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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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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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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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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2.5 CAUTIONS WHEN HANDLING THE
BATTERY
Always disconnect the negative battery cable first
and reconnect it last to avoid sparks from an acci-
dental short circuit. Otherwise, it could result in fire
or injury.
•
The battery can be very hazardous because it con-
tains sulfuric acid. It can damage your cloth, and
even burn your skin when directly contacted. If it
contacts with your eyes, you may lose your sight.
•
2.6 CAUTIONS FOR HIGH PRESSURE HOSES
Do not charge the frozen battery. Charging the fro-
zen battery can cause explosion. Let the battery
warm up to ambient temperature (16°C, 60°F) be-
fore charging.
Keep sparks and flames (match, lighter) away from
the battery. The battery can explode due to hy-
drogen gasses inside the case.Never connect the
battery's negative and positive cables with metal
for test. Use only tester when checking. the battery
voltage.
•
•
S76W015A
S76W018A
The hydraulic fluid leaks from high pressure
hoses or pipes can penetrate your skin.
•
S76W019A
Before connecting a high pressure hose or pipe,
stop the engine and depressurize it by valve. Check
the bolts for tightness before starting the engine af-
ter the hydraulic system service.
Use a cardboard or plank when checking leakage.
•
•
S76W020A
Never weld the high pressure pipe or the surround-
ing area. The pipe or hose can be heated and ex-
plode which can lead to fire or burn.
•
S76W021A
S76W017AS76W016A
SAFETY FIRST - SAFETY TIPS
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2.7 USE OF APPROPRIATE TOOLS AND
EQUIPMENT 2.8 HANDLING OF HAZARDOUS MATERIALS
All DAEDONG's genuine parts do not contain asbestos.
REMARK
Do not blow out hazardous materials, such as clutch
dust, with compressed air. Inhaling such hazardous
materials can damage your health.
•
When lifting the tractor with a hydraulic jack or a
hoist, fix it firmly and install the auxiliary support.
Never work under the tractor if the support and the
hydraulic jack (hoist) are not installed.
When using a hydraulic jack or a hoist, do not use
it over the limit of the equipment and the conveying
belt.
Make sure that the hydraulic lock operates properly
before used. Improper use of lock can cause a seri-
ous accident.
Check the buttons and operating direction of the
hoist before using it. Improper operation can cause
a serious accident.
Do not use wooden blocks or bricks as support un-
der the tractor. As the tractor's weight is continuous-
ly applied to them, they can be broken or collapsed.
•
•
•
•
•
S76W022A
These materials should be rinsed or wiped away
after sprayed with oil.
•
Use the standard tools in proper size. If an inap-
propriate tool is used, it can slip which can damage
parts or injure you.
Do not confuse units (mm, inch, etc.). Use the air
impact wrench only when unscrewing the bolts or
nuts. Such wrench should not be used especially
when assembling precisely machined parts which
its tightening torque should be strictly followed. It
can cause malfunctions.
Be careful of a socket popped out due to the turning
force when using the air impact wrench. Especially,
be extra cautious when working on connection or
socket with joint.
•
•
•
SAFETY FIRST - SAFETY TIPS
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GENERALENGINECVT
TRANSMISSION
CHASSISREAR AXLEBRAKEFRONTAXLESTEERINGHYDRAULICELECTRICINDEX
2.9 HANDLING OF ROTATING SHAFT AND
DRIVING BELT 2.10 SCALD PREVENTION
Be careful not to get caught by the rotating engine
cooling fan.
•
S76W025A
You can be seriously injured if your hand or clothes
is caught by the rotating fan belt or A/C belt.
•
S76W026A
Do not open the radiator cap when the radiator is
hot. Hot coolant or steam can be surged leading to
a serious scald.
•
S76W027A
Check the surface temperature of the container be-
fore draining the engine oil, transmission fluid, cool-
ant, etc. If it is hot, let it cool down before draining it.
There is a high risk of burning.
Perform any service on the engine parts (muffler,
exhaust manifold, etc.) only when they are not hot.
•
•
S76W028A
SAFETY FIRST - SAFETY TIPS
Do not set a hand or a foot into the vehicle’s rotat-
ing shaft or belt.
Be extra careful when you are in loose clothes.
•
•
S76W024A
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CHASSISREAR AXLEBRAKEFRONTAXLESTEERINGHYDRAULICELECTRICINDEX
S76W029A
Observe relevant environmental protection regula-
tions when disposing used oil, transmission fluid,
coolant, oil filter, etc. Otherwise, they can pollute the
environment seriously and you could be charged in
violation of regulations.
•
S76W031A
Do not weld or apply heat to the tire rim or disc. The
tire can explode due to the rapidly increased pres-
sure in the tire.
Check tires for inflation pressure, damage, deforma-
tion, extended wear on lug and damage of rim and
disc. Also check if wheel nuts are loose.
•
•
The tire rims can fall out of the tires. Therefore, stay
out of its way when checking or inflating tires.
•
2.11 DISPOSAL OF ENVIRONMENTAL WASTE 2.12 CAUTIONS WHEN HANDLING TIRES
SAFETY FIRST - SAFETY TIPS
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SUUV-W00 Apr. 2011 1-9
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GENERALENGINECVT
TRANSMISSION
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3. SAFETY DECALS
When replacing the existing part with a new one, attach the same safety decal to the new part. Otherwise, the
customer's safety will be threatened.
If a decal is damaged or detached, attach the same decal to the part.
The decals and their attaching locations are as follows.
There is part number on the bottom of decals.
•
•
•
•
3.1 THE LOCATION OF SAFETY DECAL
UUVW002A
SAFETY FIRST - SAFETY DECALS
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SAFETY FIRST
GENERALENGINECVT
TRANSMISSION
CHASSISREAR AXLEBRAKEFRONTAXLESTEERINGHYDRAULICELECTRICINDEX
(2) Part No. : U3215-85081
(6) Part No. : U3215-85071
(4) Part No. : T2615-54112(1) Part No. : U3215-85011
(5) Part No. : U3215-85101
(3) Part No. : T4625-52351 (7) Part No. : T4625-52361
SAFETY FIRST - SAFETY DECALS
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TRANSMISSION
CHASSISREAR AXLEBRAKEFRONTAXLESTEERINGHYDRAULICELECTRICINDEX
(8) Part No. : U3215-85091 (12) Part No. : U3215-85111
(11) Part No. : U3215-85041
(9) Part No. : U3215-85021
(10) Part No. : U3215-85031
(14) Part No. : U3215-85061
(15) Part No. : U3215-85121
(13) Part No. : U3215-85051
SAFETY FIRST - SAFETY DECALS
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CHASSISREAR AXLEBRAKEFRONTAXLESTEERINGHYDRAULICELECTRICINDEX
(17) Part No. : U3215-85161
(16) Part No. : U3215-85131
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TABLE OF CONTENTS
CHAPTER 2
GENERAL
1. DESCRIPTION FOR SYMBOLS AND
ABBREVIATIONS ................................... 2-2
2. UTV APPEARANCE................................ 2-3
3. SERIAL NUMBER................................... 2-3
3.1 Utv serial number location......................2-3
3.2 Engine serial number location................2-4
3.3 Others location.......................................2-4
4. DIMENSIONS.......................................... 2-5
5. SPECIFICATIONS................................... 2-6
6. GEAR ARRANGEMENT AND DRIVING
SPEED..................................................... 2-7
6.1 Gear arrangement of transmission.........2-7
6.2 Gear arrangement of rear axle...............2-8
6.3 Gear arrangement of front axle..............2-8
6.4 Driving speed .........................................2-9
7. MAINTENANCE .................................... 2-10
7.1 Maintenance schedule chart ................2-10
7.2 Lubrication and replenishment.............2-12
8. TIRE MAINTENANCE........................... 2-13
8.1 Specified inflation pressure..................2-13
8.2 Tightening torque for wheel..................2-13
9. TIGHTENING TORQUES...................... 2-14
9.1 General use screws, bolts and nuts.....2-14
9.2 Stud......................................................2-14
9.3 American standard screws, bolts and
nuts with unc or unf threads.................2-15
10. PART NUMBERASSIGNMENT STANDARD
FOR DAEDONG BOLTSAND NUTS ......... 2-16
10.1 Bolts.....................................................2-16
10.2 Nuts......................................................2-17
11. HOW TO INSTALL SPRING PIN AND
SNAP RING.......................................... 2-18
11.1 Spring pin installation...........................2-18
11.2 Snap ring assembly..............................2-18
12. UNIT CONVERSION TABLE................ 2-19
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2-2 SUUV-W00 Apr. 2011
SAFETY FIRST
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Fuel-level Headlamp - low
beam
Engine coolant-
temperature Headlamp - high
beam
Parking brake Front wheel drive-
engage
Battery not charged Neutral position
Engine oil pressure Preheat
Turn signal lamp High travel light
Differential lock Low travel light
Hazard warning
lamp
4WD.......Four Wheel Drive•
API.........American Petroleum
Institute
•
HI-LO .....High speed-Low speed•
RH/LH....Right Hand side and Left
Hand side
(Determined based on
driving direction)
•
ROPS.....Roll Over Protection
Structure
•
RPM.......Revolutions Per Minute•
SAE........Society of Automotive
Engineers
•
SMV .......Slow Moving Vehicle•
CVT........Continuously Variable
Transmission
•
UTV........ Utility Vehicle•
Symbols Abbreviations
1. DESCRIPTION FOR SYMBOLS AND ABBREVIATIONS
There are various symbols used in this manual. Their design and meanings are as follows:
GENERAL - DESCRIPTION FOR SYMBOLS AND ABBREVIATIONS
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