011
1600xd
4x4
repair
manual
619728

We reserve the right to make changes
throughout the entire manual at any time
without notice.
•
REMARK
Using unspecified parts, fuel and lubricants
other than DAEDONG's genuine parts can
damage the UTV and such damage will not be
covered by warranty.
•
IMPORTANT
PREFACE
This manual is to provide servicing personnel with information on the general speci-
fications, service, operating principle, troubleshooting, exploded view including part
name, removing and installing procedures for OFF - ROAD Utility Vehicle with high-
end technology.
All information in this manual is based on the latest product information available at
the time of publication. Therefore, some of the information in this manual may differ
from the machine you have.
We have a principle to apply update to the next edition of the manual if there is any.
However, We have no obligation to modify the contents in this manual, especially the
contents in the manual which is already distributed or published.
The modified information is available in our online electronic manual system (DEMSS).
This manual is ultimately to satisfy customers with best performance of this UTV. If
there is any typo, wrong information or question for this manual, feel free to contact
us.
Apr. 2011
service division
DAEDONG INDUSTRIAL Co., Ltd.
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CHAPTER 1 SAFETY FIRST
CHAPTER 2 GENERAL
CHAPTER 3 ENGINE
CHAPTER 5 TRANSMISSION
CHAPTER 6 CHASSIS
CHAPTER 7 REAR AXLE
CHAPTER 8 BRAKE
CHAPTER 10 STEERING
CHAPTER 9 FRONT AXLE
CHAPTER 11 HYDRAULIC SYSTEM
CHAPTER 4 CVT
CHAPTER 12 ELECTRIC SYSTEM
TABLE OF CONTENTS
CHAPTER 13 INDEX
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CHAPTER 1
TABLE OF CONTENTS
SAFETY FIRST
1. SAFETY DECALS................................... 1-2
1.1 Alert symbols..........................................1-2
2. SAFETY TIPS.......................................... 1-3
2.1 Safety gear.............................................1-3
2.2 Workplace .............................................1-3
2.2.1 Ventilating system.........................1-3
2.2.2 Safe workplace.............................1-3
2.2.3 Illumination ...................................1-3
2.2.4 Safety equipment..........................1-3
2.2.5 Keeping your work area clean......1-3
2.3 Safety instructions when preparing tractor...1-4
2.4 Fire.........................................................1-4
2.5 Cautions when handling the battery.......1-5
2.6 Cautions for high pressure hoses ..........1-5
2.7 Use of appropriate tools and equipment...1-6
2.8 Handling of hazardous materials............1-6
2.9 Handling of rotating shaft and driving belt.....1-7
2.10 Scald prevention ....................................1-7
2.11 Disposal of environmental waste ...........1-8
2.12 Cautions when handling tires.................1-8
3. SAFETY DECALS................................... 1-9
3.1 The location of safety decal ...................1-9
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1-2 SUUV-W00 Apr. 2011
SAFETY FIRST
GENERALENGINECVT
TRANSMISSION
CHASSISREAR AXLEBRAKEFRONTAXLESTEERINGHYDRAULICELECTRICINDEX
1. SAFETY DECALS
Most accidents can be avoided if basic safety in-
structions and regulations are followed. Always fol-
low the safety regulations and avoid any dangerous
situation to prevent an accident.
You can be unexpectedly injured if inspecting or
servicing the UTV without full knowledge of it. Read
the manual carefully before starting service, and
follow the instructions on service, maintenance and
inspection to prevent any injury.
•
•
1.1 ALERT SYMBOLS
The meanings of the safety-alert symbols used in this manual are as follows:
A. REMARK
Broaden your knowledge with additionally supplied
service information for optimal service.
•
S76W002A
REMARK
C. CAUTION
This mark indicates potentially hazardous situation
which, if not observed, may result in serious injury.
•
ܙ#ڬ
S76W004A
CAUTION
S76W003A
B. IMPORTANT
This mark indicates emphasis on information which
can be confused when servicing. If this information
is not carefully read and observed, the UTV cannot
fully function or may be damaged.
•
D. WARNING
This mark indicates hazardous situation which, if
not observed, may result in death or injury.
•
S76W005A
WARNING
κȷ#դܹ#$
S76W001A
READ MANUAL!
SAFETY FIRST - SAFETY DECALS
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SUUV-W00 Apr. 2011 1-3
SAFETY FIRST
GENERALENGINECVT
TRANSMISSION
CHASSISREAR AXLEBRAKEFRONTAXLESTEERINGHYDRAULICELECTRICINDEX
경고
S76W007A
S76W008A
2. SAFETY TIPS
2.1 SAFETY GEAR
2.2.1 VENTILATING SYSTEM
The service should be performed in a well-ventilated
area. If the engine should be started in an enclosed
place, an exhaust gas vent pipe should be installed.
2.2.2 SAFE WORKPLACE
California Proposition 65 Warning
Inhaling exhaust gas can cause cancer or damage
the generative function leading to infertility.
•
WARNING
S76W006A
When operating on the vehicle, wear safety gloves,
safety shoes, ear plugs, safety goggles, safety helmet,
working clothes, etc. appropriate for your working envi-
ronment.
Never wear loose fitting clothing or a tie which can be
caught by rotating part. According to the statistics, most
accidents occurred with rotating parts are due to this
inappropriate manner of wearing clothes.
2.2 WORKPLACE
The work should be done in a wide, level and safe
place to prevent slip and fall accident.
2.2.3 ILLUMINATION
The work place should be well illuminated. If working in
a dark place or under the vehicle, use the work lamp.
The work lamp should be covered with the safety cov-
er. The bulb can start a fire due to the leaked fuel when
it is broken.
2.2.4 SAFETY EQUIPMENT
Be sure to keep a first aid kit and fire extinguisher han-
dy at all times.
2.2.5 KEEPING YOUR WORK AREA CLEAN
Keep the working area clean before and during work. If any
oil or fuel is spilled, it should be cleaned up immediately.
SAFETY FIRST - SAFETY TIPS
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1-4 SUUV-W00 Apr. 2011
SAFETY FIRST
GENERALENGINECVT
TRANSMISSION
CHASSISREAR AXLEBRAKEFRONTAXLESTEERINGHYDRAULICELECTRICINDEX
S76W010A
2.3 SAFETY INSTRUCTIONS WHEN
PREPARING TRACTOR
Stop the engine and remove the key.
Put "No Operation" label on the tractor if necessary.
•
•
2.4 FIRE
S76W011A
Never smoke or allow flames or sparks in your work
area when maintaining the fuel system.
•
S76W012A
Keep flames or sparks away from the fuel container,
spray paint, etc. and be careful of leaks.
•
S76W013A
Disconnect the negative battery cable.
Always disconnect the battery cable for fire preven-
tion before wiring service.
Be extra cautious of fire when welding.
•
•
•
S76W014A
Always keep a fire extinguisher in workplace.•
SAFETY FIRST - SAFETY TIPS
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