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Husqvarna 4421-D User's Manual

1. REGULAR INTERVAL SERVICE Annual service by Check for leaks around gaskets fill plugs trained technician only etc or every 100 hours of operation F whichever comes first Kawasaki gasoline engines Adjust valve clearance See Kawasaki FH680D Service Manual Gasoline vehicles Inspect clean and gap spark plug replace if necessary See Engine authorized dealer or trained technician for service Diesel vehicles Check the v belt for proper tension or damage Adjust or replace if necessary Diesel vehicles Change engine coolant See Section 15 Radiator and Cooling System in the maintenance and service manual Diesel vehicles Check clights for Radiator tightness check hoses for cracks Replace if necessary Replace air filter element See Air Intake System on page 42 Engine air intake system Check clights for tightness check hose for cracks Check for loose hardware and tighten if General vehicle necessary Fuel filters Replace Dispose of used filters properly A WARNING If any problems are found during scheduled inspection or service do not operate vehicle until repairs are made Failure to make necessary repairs could result in fire property damage severe personal injury or death 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Page 31 PERIODIC LUBRICATION SCHEDULE Periodic Lubrication Schedule PERIODIC LUBRIC
2. SERIAL NUMBER DECAL CRUSH AREA SEA TRAILER HITCH SN DECAL Nw dd NOTICE MAXIMUM TONGUE WEIGHT 150 Ibs CCI 1011553 ON REAR RECEIVER HITCH STAY CLEAR CCI 101609401 BED LATCH CRUSH AREA DECAL WARNING DECAL ON DRIVER SIDE A WARNING AND PASSENGER SIDE Crush area Can cause severe injury Stay clear when closing VEHICLE LOADING DECAL AN WARNING VEHICLE LOADING z RIDING IN CARGO BED CAN CAUSE Read owner s manual and warnings on dash PREVENT VEHICLE ROLL OVER SEVERE INJURY OR DEATH Maximum gross vehicle weight 2750 Ib 1247 kg Place cargo forward in the cargo bed and distribute Maximum cargo load 800 Ib 363 kg evenly side to side Secure load Do not ride in cargo bed Includes cargo bed load and gross trailer weight On uneven or steep terrain reduce speed and load Maximum cargo load is reduced by the weight of Avoid stopping on or backing down steep hills optional equipment Avoid top heavy loads See owner s manual Maximum trailer hitch tongue weight 150 Ib force 667 N INLINE zo STANDARD VEHICLE AN WARNING HIGH CAPACITY VEHICLE LOADING 9 RIDING IN CARGO BED CAN CAUSE Read owner s manual and warnings on dash PREVENT VEHICLE ROLL OVER SEVERE INJURY OR DEATH Maximum gross vehicle weight 3012 Ib 1366 kg Place cargo forward in the cargo bed and distribute Maximum cargo load 1050 Ib 476 kg evenly side to side Se
3. Clean up spilled fuel Keep sparks and flames away from the vehicle and service area Failure to heed this warning could result in an explosion or fire resulting in severe personal injury or death 5 Close the valve by rotating it counterclockwise until the valve is firmly sealed 6 To resupply the filter with fuel turn the key switch to the ON position for 10 seconds See following NOTE NOTE Dispose of water according to the environmental laws and regulations for your area 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Page 45 Battery Figure 38 Fuel Filter BATTERY See General Warnings on page 8 DANGER Battery Explosive gases Do not smoke Keep sparks and flames away from the vehicle and service area Ventilate when charging or operating vehicle in an enclosed area Wear a full face shield and rubber gloves when working on or near batteries Battery Poison Contains acid Causes severe burns Avoid contact with skin eyes or clothing Antidotes External Flush with water Call a physician immediately Internal Drink large quantities of milk or water followed with milk of magnesia or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes Call a physician immediately Tools wires and metal objects can cause sparks when shorted across a battery A WARNING Wear safety glasses or approved eye protection when servicing t
4. Husqvarna 2007 Utility Vehicles Gasoline and Diesel Owner s Manual HUV 4421 G GXP HUV 4421 D NOTICE Warranty information appears on the last pages of this manual No other warranties express or implied are contained herein Your authorized representative checked the vehicle before it was delivered to you and will provide you a copy of the completed vehicle warranty registration form Husqvarna is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual This manual contains proprietary information that is protected by copyright All rights are reserved No part of this manual may be photocopied reproduced or translated to another language without the written consent of Husqvarna Inc The information contained in this document is subject to change without notice Husqvarna reserves the right to make design changes to vehicles without obligation to make these changes on units previously sold These vehicles do not conform to Federal Motor Vehicle Safety Standards for automobiles or to FMVSS 500 for low speed vehicles and are not equipped for operation on public streets roads or highways H Husqvarna Husqvarna Forest and Garden 7349 Statesville Rd Charlotte NC 28269 USA www usa husqvarna com huv 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Page 1 FOREWORD Thank you for choosing Husqvarna a world leader i
5. Gasoline vehicles 4 Prepare the fuel tank 4 1 Fill the tank with fresh fuel 4 2 Following the manufacturer s directions add a commercially available fuel stabilizer such as Sta Bil9 Run the engine in a well ventilated area to allow treated fuel to replace untreated fuel in the carburetor 4 3 Disconnect the fuel vent line from the fuel tank vent nipple Figure 36 Page 44 4 4 Plugthe fuel tank vent nipple so that it is air tight Husqvarna recommends using a slip on vinyl cap 5 Remove both spark plugs and pour 1 2 ounce 14 2 mL of SAE 10 weight oil through each of the two spark plug holes Rotate the engine crankshaft by hand several times then install both spark plugs Diesel vehicles If Biodiesel fuel is used see Biodiesel Fuel Diesel Vehicles Only on page 44 6 Prepare the fuel tank 6 1 Fill the fuel tank with fresh fuel 6 2 Disconnect the fuel vent line from the fuel tank vent nipple Figure 37 Page 44 6 3 Plug the fuel tank vent nipple so that itis air tight Husqvarna recommends using a slip on vinyl cap vehicles 7 Change engine oil See Engine Oil and Filter Change on page 36 8 Disconnect the battery cables negative cable first See WARNING To avoid unintentionally start ing on page 9 9 The battery should be clean and free of corrosion Wash the battery top and terminals with a solution of baking soda and water 1 cup 237 mL baking soda per 1 gallon 3 8 L of water R
6. owing safety statements must be heeded whenever the vehicle is being operated repaired or ser viced Safety decal identification information is also included beginning on page 4 Other specific safety state ments appear throughout this manual and on the vehicle DANGER Battery Explosive gases Do not smoke Keep sparks and flames away from the vehicle and service area Ventilate when charging or operating vehicle in an enclosed area Wear a full face shield and rubber gloves when working on or near batteries Gasoline Diesel Flammable Explosive Do not smoke Keep sparks and flames away from the vehicle and service area Service only in a well ventilated area Do not operate engine in an enclosed area without proper ventilation The engine produces carbon monoxide which is an odorless deadly poison This vehicle will not provide protection from lightning flying objects or other storm related hazards If caught in a storm while driving this vehicle exit the vehicle and seek shelter in accordance with applicable safety guidelines for your location A WARNING Follow the procedures exactly as stated in this manual and heed all DANGER WARNING and CAUTION statements in this manual as well as those on the vehicle Do not leave children unattended on vehicle Children requiring a child safety seat must not ride on the vehicle Comply with state and local laws pertaining to child safety The driver and passeng
7. CLUB CAR EXPLANATION OF EMISSION CONTROL WARRANTY 1 WARRANTY CLUB CAR warrants to the ultimate purchaser and each subsequent purchaser that the SORE or equipment is designed built and equipped so as to conform with all applicable regulations and free from defects in materials and workmanship that cause the failure of a warranted part to be identical in all material respects to that part as described in CLUB CARs application for certification The warranty period begins on the date the engine or equipment is delivered to an ultimate purchaser or first placed into service The warranty period is two years 2 COVERAGE Subject to certain conditions and exclusions as stated below the warranty on emission related parts is as follows 1 Any warranted part that is not scheduled for replacement as required maintenance in the written instructions supplied is warranted for the warranty period stated above If the part fails during the period of warranty coverage the part will be repaired or replaced by CLUB CAR according to subsection 4 below Any such part repaired or replaced under warranty will be warranted for the remainder of the period 2 Any warranted part that is scheduled only for regular inspection in the written instructions supplied is warranted for the warranty period stated above Any such part repaired or replaced under warranty will be warranted for the remaining warranty period 8 Any warranted part that is scheduled for rep
8. Do not leave children unattended on vehicle CCI 102459401 UNDERAGE WARNING DECAL Z WARNING ROLLOVER OR FALLING OFF MAY CAUSE DEATH Read owner s manual and operating instructions AN WARNING Fasten seat belts and remain seated while moving Do not modify or remove Roll over Protective Structure ROPS Replace ROPS if damaged Do not attempt repair Use seat belts during operation Do not jump from vehicle Keep away from drop offs steep slopes and unstable surfaces CCI 102961201 Children requiring a child safety seat must not ride on vehicle Comply with state and local laws pertaining to child safety Drive slowly in turns and straight up and down slopes Do not start vehicle until all occupants are seated CERTIFICATION Two 2 persons per bench seat maximum One 1 person per bucket seat maximum NOTICE AND WARNING DECAL Operate from driver side only and not on public roads Keep entire body inside vehicle while moving A WARNING Do not operate while under the influence of alcohol or drugs Never attempt jumps and avoid extreme braking in reverse Rotating Parts CCI 102224001 CCI 102884401 DRIVER PASSENGER WARNING DECAL ROTATING PARTS DECAL GAS UNDER SEAT ON DRIVER SIDE FRAME A WARNING CAN CAUSE SEVERE INJURY Rotating parts KEEP CLEAR CCI 102460201 ROTATING PARTS DECAL DIESEL UNDER SEAT ON DRIVER SIDE FRAME
9. and mechanical repair The appropriate instructions must be used when performing maintenance service or accessory installation If any problems are found during scheduled inspection or service do not operate vehicle until repairs are made Failure to make necessary repairs could result in fire property damage severe personal injury or death Do not wear loose clothing or jewelry such as rings watches chains etc when servicing the vehicle Turn key switch to the OFF position remove the key place the Forward Reverse handle in the NEUTRAL position and chock the wheels prior to servicing Moving parts Do not attempt to service vehicle while engine is running Hot Do not attempt to service hot engine or exhaust system Failure to heed this warning could result in severe burns For vehicles with cargo beds remove all cargo before raising the bed or servicing the vehicle If the vehicle is equipped with a prop rod ensure that it is securely engaged while bed is raised Do not close bed until all persons are clear of cargo bed area Keep hands clear of all crush areas Do not drop cargo bed lower gently and keep entire body clear Failure to heed this warning could result in severe personal injury or death Do not work on vehicle powertrain or under cargo bed when it is loaded Gasoline vehicles only Turn fuel shut off valve to the closed OFF position Figure 13 Page 29 To avoid unintentionally starting the vehicle Disconnec
10. oil circulation to and from the engine See following NOTE NOTE The normal oil pressure value stated in the Kawasaki engine manual is 35 45 psi at idle however the remote filter design causes oil pressure to be 18 psi which is normal for this type of oil circula tion design ENGINE OIL LEVEL CHECK 1 Remove the oil level dipstick from the oil filler tube and wipe oil from the dipstick See Figure 18 Figure 19 Figure 20 and Figure 21 on page 36 See following CAUTION CAUTION Do not remove dipstick while engine is running 2 Check oil level by fully inserting the dipstick into the tube and immediately removing it 3 Ifthe oil level is at or below the low level mark on the dipstick gauge add oil to the engine until the level is between low and full levels safe level See following CAUTION CAUTION Do not fill oil above the full level mark Doing so will result in decreased engine performance or damage to the engine My AM AL SIN d LARA Figure 18 Engine Oil Level Check Figure 19 Engine Oil Level Check Honda Gasoline Vehicles Kawasaki Gasoline Vehicles 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Page 35 Engine Oil Figure 20 Engine Oil Level Check Diesel Vehicles Figure 21 Engine Oil Level Check Diesel Vehicles With Driver side Dipstick With Passenger side Dipstick ENGINE OIL AND FILTER CHANGE Engine oil and oil filter should be changed Kawasaki gasoline
11. position Figure 11 Do not attempt to charge frozen batteries or batteries with bulged cases Discard the battery Frozen batteries can explode 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Page 25 Storage CAUTION Batteries in a low state of charge will freeze at low temperatures CLOSED OFF POSITION SELECTOR IS ALIGNED WITH OFF MARKINGS ON THE SIDES OF VALVE NM VIEWED FROM SELECTOR SIDE OF VALVE Figure 11 Fuel Shut off Valve Closed Position FULL OPEN ON PARTIALLY CLOSED POSITION POSITION A VIEWED FROM SELECTOR VIEWED FROM SELECTOR SIDE OF VALVE SIDE OF VALVE Figure 12 Fuel Shut off Valve Open Position Figure 13 Fuel Valve Partially Closed Position PREPARING THE VEHICLE FOR EXTENDED STORAGE 1 Unload the vehicle so that the tires are supporting only the weight of the vehicle 2 Store the vehicle in a cool dry place This will minimize battery self discharge If the battery appears to be weak have it charged by a trained technician Use an automotive type 12 volt battery charger rated at 10 amps or less Check electrolyte level after charging and add distilled water if necessary If the bat tery is dead see Using A Booster Battery Jump Starting on page 48 Page 26 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Storage 3 Make sure the key switch is in the OFF position and the Forward Reverse handle is in the NEUTRAL position Chock the wheels
12. result from use of this fuel Biodiesel is an excellent medium for microbial growth and contamination Microbial contamination can cause corrosion of the fuel system and prematurely plugged fuel filters See following NOTE NOTE Use of biodiesel may result in premature failure of fuel system components Kubota has docu mented problems such as plugged fuel filters and deteriorated fuel lines during testing of biodiesel Biodiesel can damage painted surfaces Be sure to remove all spilled fuel immediately to help prevent dam age to painted surfaces If biodiesel will be used in the Kubota D722 engine be sure that it meets the following requirements The fuel blend should contain no more than 5 biodiesel by volume The petroleum portion of the fuel blend must meet ASTM standard D975 and the biodiesel portion of the fuel blend must meet ASTM standard D6751 For Europe the fuel blend must meet the EN590 standard See following CAUTION CAUTION Never use any fuel that does not meet specifications or fuel in which the contents cannot be identified Using blends higher than 5 biodiesel content can affect engine life and cause deterioration of hoses tubelines injectors injector pump and seals For more information on these fuel standards please contact your nearest Kubota dealer Page 44 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Fueling Instructions If biodiesel is used be sure to apply the following
13. that the part will not adversely affect emis sion performance The manufacturer or rebuilder of the part must certify that use of the part will not result in a failure of the engine to comply with emission regulations Maintenance Follow the Periodic Service Schedule in the owner s manual Remember that this schedule is based on the assumption that your vehicle will be used for its designed purpose Sustained high load or high temperature operation or use in unusually wet or dusty conditions will require more frequent service 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Page 57 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT Your new Husqvarna Inc Husqvarna vehicle engine complies with both the U S EPA and State of California emission regulations YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board CARB and Husqvarna are pleased to explain the emission control system warranty on your 2007 vehicle engine In California new small off road engines SORE must be designed built and equipped to meet the State s stringent anti smog standards Husqvarna must warrant the emission control system on the vehicle engine for the periods of time listed below provided there has been no abuse neglect or improper maintenance of your small off road engine Your emission control system may include parts such as the carburetor or fuel injection system the ignition system and catalytic converter Also included may
14. with API classification SJ for gasoline engines and CF for diesel engines Using multi grade oils BW 20 10W 30 and 10W 40 may increase oil consumption If multi grade oil is used check the oil level more frequently 20 C 10 C 0 C 10 C 20 C 30 C 40 C 20 C 10 C 0 C T 20 C E Elo eer Ty aa 2 mao 40 4 F 14 F 32 F 50 F 68 F 86 F 104 F mE 14 F E 68 F 1 Figure 30 Oil Viscosity Chart Gasoline Vehicles Figure 31 Oil Viscosity Chart Diesel Vehicles GEARCASE LUBRICATION NOTE Dispose of used oil according to the environmental laws and regulations for your area LUBRICATION LEVEL CHECK FOR FRONT DIFFERENTIAL TRANSMISSION AND REAR DIFFERENTIAL Each gearcase component is equipped with two oil port plugs 1 and 2 Figure 32 Figure 33 and Figure 34 When the vehicle is on a level surface use the level indicator hole upper plug 1 as a lubricant level indicator Lubricant level should be even with the bottom of level indicator hole 1 LUBRICATION CHANGE FOR FRONT DIFFERENTIAL TRANSMISSION AND REAR DIFFERENTIAL Use the lower plug 2 for drainage Figure 32 Figure 33 or Figure 34 Remove both plugs to allow the lubricant to drain faster See preceding NOTE Use the lower plug 2 for drainage Figure 32 Figure 33 and Figure 34 Remove both plugs to allow the lubricant to drain faster See preceding NOTE Metal particles may be discovered in the fluid or on the magnetic
15. 4421 Gasoline and Diesel Vehicle Owner s Manual Engine Oil 7 Use a socket or wrench to replace the oil drain plug 1 Figure 22 or Figure 23 Turn the plug clockwise and tighten to 29 ft lb 40 N m for Honda gas vehicles 61 in lb 6 9 for Kawasaki gas vehicles with plastic drain plugs 14 5 ft lb 20 for Kawasaki gas vehicles with metal drain plugs or 31 ft lb 42 Nm for diesel vehicles Figure 22 Engine Oil Drain Plug and Pan Figure 23 Engine Oil Drain Plug and Oil Filter Gasoline Vehicles Diesel Vehicles Figure 24 Replace Engine Oil Filter Figure 25 Replace Engine Oil Filter Honda Gasoline Vehicles Kawasaki Gasoline Vehicles Engine Oil Filter Change 1 Drain the engine oil See Engine Oil Draining on page 36 2 Place the oil drain pan under the engine oil filter 2 Figure 23 or Figure 24 Page 38 3 Remove the engine oil filter Turn it counterclockwise and drain the residual oil in the filter port and filter into the oil drain pan See following NOTE 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Page 37 Engine Oil NOTE An oil drip guard 1 can be used to prevent excess oil from dripping onto the engine base plate Figure 26 Use an empty quart one liter container and cut the bottom off at an angle then slide the open area of the container up and under the oil filter 2 before removal Position the port of the plastic container so oil will be dire
16. 600 mL Mobil 424 Exxon Hydraul 560 or Esso Hydraul 56 lubricant Page 32 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Periodic Lubrication Schedule Figure 14 Lubrication Points Gasoline Vehicles Figure 15 Lubrication Points Diesel Vehicles 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Page 33 Brake Fluid Reservoir BRAKE FLUID RESERVOIR Figure 16 Brake Fluid and Coolant Access Figure 17 Brake Fluid Reservoir diesel vehicle shown The brake fluid reservoir 1 is located under the hood Figure 16 Raise the hood to check the brake fluid level During the brake fluid level inspection also inspect the following The presence of brake fluid on the exterior surface of the master cylinder indicates
17. AKE A WARRANTY CLAIM To make a warranty claim under this limited warranty you must present the vehicle or defective component to an authorized Husqvarna dealer Page 54 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual 6 DISCLAIMER THIS LIMITED WARRANTY IS EXCLUSIVE HUSQVARNA MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY HUSQVARNA AND EXCLUDED FROM THIS WARRANTY THE PURCHASER AND HUSQVARNA EXPRESSLY AGREE THAT THE REMEDY OF THE REPLACEMENT OR REPAIR OF THE DEFECTIVE VEHICLE OR COMPONENT THEREOF IS THE SOLE REMEDY OF THE PURCHASER HUSQVARNA MAKES NO OTHER REPRESENTATION OR WARRANTY OF ANY KIND AND NO REPRESENTATIVE EMPLOYEE OR DEALER OF HUSQVARNA HAS THE AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION PROMISE OR AGREEMENT WHICH IN ANY WAY VARIES THE TERMS OF THIS WARRANTY 7 NO CONSEQUENTIAL DAMAGES IN NO EVENT SHALL HUSQVARNA BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS RELATED TO PROPERTY OTHER THAN THE VEHICLE LOSS OF USE LOSS OF TIME INCONVENIENCE OR ANY OTHER ECONOMIC LOSS Some states allow neither limitation on the duration of an implied warranty nor exclusions or limitation of incidental or consequential damages Therefore the above limitations or exclusions may not apply to you This w
18. ATION SCHEDULE REGULAR INTERVAL SERVICE LUBRICATION POINTS RECOMMENDED LUBRICANT Gasoline vehicle Honda engine First change 20 hours Kawasaki engine First change 10 hours Diesel vehicle First change 50 hours Additional change for all engines every 100 hours of operation or annually whichever comes first Change engine oil and oil filter q Gasoline Honda engine vehicles 1 qt and 25 oz 1 7 L with filter Gasoline Kawasaki engine vehicles 1 qt and 19 oz 1 5L with filter Diesel vehicles 3 qt 2 8 L with filter See Oil Viscosity on page 39 Monthly by owner or trained technician Driveshaft Chassis Lube EP NLGI Grade 2 Semiannually by owner or trained technician or every 50 hours of operation whichever comes first Check add brake fluid Use only DOT 5 silicone brake fluid Rear suspension 2 fittings Chassis Lube EP NLGI Grade 2 First change 50 hours additional change every 100 hours of operation or annually whichever comes first Change front differential lubricant 5 oz 150 mL Mobil 424 Exxon Hydraul 560 or Esso Hydraul 56 lubricant First change 50 hours additional change every 300 hours of opera tion or annually whichever comes first Change rear differential lubricant 20 oz 600 mL Mobil 424 Exxon Hydraul 560 or Esso Hydraul 56 lubricant Change transmission lubricant TT CA 20 oz
19. AUTION Optional mud tires off road are directional and must be installed according to the directional arrow mark arrow indicates forward rotation of the tire on the side wall of each tire or the tread performance will be severely compromised The tires are made specifically for the AWD vehicle therefore Husqvarna recommends that only tires pur chased from Husqvarna be used on your AWD vehicle SUBSEQUENT OWNER REGISTRATION In the event a vehicle is bought as a used vehicle we strongly urge the new owner to register the vehicle with Husqvarna This will enable us to contact you if the need arises Please send your name address and serial number of the vehicle to Husqvarna 7349 Statesville Rd Charlotte NC 28269 Attention Vehicle Registra tion Page 50 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual VEHICLE SPECIFICATIONS Vehicle Specifications SPECIFICATIONS HUV 4421 HUV 4421 POWER SOURCE Gasoline Diesel Engine Honda 4 cycle OHV 614 20 0 maximum HP 93600 rpm per SAE J 1940 1349 twin cylinder air cooled with pressure lubrication system Engine Kawasaki 4 cycle OHV 675 cc 23 0 maximum HP 93600 rpm per SAE J 1940 1349 twin cylinder air cooled with pressure lubrication system Engine 4 cycle OHV 719 cc 20 0 maximum HP 23600 rpm per SAE J 1940 1349 three cylinder liquid cooled with pressure lubrication system Fuel system Side draft ca
20. E IS ABUSED OR USED IN AN UNINTENDED MANNER OR SHOWS INDICATIONS THAT IT HAS BEEN ALTERED IN ANY WAY INCLUDING BUT NOT LIMITED TO MODIFICATION OF THE SPEED GOVERNOR BRAKING SYSTEM STEERING TRANSAXLE OR OTHER OPERATING SYSTEMS OF THE VEHICLE TO CAUSE IT TO PERFORM OUTSIDE Husqvarna SPECIFICATIONS THE WARRANTY 15 LIKEWISE VOID IF THE VEHICLE INVOLVED SHOWS INDICATIONS THAT REASONABLE OR NECESSARY MAINTENANCE AS OUTLINED IN THE OWNER S MANUAL AND MAINTENANCE AND SERVICE MANUAL WAS NOT PERFORMED AT THE TIME AND IN THE MANNER SPECIFIED IN SUCH MANUALS 4 SOLE REMEDY Husqvarna s liability under this limited warranty or in any action whether based upon warranty contract negligence strict product liability or otherwise shall be the repair or replacement at Husqvarna s option of the vehicle or component thereof that Husqvarna deems to be defective Replacement shall mean furnishing during the applicable limited warranty period a new vehicle or factory reconditioned vehicle or component thereof that is identical or reasonably equivalent to the warranted product or component at no cost to the purchaser Repair shall mean remedying a defect in the vehicle or component thereof at no cost to the purchaser during the applicable limited warranty period If Husqvarna elects to repair the vehicle it may provide factory reconditioned parts or components All parts and components replaced under warranty shall become the property of Husqvarna 5 HOW TO M
21. G AND UNLOADING CARGO A WARNING Firmly engage park brake before loading vehicle Do not allow riders in the cargo bed Reduce vehicle load and speed when driving up or down slopes or on uneven terrain Do not exceed rated vehicle capacity Rated capacity is for level surfaces only Overloading can affect vehicle handling or cause component failure resulting in loss of control of vehicle and possible severe personal injury or death Do not load tailgate The tailgate should be in the upright position and latched securely while the vehicle is in motion To help avoid shifting vehicle load and possibly overturning the vehicle avoid sudden starts sudden stops and abrupt turns Make sure cargo is well secured Avoid top heavy loads The center of gravity of load should never exceed 15 inches 38 cm above the bottom of the cargo bed The cargo s center of gravity may affect handling steering and braking of the vehicle When the vehicle is loaded reduce speed and drive slowly in turns Unload cargo bed before raising vehicle with lift hoist or jack Avoid stopping on a hill when loaded If you must stop on a hill avoid sudden starts or rolling backwards and stopping suddenly Failure to heed this warning may cause vehicle to overturn possibly resulting in severe personal injury WARNING CONTINUED ON NEXT PAGE Page 22 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Vehicle Load Capacit
22. N THE MANNER SPECIFIED IN SUCH MANUALS 5 NO CONSEQUENTIAL DAMAGES In no event shall Club Car be liable for any incidental or consequential damages including but not limited to loss related to property other than the vehicle loss of use loss of time inconvenience or any other economic loss This warranty is applicable only where the California or U S EPA emission control system warranty regulation is in effect 6 HOW TO MAKE A WARRANTY CLAIM To make a warranty claim under this limited warranty you must present the vehicle or defective component to an authorized CLUB CAR dealer or send the defective component freight prepaid to WARRANTY SERVICES CLUB CAR INC 4125 Washington Road Evans Georgia 30809 U S A 706 863 3000 IF THE WARRANTY REGISTRATION FORM IS NOT COMPLETED AND RETURNED TO CLUB CAR AT THE TIME OF THE ORIGINAL RETAIL SALE PURCHASER MUST PROVIDE PROOF OF DATE OF PURCHASE WITH ANY WARRANTY CLAIM Page 58 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Husqvarna Part Number 531 30 81 86 Edition Code 0706C0307B CCI P N 103218307
23. NEL A WARNING CAN CAUSE SEVERE INJURY HOT manifold KEEP CLEAR CCI 102459001 HOT MANIFOLD WARNING DECAL ON ENGINE VALVE COVER WINCH CABLE WARNING DECAL FOR VEHICLES WITH WINCH ACCESSORY A WARNING FRAME GROUND WARNING DECAL WINCH CABLE FRACTURE COULD RESULT ON VEHICLE FRAME NEAR BATTERY IN SERIOUS INJURY OR DEATH Do not use winch while persons are seated on the vehicle A WAR N l N G Use remote operation switch for winch control Stand to the side and away from the vehicle to operate winch Read winch operator manual before operating winch Hh Negative frame ground Can cause severe injury 12231601 Do not contact positive battery post or cable ON FRONT BODY to frame Disconnect negative battery cable first CCI 102459101 Z WARNING CAN CAUSE SEVERE BURNS Hot Surface CCI 102458901 HOT SURFACE WARNING DECAL ON COOLANT PIPES AND UNDERSIDE OF BOTH SEATS ROTATING PARTS AND HOT MANIFOLD DECAL ON DRIVER SIDE VEHICLE FRAME A WARNING A WARNING CAN CAUSE SEVERE INJURY CAN CAUSE SEVERE INJURY Rotating parts KEEP CLEAR Hot manifold and muffler KEEP CLEAR 102459501 Page 4 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Vehicle Feature Identification ALL HUV 4421 MODELS A WARNING YOUNG DRIVERS INCREASE CHANCE OF DEATH Young drivers may not be able to control vehicle No drivers younger than 16 years old
24. See Lubrication Level Check for Front Differential Transmission and Rear Differential on page 40 General vehicle Wash engine compartment and underside of vehicle Do not wash engine when hot First adjustment after 20 hours additional every 100 hours of operation Engine Honda Adjust valve clearance See Honda GX620 Service Manual CCI P N 102615401 Semiannual service by trained technician only or every 50 hours of operation whichever comes first Battery Clean terminals and wash dirt from casing check electrolyte level Add distilled water if necessary See page 47 Front wheel alignment and toe in Check and adjust if necessary See Section 7 Steering and Front Suspension in the appropriate maintenance and service manual Electrical wiring and connections Check for tightness and damage Brake system Inspect master cylinder brake lines and hoses for damage or leakage Check park brake cables for damage replace if necessary Check brake pads and discs replace if necessary For brake wear in procedure see Hydraulic Brakes in the Pre Operation and Daily Safety Checklist on page 17 See also Section 6 Brake System in the appropriate maintenance and service manual Periodic Service Schedule continued on next page Page 30 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Periodic Service Schedule PERIODIC SERVICE SCHEDULE
25. TBE by volume METHANOL methyl or wood alcohol 5 by volume You may use gasoline containing up to 5 methanol by volume as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 596 methanol by volume may cause starting and or performance problems It may also damage metal rubber and plastic parts of your fuel system If you notice any undesirable operating symptoms try another service station or switch to another brand of gasoline Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under warranty Page 56 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Emission Control System Information Source of Emissions The combustion process produces carbon monoxide oxides of nitrogen and hydrocarbons Control of hydro carbons and oxides of nitrogen is very important because under certain conditions they react to form photo chemical smog when subjected to sunlight Carbon monoxide does not react in the same way but it is toxic Honda utilizes lean carburetor settings and other systems to reduce the emissions of carbon monoxide oxides of nitrogen and hydrocarbons The U S and California Clean Air Acts EPA and California regulations required all manufacturers to furnish written instructions describing the oper ation and maintenance of emission
26. WARNING and CAUTION 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Page 49 Subsequent Owner Registration WARNING Before beginning a winch operation Turn key switch to the OFF position put Forward Reverse handle in the NEUTRAL position and engage the park brake Do not use winch while persons are seated on the vehicle Stand to the side and away from the vehicle to operate winch CAUTION Use of the winch for an extended period of time could discharge the battery Keep winch operations as short as possible and drive the vehicle for several minutes after the winch operation to recharge the battery MUD TIRE OPTION All wheel drive AWD vehicles equipped with optional mud tires are intended only for off road operation they are not designed for use on paved surfaces such as asphalt and concrete Frequent driving on paved sur faces will significantly decrease the life of the mud tires Vehicle performance will also be reduced when driv ing on paved surfaces See following WARNING and CAUTION A WARNING To avoid the risk of rollover when operating a vehicle equipped with mud tires on a paved surface reduce speed use extreme caution and drive slowly in turns The diameter of all tires on the vehicle must be equal otherwise the all wheel system will not operate as intended and could result in severe personal injury or death Never install tires of different diameters on the vehicle C
27. a leak The brake fluid reservoir diaphragm located in the cap should not have holes or other damage BRAKE FLUID Brake fluid level should be within 1 4 inch 6 mm from the top of the reservoir Figure 17 Also brake fluid should be clean with no residue in the bottom of the reservoir or other evidence of contamination CAUTION Use only DOT 5 silicone brake fluid Use of any other type brake fluid is not recommended ENGINE OIL Even though the low oil warning light on the instrument panel should illuminate if the oil level becomes low the engine oil level should be checked daily The vehicle should be on a level surface when the oil is checked Do not overfill the engine with oil OIL PRESSURE GASOLINE ENGINE Honda engine The Honda gasoline engine has an oil filter that is mounted on a bracket next to the back side of the front panel Inlet and outlet oil carrying hoses enable oil circulation to and from the engine See follow ing NOTE Page 34 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Engine Oil NOTE The normal oil pressure value stated in the Honda engine manual is 28 psi at idle however the remote filter design causes oil pressure to be 18 psi which is normal for this type of oil circulation design Kawasaki engine The Kawasaki gasoline engine has an oil filter that is mounted on a bracket between and in front of the engine and transmission Inlet and outlet oil carrying hoses enable
28. ack into the FORWARD position until stopped Press the brake pedal as necessary and press the accelerator pedal partially when descending a hill With the accelerator pedal partially pressed the governor will cause the engine to assist the brakes in controlling downhill speed ALL WHEEL DRIVE AWD OPERATION All HUV 4421 G and HUV 4421 D vehicles feature an all wheel drive AWD system AWD system auto matically directs power to the wheel or wheels that have the most traction providing optimum traction at all times For example if all wheels except the rear passenger side wheel lose traction then power will be directed to the rear passenger side wheel The all wheel drive vehicle can adapt traction for a wide variety of driving surfaces and conditions See following WARNING A WARNING When servicing the vehicle with part of the vehicle on jack stands do not operate the engine with the Forward Reverse handle in either the FORWARD or REVERSE position The all wheel drive system will engage any wheel s front or rear with traction See Figure 2 on page 9 The diameter of all tires on the vehicle must be equal otherwise the all wheel drive system will not operate as intended and could result in severe personal injury or death Never install tires of different diamters on the vehicle Page 20 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Bed Latch and Prop Hod Under most circumstances the driver will not nee
29. ack stands do not operate the engine with the Forward Reverse handle in either the FORWARD or REVERSE position The all wheel drive system will engage any wheel s front or rear with traction Figure 2 All wheel Drive Warning 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Page 9 General Information GENERAL INFORMATION This manual includes operating procedures maintenance and regular servicing information for all gasoline and diesel HUV 4421 G and HUV 4421 D vehicles All operating procedures maintenance and regular ser vicing are identical unless otherwise noted MODEL IDENTIFICATION The serial number of each vehicle is printed on a bar code decal mounted on the frame above the brake pedal Example RC0601 123456 Figure 3 There is also a second serial number decal mounted on the rear body frame behind the fuel tank The fuel tank must be removed to view this decal See following NOTE NOTE Have the vehicle serial number available when ordering parts or making inquiries 6 Husqvarna SERIAL NUMBER mmm DHO0601 123456 CHARLOTTE NC 28269 Figure 3 Serial Number CONTROLS AND INDICATORS See General Warnings on page 8 A WARNING Before allowing anyone to drive the vehicle make sure the driver is familiar with all controls and operating procedures Do not tamper with the high idle speed setting on the diesel vehicle Doing so will void the warranty as well as damage the engine an
30. al workmanship and repair labor cost as to those items specifically listed above for the periods specified Such repair labor shall be performed only by Husqvarna its authorized dealers or a service agency approved by Husqvarna IF THE WARRANTY REGISTRATION FORM IS NOT COMPLETED AND RETURNED TO Husqvarna AT THE TIME OF THE ORIGINAL RETAIL SALE PURCHASER MUST PROVIDE PROOF OF DATE OF PURCHASE WITH ANY WARRANTY CLAIM 2 EXCLUSIONS Excluded from any Husqvarna warranty are all fuses filters decals except safety decals spark plugs light bulbs lubricants trim pieces seats routine wear items such as the charger plug and receptacle brake shoes belts brushes bushings engine mounts mats and pads maintenance adjustments cosmetic deterioration and items which deteriorate or fail due to exposure or ordinary wear and tear Batteries battery charger onboard computer and solid state speed controller are covered under separate Husqvarna warranties Also excluded from any Husqvarna warranty is damage to a vehicle or component resulting from a cause other than a defect including unreasonable or unintended strain or use improper installation of accessories installation of parts or accessories that are not original equipment overloading accident alteration abuse or neglect Transportation expenses for warranty services are also excluded from this warranty 3 VOIDING OF WARRANTY THIS AND ANY OTHER WARRANTY SHALL BE VOID IF THE VEHICL
31. ana aa ie Ra AA AA AARE EAE A RRENA ERL 24 SlOIagO e e tt e A A O Gee adn teu 25 Maintenance seni LE 28 Periodic Service Schedule 4 222244 0 0 00 000 00 10110000 08660000 0 29 Periodic Lubrication Schedule 2420 40 0 0 Arr ARKA KRA rent KKR RK RR nnne nnns 32 Brake Fluid Bieservolr a etras edt e erre pce Pe ke et e FAN bre AA FR GA Sh 34 Engine Oil s ettet OE Rb dece E et et ee M dc ee be ae P e eu gate vet o duc 34 aearcase l UDFICatlon s dett Esse pd un duds ens bo n A 40 Engine Coolant Diesel Vehicles 2 2 4 22 1 20 000 42 Air Intake System eot erede te eb trem ete edo etie e dede eram edu 42 Fueling Instictions 2 Ween ueteres eec ce dee Le ee eee xe docu deb qu cue p ee Do c 43 Batley 55i tede 46 Using Booster Battery Jump Starting ussnnusessrssrrsrssrrrsrrrssrrsssrrsnsrsnrrs rss rss essens rr sr RAA SR RAR nennen nnns nns 48 Cleaning the Vehicle nieis ai cede eee nde v Pee ee 49 ACES ONOS ose edit nis E inta di LIS EE I unc d 49 Subsequent Owner Registration missmmmssssrsrsrrssrrsssrrssrrsssrsnsrrssrr ss AR ener senes AR RA KRA RAR RR nnns nen 50 Vehicle SpecifiCaliOlis en ch P e ril ga ede oa erede 51 Ve
32. another vehicle or a trailer can have adverse effects on vehicle handling Be especially cautious when towing other equipment with this vehicle See Vehicle Load Capacities on page 23 for vehicle capacity information Parking the vehicle with a trailer on a hill should be avoided If you must park on a hill apply the brakes and have someone chock the trailer tires The brakes should be released to allow the chocks to absorb the trailer load After the trailer tires have been chocked engage the park brake TRANSPORTING ON A TRAILER A WARNING Gasoline vehicles only Turn fuel shut off valve to the closed OFF position Figure 11 Page 26 Do not allow riders in the trailer being towed Avoid sudden starts sudden stops and tight turns when towing Avoid stopping on a hill when towing If you must stop on a hill avoid sudden starts or rolling backwards and stopping suddenly Failure to heed this warning could cause the vehicle to overturn possibly resulting in severe personal injury Reduce normal driving speed when transporting a vehicle on a trailer WARNING CONTINUED ON NEXT PAGE Page 24 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Storage A WARNING For use on public roads the trailer must meet all federal state and local requirements such as taillights brake lights etc Never tow a vehicle behind a passenger vehicle or truck on a public road unless it is on an approved trailer The vehicle
33. ark plug cap spark plug Positive Crankcase Ventilation PCV System PCV valve oil filler cap Misc Parts Belts fuel hose hosing tubing fittings seals gasket and clights associated with the above systems Emission related parts will vary between vehicles therefore certain vehicles my not include all of the listed parts or may include equivalent parts 3 EXCLUSIONS Excluded from this warranty is damage to a vehicle or component resulting from a cause other than a defect including unreasonable or unintended strain or use improper installation of accessories installation of parts or accessories that are not original equipment overloading accident alteration abuse or neglect This warranty covers only those failures resulting from defects in material or workmanship Transportation expenses for warranty services are also excluded from this warranty 4 VOIDING OF WARRANTY THIS AND ANY OTHER WARRANTY SHALL BE VOID IF THE VEHICLE IS ABUSED OR USED IN AN UNINTENDED MANNER OR SHOWS INDICATIONS THAT IT HAS BEEN ALTERED IN ANY WAY INCLUDING BUT NOT LIMITED TO MODIFICATION OF THE SPEED GOVERNOR BRAKING SYSTEM STEERING TRANSAXLE OR OTHER OPERATING SYSTEMS OF THE VEHICLE TO CAUSE IT TO PERFORM OUTSIDE CLUB CAR SPECIFICATIONS THE WARRANTY IS LIKEWISE VOID IF THE VEHICLE INVOLVED SHOWS INDICATIONS THAT REASONABLE OR NECESSARY MAINTENANCE AS OUTLINED IN THE OWNERS MANUAL AND MAINTENANCE AND SERVICE MANUAL WAS NOT PERFORMED AT THE TIME AND I
34. arranty gives you specific legal rights and you may also have other rights which vary from state to state 8 INFORMATION For further information contact WARRANTY SERVICES HUSQVARNA FOREST amp GARDEN 7349 STATESVILLE ROAD CHARLOTTE NC 28269 OR CALL 1 800 448 7543 9 WARNING Any modification or alteration of any vehicle beyond factory specifications including those that affect the weight distribution stability or speed of the vehicle can cause serious personal injury or death 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Page 55 TECHNICAL amp CONSUMER INFORMATION GASOLINE ENGINES Carburetor Modification for High Altitude Operation At high altitude the standard carburetor air fuel mixture will be too rich Performance will decrease and fuel consumption will increase A very rich mixture will also foul the spark plug and cause hard starting Operation at an altitude that differs from that at which this engine was certified for extended periods of time may increase emissions High altitude performance can be improved by specific modifications to the carburetor If you always operate your engine at altitudes above 5 000 feet 1 500 meters have your servicing dealer perform this carburetor modification This engine when operating at high altitude with the carburetor modifications for high altitude use will meet each emission standard throughout its useful life Even with carburetor notification engine hor
35. be hoses belts connectors and other emission related assemblies Where a warrantable condition exists Husqvarna will repair your vehicle engine at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE This emission control system is warranted for two years If any emission related part on your equipment is defective the part will be repaired or replaced by Husqvarna OWNER S WARRANTY RESPONSIBILITIES As the vehicle engine owner you are responsible for the performance of the required maintenance listed in your owner s manual Husqvarna recommends that you retain all receipts covering maintenance on your vehicle engine but Husqvarna cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the vehicle engine owner you should however be aware that Husqvarna may deny you warranty coverage if vehicle engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting vehicle engine to a Husqvarna distribution center as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding your warranty rights and responsibilities you should contact WARRANTY SERVICES HUSQVARNA FOREST amp GARDEN PRODUCT MARKETING MANAGER AUTOMOWER 7349 STATESVILLE ROAD CHARLOTTE NC 28269
36. brake pedal PARK BRAKE The park brake pedal 3 is located to the left of the brake pedal Figure 4 and Figure 5 Page 11 To engage the park brake first apply pressure to the brake pedal then firmly press the park brake pedal until it latches into place To disengage the park brake pull the park brake release handle 4 Figure 6 See following WARNING A WARNING The park brake has multiple locking positions and should be firmly locked to prevent the vehicle from rolling Figure 6 Park Brake Release STEERING ADJUSTMENT LOCK The steering wheel position is adjustable To adjust the steering wheel position press down on the steering adjustment lock lever 5 then move the steering wheel to the desired position Figure 4 and Figure 5 Page 11 While holding the steering wheel in the desired position pull up on the steering adjustment lock lever to firmly lock the steering column in position See following WARNING A WARNING Ensure that the steering wheel lock is fully engaged before operating the vehicle 12 VOLT ACCESSORY OUTLET The 12 volt accessory outlet 11 is located to the right of the key switch Figure 4 and Figure 5 Page 11 It provides a constant 12VDC with the key switch in the ON or OFF position See following NOTE NOTE Extended use of this accessory outlet can cause the battery to become heavily discharged 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Page 13 Con
37. control systems The following instructions and procedures must be followed in order to keep the emissions from your Honda engine within the emissions standards Tampering and Altering Tampering with or altering the emission control system may increase emissions beyond the legal limit Among those acts that constitute tampering are Removal or alteration of any part of the intake fuel or exhaust systems Altering or defeating the governor linkage or speed adjusting mechanism to cause the engine to oper ate outside its design parameters Problems That May Affect Emissions If you are aware of any of the following symptoms have your engine inspected and repaired by your servicing dealer Hard starting or stalling after starting Rough idle Misfiring or backfiring under load After burning backfiring Black exhaust smoke or high fuel consumption Replacement Parts The emission control systems on your Honda engine were designed built and certified to conform with EPA and California emission regulations We recommend replacement parts be purchased from Husqvarna Inc These original design replacement parts are manufactured to the same standards as the original parts so you can be confident of their performance The use of replacement parts that are not of the original design and quality may impair the effectiveness or your emission control system A manufacturer of an aftermarket part assumes the responsibility
38. cted into the oil pan 3 A drip guard can be made by folding a piece of cardboard thin metal or plastic under the oil filter forming a channel to direct the filter port oil into the drain pan Dispose of used oil according to the environmental laws and regulations for your area Figure 26 Remove Engine Oil Filter Figure 27 Coat Rubber Seal 4 Usea clean lint free rag to wipe the oil filter port flange surface clean where the oil filter gasket seats 5 To help seal the new oil filter to the oil port flange apply a light coat of white lithium NLGI Number 2 grease Dow Corning BR2 Plus or equivalent or new engine oil to the rubber seal around the outside surface of the filter before attaching it to the oil filter port Figure 27 Page 38 Install the new oil filter gas P N 603 00 00 06 diesel P N 603 00 00 41 onto the engine oil filter port See following NOTE NOTE Use only oil filters designed for your engine 6 Tighten the oil filter by hand 2 3 turn after gasket contact Do not use a band wrench or channel lock pliers Page 38 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Engine Oil 7f fN V J E 4 AS 5 Vf e SAC e 5 4 i gt SY Y Pm Bu AT Figure 28 Add Engine Oil Gasoline Vehicles Figure 29 Add Engine Oil Diesel Vehicles Honda Shown Engine Oil Filling 1 Add engine oil use a funnel or pour spout to direct the oil into the opening Figure 28 or Figure 29 With
39. cure load j Do not ride in cargo bed Includes cargo bed load and gross trailer weight On uneven or steep terrain reduce speed and load Maximum cargo load is reduced by the weight of Avoid stopping on or backing down steep hills optional equipment Avoid top heavy loads See owner s manual Nemo ale Servi ola st Roe 1 HIGH CAPACITY OPTION 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Page 5 Vehicle Feature Identification Practice Safety IK Rotating Parts Safety signs like you see above may at first seem shocking but their impact is mild compared with the reality of severe personal injury Your safety and satisfaction are of the utmost importance to us That is why before operating the vehicle we urge you to review the information in this manual Understand and become familiar with the DANGER WARNING and CAUTION statements and procedures it contains along with the safety decals that are affixed to your vehicle Take time to understand the language of safety It is a language that can save your life PROPOSITION 65 STATE OF CALIFORNIA WARNING This product contains or emits chemicals or substances that have been determined by the state of California to cause cancer and birth defects or other reproductive harm Page 6 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Safety Details SAFETY DETAILS A WARNING This owner s ma
40. d other components and could result in property damage personal injury or death due to unsafe speeds Do not shift the Forward Reverse handle while the vehicle is in motion Engine must be at idle before shifting the Forward Reverse handle Failure to do so may result in injury to inattentive passengers and or damage to the vehicle To avoid unintentionally starting or rolling the vehicle set the park brake place the Forward Reverse handle in the NEUTRAL position turn the key switch to the OFF position and remove the key when leaving the vehicle Page 10 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Controls and Indicators 0 5 Cj Figure 5 Instrument Panel Diesel Vehicles 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Page 11 Controls and Indicators KEY SWITCH GASOLINE VEHICLES The key switch 7 is mounted on the instrument panel to the right of the steering column Figure 4 Page 11 It has three positions OFF ON and START To start the vehicle place the Forward Reverse handle in the NEUTRAL position and turn the key to the START position and hold it there until the engine starts Activate the choke 14 as necessary If the engine does not start after 10 15 seconds release the k
41. d to do anything to engage the AWD system however the front differential may become locked rotate at the same speed regardless of the terrain under certain condi tions If the front differential becomes locked drive slowly in reverse for at least 10 feet 3 meters then brake gently See following WARNING A WARNING Reduced steering control can occur if the front differential becomes locked To help prevent this condition avoid extremely hard braking in reverse STOPPING THE VEHICLE To stop the vehicle release the accelerator pedal and press the brake pedal until the vehicle comes to a com plete stop See following WARNING and CAUTION A WARNING Driving through water may affect the brakes After driving through water check effectiveness of the brakes by gently pressing the brake pedal If the vehicle does not slow down at the normal rate continue to press the brake pedal until the brakes dry out and normal performance returns CAUTION When stopped on a hill use the brake pedal to hold your position Do not use the accelerator pedal to hold position PARKING AND LEAVING THE VEHICLE 1 After stopping the vehicle firmly set the park brake Make sure it is fully engaged This will prevent the vehicle from rolling 2 Turn the key switch to the OFF position remove the key and place the Forward Reverse handle in the NEUTRAL position BED LATCH AND PROP ROD See General Warnings on page 8 The bed
42. dlights on or off See following NOTE NOTE Using the headlights for extended periods while the engine is either off or idling will discharge the battery ELECTRIC BED LIFT Vehicles with Electric Bed Lift Option The electric bed lift switch 13 is located on the instrument panel to the left of the key switch Figure 4 and Figure 5 Page 11 See following NOTE NOTE Remove cargo before raising the bed To lift the bed push up and hold the rocker switch in the upper position Release the switch to stop the lifting operation To close the bed press down and hold the switch in the lower position The bed lift will make a loud clicking sound to signal that the bed is in the rest position HIGH TEMPERATURE WARNING LIGHT DIESEL VEHICLES ONLY The high temperature warning light 10 is located on the instrument panel to the left of the steering column next to the low oil warning light 9 Figure 5 Page 11 The diesel engine is liquid cooled if the engine cool ant has exceeded its normal safe operating temperature the warning light will illuminate If the warning light lights up stop the vehicle and allow it to idle for approximately five minutes before stopping the engine Con tact the dealer distributor or a trained technician See following WARNING WARNING Allow the engine to cool before servicing the engine coolant system Engine coolant can cause severe burns Page 14 2007 HUV 4421 Gasoline and Diesel Vehicle Owner
43. drain plug when changing the differential or transmission fluid These particles are normal and expected for the first few fluid changes This is a result of the gears being net forged meaning the gears are forged to a shape very close to the final gear size but the teeth are not finish machined prior to assembly The finish machining occurs when the gears make contact under load during vehicle operation The magnetic drain plug is included in the design to collect the metal par ticles generated from the gear break in process This is an established process and is not detrimental to gear service life Front differential Clean and install the drain plug 2 and washer before filling the front differential with new lubricant Figure 32 Tighten the drain plug to 9 ft lb 12 N m Use a funnel when filling the front differential through Page 40 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Gearcase Lubrication the lubricant level indicator hole 1 See Periodic Lubrication Schedule on page 32 Tighten the level indi cator plug to 10 ft lb 14 N m Figure 32 Front Differential Lubrication Level Figure 33 Transmission Lubrication Level Transmission Clean and install the drain plug 2 before filling the transmission with new lubricant Figure 33 Tighten the drain plug to 8 ft lb 11 N m Remove the fill plug from the top of the transmission case and use a funnel to fill the transmission with lubricant See Period
44. driver side frame Failure to heed this caution could damage the engine by allowing excessive contamination to enter the air intake system AIR FILTER REPLACEMENT The air filter should be inspected periodically and replaced when necessary Filter changes should not exceed the recommended interval See Periodic Service Schedule on page 29 More frequent service may be required in extremely dirty operating environments In the event of a loss of power sluggish acceleration or a roughly running engine service the air filter immediately Page 42 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Fueling Instructions Air Filter Removal 1 gt Raise the cargo bed and locate the air filter canister Release both canister tab locks Figure 35 Pull the canister cap away from the canister Remove the air filter cartridge 1 See following NOTE NOTE The air filter cartridge is specifically designed for this engine It only fits into the canister one way Use only the Husqvarna part P N 603 00 00 10 designed for this engine OVR RR SS PDA SAM Figure 35 Air Filter Cartridge Air Filter Installation 1 2 3 Push the new air filter cartridge onto the nozzle inside the canister Place the canister cap marked TOP on the top center of the canister Secure the canister cap with both tab locks FUELING INSTRUCTIONS See General Warnings on page 8 DANGER Turn key switc
45. e belt does not retract smoothly pull it out and check for kinks or twists Then make sure it remains free of twists as it retracts Figure 7 Release Safety Belt A WARNING Do not operate the vehicle with the ROPS removed Doing so could result in property damage personal injury or death Do not remove or modify any component of the ROPS structure Doing so will result in voiding the ROPS certification and could weaken the ROPS resulting in serious injury or death Do not operate the vehicle if the ROPS is damaged If the ROPS is damaged replace the structure Do not attempt repair The driver and passenger must be restrained at all times with the safety belts provided to help prevent injury in the event of sudden braking collision or roll over In the event of a roll over do not attempt to jump or otherwise exit the vehicle Remain seated with safety belt fastened and with arms and legs inside the vehicle WARNING CONTINUED ON NEXT PAGE 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Page 15 Seat Latch and Adjustment WARNING After inserting the tab make sure the tab and buckle are locked and that the belt is not twisted Loose fitting safety belts could increase the chance of injury due to sliding under the belt if sudden braking should occur Keep the safety belt snug and positioned as low on the hip bone as possible Use a single safety belt for one person at a time Do not use a s
46. e Owner s Manual Page 53 HUSQVARNA LIMITED TWO YEAR WARRANTY FOR 2007 TRANSPORTATION AND UTILITY VEHICLES 1 WARRANTY Husqvarna INC Husqvarna hereby warrants to the Original Retail Purchaser that its new 2007 Model Transportation and Utility Vehicles purchased from Husqvarna or an authorized dealer shall be free from defects in material and workmanship under normal use and service as a transportation or utility vehicle for the periods stated below subject to the provisions limitations and exclusions contained in this limited warranty LIMITED TWO YEAR 2000 HOUR WARRANTY The engine assembly unitized transaxle assembly gasoline vehicle motor transaxle assembly electric vehicle main frame assembly box bed hydraulic dump kit Custom Cab assembly and doors and Driving Range Protective Enclosure are warranted with respect to parts and labor against defects in material and workmanship for a period of two years or 2000 hours of operation whichever first occurs from the date of purchase LIMITED ONE YEAR 1000 HOUR WARRANTY All remaining components of the vehicle not specified otherwise the Portable Refreshment Center and all other original equipment options and accessories supplied by Husqvarna are warranted with respect to parts and labor against defects in material and workmanship for a period of one year or 1000 hours of operation whichever first occurs from the date of purchase This limited warranty covers materi
47. e brakes to reduce speed when coasting downhill Never attempt jumps Keep away from drop offs steep slopes and unstable surfaces Avoid extremely hard braking in reverse No one should drive the vehicle without first being instructed in the proper operation and use of vehicle con trols An experienced operator should accompany each first time driver on a test drive before allowing the driver to operate the vehicle alone To ensure safe operation of the vehicle follow exactly and in order all of the following procedures Read and understand all instructions before driving the vehicle STARTING THE VEHICLE 1 Read safety warnings on the instrument panel and vehicle loading information located in the cargo bed Be sure load if any is secure Study and understand all controls px 209 Be sure all passengers are seated with their safety belts fastened and are holding on to hand holds Driver should have both hands on the steering wheel 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Page 19 Driving Instructions Make sure wheels are turned in desired direction and nothing is in your path Make sure the Forward Reverse handle is in the NEUTRAL position Press and hold the brake pedal To start the vehicle 8 1 Gasoline vehicles Turn the key to the START position and hold it there until the engine starts Activate the choke as necessary If the engine does not start after 10 15 seconds release the k
48. ed without charge to the owner Such use will not reduce the warranty obligations of CLUB CAR 10 Add on or modified parts that are not exempted by the Air Resources Board may not be used The use of any non exempted add on or modified parts by the ultimate purchaser will be grounds for disallowing a warranty claims CLUB CAR will not be liable to warrant failures of warranted parts caused by the use of a non exempted add on or modified part CLUB CAR its authorized dealers or a service agency approved by CLUB CAR ITEMS COVERED BY THIS WARRANTY The repair or replacement of any warranted part otherwise eligible for warranty coverage may be excluded from such warranty coverage if CLUB CAR demonstrates that the engine or equipment has been abused neglected or improperly maintained and that such abuse neglect or improper maintenance was the direct cause of the need for repair or replacement of the part That notwithstanding any adjustment of a component that has a factory installed and properly operating adjustment limiting device is still eligible for warranty coverage The following emission warranty parts list are covered SYSTEMS COVERED PARTS DESCRIPTION Fuel Metering Carburetor assembly fuel injection pump fuel injection nozzle fuel regulator Exhaust Catalyst Air Induction Air filter housing air filter crankcase breather tube Ignition Flywheel magneto ignition pulse generator ignition coil assembly ignition control module sp
49. eld and rubber gloves when working on or near batteries 5 Carefully check the electrolyte level and add distilled water if necessary Do not fill the battery cells above the designated fill line Replace battery cell caps 6 Clean both battery terminals with a solution of baking soda and water 1 cup 237 mL baking soda per 1 gallon 3 8 L of water Rinse thoroughly Do not allow this solution to enter the battery Tighten battery terminals to 144 in lb 16 N m Let the terminals dry and then spray them with Battery Terminal Protector Spray P N 603 00 00 03 See following CAUTION A WARNING If battery wire terminals are damaged or corroded replace or clean them as necessary Failure to do so may cause them to overheat during operation and could result in a fire property damage or personal injury Be sure the battery hold down clight is properly tightened Tighten to 9 ft Ib 12 2 A loose clight may allow the battery to become damaged from vibration or jarring If battery appears weak have it charged by a trained technician The battery should never be left discharged any longer than absolutely necessary do not leave discharged overnight 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Page 47 Using A Booster Battery Jump Starting USING A BOOSTER BATTERY JUMP STARTING A WARNING Wear safety glasses or approved eye protection when servicing the vehicle Wear a full face shield and rubber glov
50. engine after the first 10 hours of operation Honda gasoline engine after the first 20 hours of operation Kubota diesel engine after the first 50 hours of operation After that the oil should be changed every 100 hours of operation or annually whichever comes first Engine Oil Draining 1 Turn the key switch to the OFF position and remove the key Place the Forward Reverse handle in the NEUTRAL position Chock the front wheels 2 Disconnect the battery cables negative cable first See WARNING To avoid unintentionally start ing on page 10 3 Remove the oil filler cap to allow the oil to drain properly 4 Position a pan designed for oil changes under the drain plug Figure 23 or Figure 24 Page 37 5 From the underside of the vehicle use a socket or wrench to remove the drain plug 1 Turn the plug counterclockwise and drain the engine oil into the pan See following WARNING A WARNING Do not attempt to change engine oil when the engine is hot or even warm Hot engine oil can cause skin burns Wear safety glasses or approved eye protection when servicing the vehicle Wear rubber gloves when handling oil drain plug oil filter and oil drain pan 6 Clean the oil drain plug threads with solvent to remove oil and oil residue Make sure that the compres sion washer or sealing o ring remains on the drain plug Inspect the compression washer or the sealing o ring and replace if necessary Page 36 2007 HUV
51. er must be restrained at all times with the safety belts provided to help prevent injury in the event of sudden braking collision or roll over No more than one person per bucket seat at one time No more than two persons per bench seat at one time Do not allow people to ride in any part of the vehicle that is not equipped with a seat and a safety belt Do not allow a passenger to hold a child in his or her lap while the vehicle is moving Prior to leaving the vehicle unattended or servicing the vehicle set the park brake place the Forward Reverse handle in the NEUTRAL position turn the key switch to the OFF position and remove the key Chock the wheels when servicing the vehicle Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle performance severe personal injury or death Any modification or change to the vehicle that affects the stability or handling of the vehicle or increases maximum vehicle speed beyond factory specifications could result in severe personal injury or death Check the vehicle for proper location of all vehicle safety and operation decals and make sure they are in place and are easy to read For vehicles with cargo beds remove all cargo before raising the bed or servicing the vehicle If the vehicle is equipped with a prop rod ensure that it is securely engaged while bed is raised Do not close bed until all persons are clear of cargo bed area Keep hands clear of al
52. es when working on or near batteries When jumping from a booster battery make final connection negative at engine frame Do not jump start or charge a frozen or damaged battery Unplug charger before connecting or disconnecting cables to the battery Never lean over battery while boosting testing or charging If itis necessary to use a booster battery to start the engine BE CAREFUL 1 Turn the key switch to the OFF position Place the Forward Reverse handle in the NEUTRAL position engage the park brake and chock the wheels 2 Ensure the booster battery is 12 volt See following NOTE NOTE A starting battery is recommended but a deep cycle battery can be used if necessary 3 Access the engine compartment by raising the cargo bed See WARNING For vehicles with cargo beds on page 8 4 Locate the vehicle battery on the driver s side of the vehicle under the cargo bed Figure 41 5 Connect the end of the first cable 1 to the positive terminal of the booster battery Connect the other end of the same cable 2 to the positive terminal of the vehicle battery See DANGER Battery Explo sive gases on page 8 6 Connect the end of the second cable 3 to the negative terminal of the booster battery Connect the other end of the same cable 4 to the battery frame ground 7 Sitin the driver s seat and start the engine 8 Afterthe engine has started remove the frame ground cable 4 first Rem
53. ey and repeat the procedure Once the engine starts release the key and it will return to the ON posi tion The engine will idle in neutral 8 2 Diesel vehicles To preheat glow plugs in cold weather turn the key to the PREHEAT position and hold itthere for 10 15 seconds Turn the key to the START position and hold it there until the engine starts If the engine does not start after 10 15 seconds turn the key to the OFF position and repeat the procedure Once the engine starts release the key and it will return to the ON position The engine will idle in neutral 9 Release the park brake 10 Keep the brake pedal engaged and select direction of travel by placing the shift handle in the desired position Figure 4 or Figure 5 Page 11 The engine must be at idle before the shift handle is moved A buzzer will sound as a warning when the Forward Reverse handle is in the REVERSE position 11 Release the brake pedal completely and then slowly press the accelerator pedal As the accelerator pedal is pressed the vehicle will begin to move Vehicle speed will increase as the accelerator is pressed until full speed is reached All wheel drive will automatically drive the appropriate wheel s as required See following WARNING A WARNING Operator must control vehicle speed when going downhill Never shift the vehicle out of the FORWARD position while going downhill If you do you will not be able to shift into the REVERSE position or b
54. ey and repeat the procedure Once the engine starts release the key and it will return to the ON position The engine will idle in neutral The engine will continue to idle until the key is turned to the OFF position See following WARNING CAUTION and NOTE A WARNING Moving parts Keep clear of the engine compartment while the engine is running CAUTION Do not shift the Forward Reverse handle while the accelerator pedal is pressed Shift the handle only when the vehicle is at a complete stop and the engine is at idle Failure to heed this caution could result in damage to the transmission NOTE The key can be removed only when the key switch is in the OFF position KEY SWITCH DIESEL VEHICLES The key switch 7 is mounted on the instrument panel to the right of the steering column Figure 5 Page 11 It has four positions PREHEAT OFF ON and START Use the PREHEAT feature if the temperature falls below 23 F 5 C Do not hold the key in the PREHEAT position longer than 20 seconds To preheat the glow plugs in cold weather turn the key to the PREHEAT position and hold it there for 10 15 seconds Then turn the key to the START position and hold it there until the engine starts If the engine does not start after 10 15 seconds turn the key to the OFF position and repeat the procedure Once the engine starts release the key and it will return to the ON position The engine will idle in neutral The engine will conti
55. fety seat must not ride on the vehicle Comply with state and local laws pertaining to child safety Operate the vehicle from the driver seat only To help prevent falls from the vehicle remain seated with safety belt fastened and hold on to hand holds at all times Driver should keep both hands on the steering wheel when the vehicle is in motion To help prevent the possibility of serious injury keep entire body inside the vehicle To help prevent overturning the vehicle drive slowly in turns To help prevent overturning the vehicle drive slowly straight up and down slopes Avoid driving the vehicle on slopes exceeding 20 incline Avoid stopping a loaded vehicle on a hill If a loaded vehicle must be stopped on a hill avoid sudden starts or rolling backwards and stopping suddenly Failure to heed this warning could result in overturning the vehicle To help avoid possible injury to inattentive passengers and or damage to the vehicle avoid sudden starts sudden stops and abrupt turns To help avoid the possibility of losing control of or overturning the vehicle reduce speed for adverse driving conditions such as wet grass or rough terrain Do not use the vehicle on public roads It is neither designed nor intended for street use and should not be licensed for use on public roads The vehicle should be driven in only specified areas by trained drivers Do not drive while under the influence of alcohol drugs or medications Us
56. filter change the engine requires Honda gasoline engines 1 qt and 25 oz 1 7 L of oil per change Kawasaki gasoline engines 1 qt and 19 oz 1 5 L of oil per change Kubota diesel engines 3 qt 2 8 L of oil per change 2 Refer to oil viscosity guidelines for selection of oil grade Figure 30 or Figure 31 See following CAU TION CAUTION Do not exceed recommended oil capacity Doing so will decrease engine performance or result in damage to the engine 3 Connect the battery cables positive cable first and tighten terminals to 144 16 Coat ter minals with Battery Terminal Protector Spray P N 603 00 00 03 4 With the Forward Reverse handle in the NEUTRAL position start and run the engine for a few minutes Observe both the drain plug and the oil filter from under the vehicle and watch for oil leaks If a leak is detected check the tightness of the oil filter and drain plug Tighten repair and or replace components as necessary See following NOTE NOTE Wait five minutes after turning off the engine before removing the dipstick 5 Remove the dipstick and check the engine oil as a final step Replace the dipstick OIL VISCOSITY Choose the viscosity according to the temperature as shown in the appropriate oil viscosity chart Figure 30 or Figure 31 See following NOTE 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Page 39 Gearcase Lubrication NOTE Use engine oil
57. g delivery Use the following list as a guide to inspect the vehicle This list should be used daily and in conjunction with the Performance Inspection and the Periodic Service Schedule on page 29 to ensure that the vehicle is in proper working condition Any problems should be corrected by a dealer distributor or a trained technician General All the parts should be in place and properly installed Be sure that all nuts bolts and screws are tight Check hose clights for tight fit Safety and information decals Check to ensure that all safety and information decals are in place and can be read easily See pages 4 through 5 ROPS Check to ensure the ROPS is not damaged and all hardware is secure See Roll Over Protec tive Structure and Safety Belts on page 15 Safety belts Visually inspect for cuts fraying and loose parts See Roll Over Protective Structure and Safety Belts on page 15 Tires Check for proper tire pressure Visually inspect tires for wear damage and proper inflation on a daily basis See Vehicle Specifications on page 51 Battery Check electrolyte to ensure it is at the proper level Figure 40 Page 47 Check battery posts Wires should be tight and free of corrosion and battery should be fully charged Engine Check for proper engine oil and coolant levels and leaks See Engine Oil on page 34 Check air filter and replace if necessary Fuel Check fuel level See Fueling Instructions on page 43 Check fuel tan
58. guidelines Ensure the fuel tank is as full as possible at all times to prevent moisture from collecting Ensure that the fuel tank cap is securely tightened to prevent water from entering the fuel tank Drain all water from the fuel filter daily before operating vehicle See Draining Water from Fuel Filter Check the engine oil level daily before the engine is started See Engine Oil Level Check on page 35 Before vehicle storage run the engine with conventional diesel fuel for at least 30 minutes to flush the biodiesel from the engine See Preparing the Vehicle for Extended Storage on page 26 See fol lowing NOTE NOTE Biodiesel does not have long term stability and must not be left in engines longer than three months This fuel type attracts moisture and may contain higher water content than conventional diesel fuel Fuel system maintenance cleaning and fuel line replacement are required more frequently for engines that are operated with biodiesel DRAINING WATER FROM FUEL FILTER Diesel Vehicles Only Water should be drained from the fuel filter daily The fuel filter is mounted on a plate by the lower seat support panel Figure 38 1 Position a pan under the fuel filter 2 Lift the passenger side seat 3 Locate the valve 1 on the underside of the filter Turn the valve clockwise until water begins to stream from the filter 4 Drain the water until it changes color to fuel See following WARNING WARNING
59. h to the OFF position before fueling Never pour fuel into the fuel tank when the engine is hot or while it is running To avoid electric arc caused by static electricity the fuel storage pumping device must be grounded If the pump is not grounded the vehicle must be grounded to the pump before and during the fueling operation To avoid the possibility of fire clean up any spilled fuel before operating the vehicle Remove the fuel cap and fill the tank with fuel Gasoline vehicles have a black fuel cap diesel vehicles have a green fuel cap See preceding DANGER and following NOTE 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Page 43 Fueling Instructions NOTE Gasoline vehicles Use unleaded gasoline only Whenever possible avoid using oxygenated fuels and fuels that are blended with alcohol Diesel vehicles Use only diesel fuel grade no 2 with a cetane rating of 45 or higher 2 Replace the fuel cap Ensure that the cap is tightened securely 3 Clean any spilled fuel from the cap or around the fuel cap area VENT Figure 36 Fuel Tank Gasoline Vehicles Figure 37 Fuel Tank Diesel Vehicles Biodiesel Fuel Diesel Vehicles Only Biodiesel has unique qualities that should be considered before it is used in the Kubota D722 diesel engine During cold weather plugged fuel lines plugged fuel systems hard starting and other unknown failures can
60. he brake pedal is fully pressed under heavy pressure the pedal should feel firm and the distance between the back of the pedal and the floorboard should be a minimum of 1 25 inches 3 2 cm Brake adjustment must be maintained so the brake pedal cannot be pressed to the floorboard under any circumstance Park brake When latched the park brake should lock the wheels and hold the vehicle stationary on an incline of 20 or less Reverse buzzer The reverse buzzer should sound as a warning when the Forward Reverse handle is in the REVERSE position Steering The vehicle should be easy to steer and should not have any play in the steering wheel Be sure the steering wheel adjustment lever is securely locked into position Accelerator After starting the engine with the key switch and placing the Forward Reverse handle in the FORWARD position the vehicle should accelerate smoothly to full speed as the accelerator pedal is pressed When the pedal is released it should return to the original position and the engine should idle This vehicle operates at a reduced speed in reverse Governor Check maximum vehicle speed The vehicle should operate in forward at a maximum speed of 25 mph 40 km h on a level surface General Listen for any unusual noises such as squeaks or rattles Check the vehicle s ride and perfor mance Have a dealer or a trained technician investigate anything unusual DRIVING INSTRUCTIONS A WARNING Only licensed drive
61. he vehicle Follow all instructions carefully when working with batteries When jumping from a booster battery make final negative connection at engine frame Do not jump start or charge a frozen or damaged battery Unplug charger before connecting or disconnecting cables to the battery Never lean over battery while boosting testing or charging Page 46 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Battery The battery in this vehicle is a 12 volt low maintenance battery that requires infrequent checks Figure 39 Electrolyte level should be checked semiannually 5 BATTERY L CAP FRONT Ex LEVEL OF VEHICLE amp amp INDICATOR PLATES ELECTROLYTE LEVEL AT LEAST 1 2 INCH 13 MM ABOVE PLATES OR TO LEVEL INDICATOR Figure 39 Battery Figure 40 Battery Electrolyte Level 1 Turn the key switch to the OFF position and remove the key Place the Forward Reverse handle in the NEUTRAL position Chock the wheels 2 Access the engine compartment See WARNING For vehicles with cargo beds on page 8 2 1 Remove the driver side seat 3 Disconnect the battery cables negative cable first See WARNING To avoid unintentionally start ing on page 9 4 Use aflat blade screwdriver and carefully remove the battery cell caps from the battery See following WARNING WARNING Wear safety glasses or approved eye protection when servicing the vehicle Wear a full face shi
62. hicle Feature Identification ALL HUV 4421 MODELS DIESEL WARNING DECAL A WARNING DIESEL FUEL EXPLOSION FIRE Can cause severe injury or death No smoking sparks or open flame Stop engine allow to cool before refueling Read owner s manual and vehicle safety warnings Study and understand controls TO START ENGINE Place shift lever in NEUTRAL and press brake pedal Turn key to START and hold until engine starts Diesel Vehicles Only If required turn key to PREHEAT and hold for 10 15 seconds CCI 102459201 DIESEL VEHICLES ONLY GASOLINE WARNING DECAL ON PASSENGER GIDE SEAT SUPPORT AN WARNING With vehicle stopped and engine at idle select vehicle direction GASOLINE EXPLOSION FIRE AB Foward Neutral 0 Reverse Buzzer will sound Can cause severe injury or death Release park brake and slowly press accelerator pedal to smoking sparks or open flame increase speed VARSE All wheel drive will automatically drive appropriate wheel s off during storage or transport CCI 101547601 TO STOP VEHICLE Release accelerator pedal and push brake pedal GASOLINE VEHICLES ONLY BEFORE LEAVING VEHICLE ON PASSENGER SIDE SEAT SUPPORT Turn key to OFF and remove key Place shift lever in NEUTRAL Firmly set park brake 0 OPERATING INSTRUCTIONS ON INSTRUMENT PA
63. ic Lubrication Schedule on page 32 Apply Loctite 567 to the threads of the fill plug and tighten to 21 ft Ib 28 N m Check the level of lubricant at the level indicator plug 1 Apply Loctite 567 to the threads of the level indicator plug and tighten to 21 ft lb 28 N m Rear differential Clean and install the drain plug 2 and washer before filling the rear differential with new lubricant Figure 34 Tighten the drain plug to 8 ft lb 10 8 N m Use a funnel to fill the differential through the lubricant level indicator hole 1 See Periodic Lubrication Schedule on page 32 Apply Loctite 567 to the threads of the level indicator plug and tighten to 21 ft lb 28 N m 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Page 41 Engine Coolant Diesel Vehicles Figure 34 Rear Differential Lubrication Level ENGINE COOLANT DIESEL VEHICLES ENGINE COOLANT LEVEL CHECK The coolant reserve tank 2 is located under the hood on the passenger side Figure 16 Raise the hood to check the coolant level before every operation 1 Checkthe coolant level of the reserve tank 2 If the coolant is at or below the LOW mark add pre mixed coolant until the level reaches the FULL mark If a leak is detected have it checked by a trained techni cian See following WARNING A WARNING Hot Coolant reserve tank is pressurized Do not remove cap when engine is hot AIR INTAKE SYSTEM CAUTION Do not drill into the
64. ies A WARNING Reduce speed and avoid sudden stops when backing up Failure to do so may cause the vehicle to overturn or flip over backwards Maximum cargo load must be reduced by the weight of optional equipment Center and secure cargo as far forward as possible in the cargo bed Do not overload the vehicle See Vehi cle Load Capacities on page 23 for vehicle capacities VEHICLE LOAD CAPACITIES Maximum Occupant Capacity The maximum occupant capacity is the maximum allowable weight for occupants operator and passengers to operate the vehicle safely Gross Trailer Weight Gross trailer weight is the combination of the trailer weight and the trailer load weight Maximum Payload Capacity The maximum payload capacity is the maximum amount of load that the vehicle can haul in the cargo bed and or tow in a trailer The combined weight of bed load and gross trailer weight cannot exceed the vehicle s stated maximum payload capacity Vehicle Rated Capacity The vehicle rated capacity is the maximum amount of weight the vehicle can carry haul and tow This capac ity includes weight of occupants bed load and gross trailer weight Maximum Gross Vehicle Weight The maximum gross vehicle weight is the combination of the vehicle weight and the maximum vehicle capac ity The stated maximum gross vehicle weight must not be exceeded to maintain safe vehicle operation Maximum payload capacity must be reduced accordingly when an
65. ingle safety belt for two or more people this includes children No more than one person per bucket seat at one time No more than two persons per bench seat at one time Do not allow people to ride in any part of the vehicle that is not equipped with a seat and a safety belt Do not allow a passenger to hold a child in his or her lap while the vehicle is moving This vehicle is not designed to meet child seat compatibility requirements Children requiring a child safety seat must not ride on the vehicle Comply with state and local laws pertaining to child safety CAUTION Be careful not to damage the safety belt webbing or hardware Inspect the safety belt system periodically Check for cuts fraying and loose parts Damaged parts should be replaced immediately Do not disassemble or modify the system Keep safety belts clean and dry If cleaning is necessary use a mild soap and lukewarm water solution Do not use bleach dye or abrasive cleaners as they may severely weaken the safety belts Do not insert coins clip etc in the buckle as this may prevent the tab from locking into the buckle properly If the safety belt does not function normally contact your dealer distributor or trained technician immediately Do not occupy the seat until the safety belt is repaired SEAT LATCH AND ADJUSTMENT The vehicle seat s are hinged to allow easy access to the engine compartment To raise the seat bottom grasp the rear side of the sea
66. inse the solution off the battery Do not allow this solution to enter the battery Be sure the terminals are tight Let the terminals dry and then coat them with Battery Terminal Protector Spray P N 603 00 00 03 10 Adjust the tires to the recommended tire pressure See Vehicle Specifications on page 51 11 Perform semiannual periodic lubrication See Periodic Lubrication Schedule on page 32 12 Thoroughly clean the front body rear body seats cargo bed engine compartment and underside of vehicle 13 Do not engage the park brake Chock the wheels to prevent the vehicle from rolling RETURNING THE STORED VEHICLE TO SERVICE 1 Make sure the key switch is in the OFF position and the Forward Reverse handle is in the NEUTRAL position Chock the wheels 2 Restore the fuel system to operation Figure 36 or Figure 37 Page 44 2 1 Remove the plug from the fuel tank vent 2 2 Connect the vent tube to the fuel tank vent 3 Connect the battery cables positive cable first and tighten the terminals to 144 16 N m Coat terminals with Battery Terminal Protector Spray P N 603 00 00 03 4 Gasoline vehicles only Completely open the fuel shut off valve Figure 12 Page 26 Ensure the valve is fully open A partially closed fuel shut off valve combined with the use of the choke can result in a fouled spark plug and engine failure Figure 13 Page 26 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Page 27 Main
67. inum Front body Geloy XTWM206 Tires All Terrain 25 x 10 5 12 front and rear tubeless 4 ply rated load range Mud 25 x 11 12 front and rear tubeless 4 ply rated load range DIMENSIONS WEIGHT NOTE Items marked with an asterisk indicate approximate values Overall length box bed configuration without brushguard 122 in 309 9 cm Overall width without mirror with mirror 58 5 in 148 5 cm 63 6 in 161 5 cm Overall height with ROPS with mud tires with all terrain tires 82 3 in 209 cm Wheelbase 81 5 in 207 cm Ground clearance under differential 8 2 in 20 8 cm Front and rear wheel tread 48 8 in 124 cm Weight 2 passenger gasoline with electric bed lift mud tires and without brush guard 2 passenger diesel with electric bed lift mud tires and brush guard 4 passenger gasoline with all terrain tires 4 passenger diesel with all terrain tires 1450 Ib 657 6 kg 1597 Ib 724 2 kg Forward speed 25 mph 40 km h Governed RPM 3825 Turning Radius 138 in 350 5 cm Load bed height 34 in 86 4 cm Load bed size box bed inside dimensions 48 0 x 49 8 x 10 9 in 122 x 127 x 28 cm 15 3 cubic feet Maximum payload capacity level surface only 800 Ib 363 kg High capacity option 1050 Ib 476 kg Vehicle rated capacity payload driver and passenger level surface on
68. k lines fuel cap pump and fuel filters for fuel leakage Drain water from the fuel filter diesel vehicle See Draining Water from Fuel Filter on page 45 Exhaust system Check for leaks Hydraulic brakes Check fluid level Wear in the brakes before initial vehicle operation On a flat open surface accelerate the vehicle to moderate speed then apply the brakes under modest steady pres sure Repeat this procedure five times See following NOTE NOTE Perform the wear in procedure when the vehicle has been in operation for less than a week or when the brake pads or rotor have been replaced 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Page 17 Performance Inspection PERFORMANCE INSPECTION After you have familiarized yourself with the vehicle controls and have read and understood the driving instructions take the vehicle for a test drive Use the following list in addition to the Pre Operation and Daily Safety Checklist as a guide to inspect the vehicle daily for proper operation Any problems should be corrected by a dealer distributor or a trained tech nician Forward Reverse shifter Check for proper operation See Controls and Indicators on page 10 Brakes Be sure the brakes function properly When brake pedal is fully pressed under moderate pres sure the vehicle should come to a smooth straight stop If the vehicle swerves or fails to stop have the brake system checked and adjusted as required When t
69. l crush areas Do not drop cargo bed lower gently and keep entire body clear Failure to heed this warning could result in severe personal injury or death WARNING CONTINUED ON NEXT PAGE Page 8 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual General Warnings A WARNING Only trained technicians should service or repair the vehicle Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair The appropriate instructions must be used when performing maintenance service or accessory installation To avoid unintentionally starting the vehicle Disconnect battery cables negative cable first Figure 1 Gasoline vehicles only Disconnect the spark plug wires from the spark plugs Frame ground Do not allow tools or other metal objects to contact frame when disconnecting battery cables or other electrical wiring Do not allow a positive wire to touch the vehicle frame engine or any other metal component Wear safety glasses or approved eye protection when servicing the vehicle Wear a full face shield and rubber gloves when working on or near batteries Do not wear loose clothing or jewelry such as rings watches chains etc when servicing the vehicle Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring When servicing the vehicle with part of the vehicle on j
70. lacement as required maintenance in the written instructions supplied is warranted for the period of time before the first scheduled replacement date for that part If the part fails before the first scheduled replacement the part will be repaired or replaced by CLUB CAR according to subsection 4 below Any such part repaired or replaced under warranty will be warranted for the remainder of the period prior to the first scheduled replacement point for the part 4 Repair or replacement of any warranted part under the warranty provisions herein must be performed at a warranty station at no charge to the owner 5 Notwithstanding the provisions herein warranty services or repairs will be provided at all of our distribution centers that are franchised to service the subject engines or equipment 6 The engine or equipment owner will not be charged for diagnostic labor that is directly associated with diagnosis of a defective emission related warranted part provided that such diagnostic work is performed at a warranty station 7 CLUB CAR is liable for damages to other engine or equipment components proximately caused by a failure under warranty of any warranted part 8 Throughout the engine or equipment warranty period stated above CLUB CAR will maintain a supply of warranted parts sufficient to meet the expected demand for such parts 9 Any replacement part may be used in the performance of any warranty maintenance or repairs and must be provid
71. latch Figure 8 has an automatically engaging prop rod and prop rod track Figure 9 as standard features To lift the bed pull the bed latch handle toward the rear of the vehicle and lift the bed The prop rod will come to rest in one of the notches in the prop rod track To close the bed lift the bed so that the prop rod is no longer supported in one of the track notches Push the prop rod toward the front of the vehicle to free it from the track notch and gently lower the bed DO NOT drop the bed See following DANGER WARNING and NOTE DANGER Use caution when working under bed Be sure prop rod is secure Otherwise the bed will fall resulting in severe personal injury or death 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Page 21 Loading and Unloading Cargo WARNING For vehicles with cargo beds remove all cargo before raising the bed or servicing the vehicle If the vehicle is equipped with a prop rod ensure that it is securely engaged Do not close bed until all persons are clear of cargo bed area Keep hands clear of all crush areas Do not drop cargo bed lower gently and keep entire body clear Failure to heed this warning could result in severe personal injury or death NOTE HUV 4421 G and HUV 4421 D vehicles are equipped with an automatically engaging prop rod Figure 9 unless equipped with the electric bed lift accessory Figure 8 Bed Latch Figure 9 Prop Rod LOADIN
72. ly 1200 Ib 544 kg High capacity option 1450 Ib 658 kg Maximum gross vehicle weight fully loaded vehicle including accessories 2750 Ib 1247 kg High capacity option 3012 Ib 1366 kg Standard seating capacity 2 LIQUID CAPACITIES Engine Honda crankcase with filter SAE 10W 30 API classification SJ at ane D 92 Engine Kawasaki crankcase with filter SAE 10W 30 classification SJ 1 qt ag iy 92 Engine crankcase with filter SAE 10W 30 classification CF 3 qt 2 8L Front differential Mobil 424 Exxon Hydraul 560 or Esso Hydraul 56 lubricant 5 oz 150 mL 5 oz 150 mL LIQUID CAPACITIES CONTINUED Gasoline Diesel Rear differential Mobil 424 Exxon Hydraul 560 or Esso Hydraul 56 lubricant 20 oz 600 mL Transmission Mobil 424 Exxon Hydraul 560 or Esso Hydraul 56 lubricant 20 oz 600 mL Specifications continued on next page Page 52 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Vehicle Specifications SPECIFICATIONS HUV 4421 HUV 4421 Engine coolant mixture of 55 propylene glycol and 45 water n a 2981 Brake fluid DOT 5 silicone brake fluid 8 oz 240 ml Fuel tank unleaded gasoline Oren Fuel tank diesel grade no 2 with cetane rating of 45 or higher Eon TIRE PRESSURE All terrain tread and mud tires 20 22 psi 1 38 1 52 Bars 2007 HUV 4421 Gasoline and Diesel Vehicl
73. n outdoor products You have chosen the finest utility vehicle on the market Please protect your investment and ensure that your Husqvarna vehicle provides years of reliable superior performance by reading and following the maintenance instructions in this manual Your comfort and safety are important to us so we urge you to read and follow the step by step operating instructions and safety procedures in this manual These instructions must be followed in order to avoid the risk of severe personal injury If you rent or loan your vehicle to others we recommend that you ask them to read this manual before they operate the vehicle Husqvarna products are backed by a customer support system designed to offer you fast courteous service In the event that your Husqvarna vehicle needs repairs or service we recommend that your local authorized Husqvarna representative perform them For the name and address of the Husqvarna representative nearest you logon to our web site at www usa husqvarna com If you would prefer to write to us direct your letter to Husqvarna Attention Marketing Services 7349 Statesville Rd Charlotte NC 28269 USA Your local autho rized Husqvarna representative can also provide technical advice parts and service manuals We hope you will consider this owner s manual a permanent part of your Husqvarna vehicle If you sell the vehicle please include the manual so that the next owner will have the important operating safety a
74. nd main tenance information it contains Translated owner s manuals can be downloaded from the Husqvarna web site at www usa husqvarna com huv Page 2 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual TABLE OF CONTENTS SICWABIJCUI A P 7 General Warnings e etd ei o t e RR Rd am Ete 8 General Information a E pp aieo it ondas 10 Modelildentification 25 52 95 2 5 rii eite ise enc die ied 10 Gontrols and Indicators 22 e po taper ei 10 Roll Over Protective Structure and Safety 15 Seat Latch and Adjustment interi einn 16 Pre Operation and Daily Safety Checklist 4 1 0 2000 eene enne nnns 17 PertormanceInspeGtion o cvv ertet ae 18 Driving Instructloris 2 18 A bei iei 21 Loading and Unloading Cargo sse nennen enhn AS RS NANG UA SRA NAR K RD nennen nnns nnne nnns 22 Vehicle Load Capacities 2 e HE oet ete btt in endete ose ei ated tete 23 Towing with the Vehicle eerte bee tee ee Leg ede e e Lene eed dee eee ly 24 Transporting ora Trailer ek
75. nual should be read completely before attempting to drive or service the vehicle Failure to follow the instructions in this manual could result in property damage severe personal injury or death It is important to note that some vital statements throughout this manual and on the decals affixed to the vehi cle are preceded by the words DANGER WARNING or CAUTION For your protection we recommend that you take special notice of these safety precautions Safety precautions are essential and must be followed If any of the operation or warning decals on the vehicle become damaged have been removed or cannot be easily read they should be replaced immediately to avoid possible property damage personal injury or death Contact your dealer DANGER ADANGER indicates an immediate hazard that will result in severe personal injury or death A WARNING A WARNING indicates an immediate hazard that could result in severe personal injury or death CAUTION A CAUTION with the safety alert symbol indicates a hazard or unsafe practice that could result in minor personal injury CAUTION A CAUTION without the safety alert symbol indicates a potentially hazardous situation that could result in property damage gm negative XT cable first Figure 1 Battery Cable Removal 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Page 7 General Warnings GENERAL WARNINGS The foll
76. nue to idle until the key is turned to the OFF position See previous WARN ING CAUTION and NOTE FORWARD REVERSE CONTROL The Forward Reverse handle 6 is located on the right side of the instrument panel Figure 4 and Figure 5 Page 11 The handle has three distinct positions FORWARD A NEUTRAL B and REVERSE C Push the handle up to operate the vehicle in the forward direction or pull the handle down to operate the vehicle in reverse The engine can be started only when the handle is in the NEUTRAL middle position The engine must be at idle before shifting the Forward Reverse handle See WARNING and CAUTION on page 12 This vehicle operates at a reduced speed in reverse The reverse buzzer will sound as a warning when the Forward Reverse handle is in the REVERSE position ACCELERATOR PEDAL The accelerator pedal 1 is the pedal farthest to the right Figure 4 and Figure 5 Page 11 With the engine running and the Forward Reverse handle in the FORWARD or REVERSE position vehicle speed will increase as the accelerator pedal is pressed When the accelerator pedal is released it will return to the original position and the engine will idle See WARNING and CAUTION on page 12 Page 12 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Controls and Indicators BRAKE PEDAL The brake pedal 2 is located to the immediate left of the accelerator pedal Figure 4 and Figure 5 Page 11 To slow or stop the vehicle press the
77. ove the cable from the pos itive terminal 2 Then remove the cables from the booster battery See following CAUTION CAUTION The alternator can be damaged if the following actions occur Engine is operated with battery cables disconnected Booster cables are connected wrong Figure 41 Jump Starting Page 48 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Cleaning the Vehicle CLEANING THE VEHICLE Each vehicle is equipped with hand wash washable front and rear bodies The vehicle has a powder coated steel cargo bed or optional aluminum flat bed Use commercial automotive cleaning solutions with a sponge or soft cloth for normal cleaning garden hose at normal residential water pressure is adequate To remove oxidation or discoloration from aluminum use a commercially available aluminum cleaner paste and fine grade No 00 steel wool The manufacturer does not recommend any type of pressure washing or steam cleaning Such a process will expose electrical components to moisture Moisture entering electrical components can result in water dam age and subsequent component failure Use non abrasive wax products Battery acid fertilizers tars asphalt creosote paint or chewing gum should be removed immediately to prevent possible stains The seats of the vehicle will last longer with proper cleaning Use a solution of 10 liquid soap and warm water applied with a soft cloth For imbedded dirt a soft bristle b
78. rburetor with float bowl fixed jets fuel filters and impulse fuel pump Fuel system Mechanical injection fuel water separator fuel filters and electric fuel pump Governor Honda engine Automatic ground speed sensing internally geared in transmis sion Governor Kawasaki engine internal to engine centrifugal ball Governor internal to engine mechanical centrifugal ball Ignition Transistorized magneto Ignition Compression Transmission Forward and reverse with neutral 5 39 1 forward 7 79 1 reverse Electrical system 12 volt 500 cca at 0 F 17 8 C 650 at 32 F 0 C 105 minute reserve capacity and 35 amp charging capacity Torque converter Automatic variable speed dry type STEERING SUSPENSION BRAKES Suspension Front Independent double A arms with coil over shock absorbers Rear Swing arms with coil over shock absorbers Steering Self adjusting rack and pinion Ackerman Brakes Hydraulic brake system brake pads and discs on each wheel with separate foot operated park brake BODY CHASSIS Frame Chassis Box tube aluminum Specifications continued on next page 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Page 51 Vehicle Specifications SPECIFICATIONS HUV 4421 HUV 4421 BODY CHASSIS CONTINUED Gasoline Diesel Side and rear body Plastic Cargo bed Powder coated steel or alum
79. rs should be allowed to drive the vehicle Before allowing anyone to drive the vehicle make sure the driver is familiar with all controls and operating procedures No one under the age of 16 years should be allowed to drive the vehicle No more than one person per bucket seat at one time No more than two persons per bench seat at one time Do not allow people to ride in any part of the vehicle that is not equipped with a seat and a safety belt Do not allow a passenger to hold a child in his or her lap while the vehicle is moving Do not allow riders in the cargo bed For night use the vehicle must be equipped with headlights taillights and reflectors The vehicle is not specially equipped for handicapped persons WARNING CONTINUED ON NEXT PAGE Page 18 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Driving Instructions A WARNING Be sure all passengers are capable of securing themselves in a moving vehicle before allowing them to ride in one Be sure all persons can properly operate the vehicle prior to allowing them to drive the vehicle Stop the vehicle before shifting the Forward Reverse handle Engine must be at idle before shifting the Forward Reverse handle Failure to do so may result in injury to inattentive passengers and or damage to the vehicle To help avoid being struck do not stand in front of or behind the vehicle Do not leave children unattended on vehicle Children requiring a child sa
80. rush may be used For heavy soiling difficult stains or scratches blemishes or other body damage see the appropriate maintenance and service manual See following NOTE NOTE Dispose of waste water properly ACCESSORIES There is a complete line of accessory equipment available from our dealers distributors Care should be taken that these accessories are properly installed by trained technicians and that they are used in the manner for which they were designed See following WARNING and CAUTION A WARNING Custom cab assemblies canopy tops weatherproof enclosures and windshields will not protect occupants from flying objects If the vehicle is equipped with an electric powered bed lift remove the bed before servicing the bed lift system CAUTION Do not drill into the driver side frame Failure to heed this caution could damage the engine by allowing excessive contamination to enter the air intake system ELECTRIC WINCH ACCESSORY If your vehicle is equipped with an electric winch read and follow all manufacturer safety warnings and instructions in the winch operator manual as well as the following WARNING and CAUTION statements Make sure a winch warning decal is affixed to the vehicle on the seat support panel next to the receptacle for the remote operation switch The winch kit available includes a remote operation switch which enables the operator to move away from the vehicle and cable See following
81. s Manual Roll Over Protective Structure and Safety Belts ROLL OVER PROTECTIVE STRUCTURE AND SAFETY BELTS HUV 4421 G and HUV 4421 D vehicles are equipped with a Roll Over Protective Structure ROPS and safety belts for each occupant See following WARNING A WARNING The ROPS must be properly installed before operating the vehicle Husqvarna strongly urges that the vehicle s occupants be properly restrained at all times with the safety belts provided Pregnant woman Consult your doctor for specific recommendations The safety belt should be worn securely and as low as possible over the hips and not on the waist Injured person Depending on the injury first check with your doctor for specific recommendations To secure the safety belt sit up straight and well back in the seat Pull the safety belt out of the retractor and insert the tab into the buckle A click will be heard when the tab locks into the buckle Position the lap belt as low as possible on the hips not on the waist The retractor will lock the belt during a sudden stop It also may lock if the occupant leans forward too quickly A slow easy motion will allow the belt to extend and the occupant can move freely If the safety belt cannot be pulled out of the retractor firmly pull the belt and release it It should then pull smoothly out of the retractor To release the safety belt press the buckle release button 1 and allow the belt to retract Figure 7 If th
82. sepower will decrease about 3 5 for each 1 000 foot 300 meter increase in altitude The effect of altitude on horsepower will be greater than this if no carburetor mod ification is made NOTE When the carburetor has been modified for high altitude operation the air fuel mixture will be too lean for low altitude use Operation at altitudes below 5 000 feet 1 500 meters with a modified carburetor may cause the engine to overheat and result in serious engine damage For use at low altitudes have your servicing dealer return the carburetor to original factory specifications Oxygenated Fuels Some conventional gasolines are being blended with alcohol or an ether compound These gasolines are col lectively referred to as oxygenated fuels To meet clean air standards some areas of the United States and Canada use oxygenated fuels to help reduce emissions If you use an oxygenated fuel be sure it is unleaded and meets the minimum octane rating requirement Before using an oxygenated fuel try to confirm the fuel s contents Some states provinces require this infor mation to be posted on the pump The following are the EPA approved percentages of oxygenates ETHANOL ethyl or grain alcohol 1096 by volume You may use gasoline containing up to 1096 ethanol by volume Gasoline containing etha nol may be marketed under the name Gasohol MTBE methyl tertiary butyl ether 1596 by volume You may use gasoline containing up to 15 M
83. t battery cables negative cable first Figure 1 Page 7 WARNING CONTINUED ON NEXT PAGE Page 28 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Periodic Service Schedule WARNING Gasoline vehicles only Disconnect the spark plug wires from the spark plugs If wires are removed or replaced make sure wiring and wire harness are properly routed and secured Failure to properly route and secure wiring could result in vehicle malfunction property damage personal injury or death Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 Ib 454 kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When servicing the vehicle with part of the vehicle on jack stands do not operate the engine with the Forward Reverse handle in either the FORWARD or REVERSE position The all wheel drive system will engage any wheel s front or rear with traction See Figure 2 on page 9 PERIODIC SERVICE SCHEDULE See General Warnings on page 8 A WARNING Service repairs and adjustments must be made per instructions in the appropriate maintenance and service manual NOTE If the vehicle is constantly subjected to heavy use or severe operating conditions the preventive maintenance procedures sho
84. t bottom and pull firmly in a forward upward direction See following WARN ING WARNING Make sure seat hinges and latches are securely engaged before operating the vehicle Vehicles with bucket seat option The driver side bucket seat is adjustable and can be moved forward or backward to accommodate the driver To adjust this seat push the lever located under the driver seat to the left towards outside of the vehicle Position the seat and return the lever to its original position See following WARNING A WARNING Do not adjust the driver side seat while the vehicle is in motion Page 16 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Pre Operation and Daily Safety Checklist To adjust the passenger side seat 1 2 3 4 5 Remove the seat from the vehicle Remove the four bolts and washers from the bottom of the seat mounting plate Align the mounting plate holes with holes in the seat to achieve the desired seat position Install washers and bolts and tighten to 96 10 8 N m Install the seat See preceding WARNING Make sure seat hinges and latch PRE OPERATION AND DAILY SAFETY CHECKLIST Each vehicle has been thoroughly inspected and adjusted at the factory however upon receiving your new vehicle s you should become familiar with the controls indicators and operation Carefully inspect each vehicle to ensure that it is in proper working condition before acceptin
85. tenance 5 Place the Forward Reverse handle in the NEUTRAL position Crank the engine until fuel is pumped into the carburetor gasoline vehicles and the fuel lines all vehicles and the engine starts Turn the engine off See following NOTE NOTE Due to the oil added to the gasoline engine in preparation for storage the engine may smoke excessively for a short time when it is run for the first time after storage 6 Perform the Pre Operation and Daily Safety Checklist on page 17 and the Performance Inspection on page 18 MAINTENANCE See General Warnings on page 8 To ensure trouble free vehicle performance follow an established preventive maintenance program Regular and consistent maintenance can prevent vehicle downtime and expensive repairs Use the Pre Operation and Daily Safety Checklist on page 17 the Performance Inspection on page 18 and the following Periodic Service Schedule and Periodic Lubrication Schedule to keep the vehicle in proper working condition Any vehicle not functioning correctly should not be used until it is properly repaired This will prevent further damage to the vehicle and help prevent injury to occupants resulting from unsafe conditions Contact your local dealer distributor for repairs and semiannual and annual periodic service A WARNING Only trained technicians should service or repair the vehicle Anyone doing even simple repairs or service should have knowledge and experience in electrical
86. to be transported should be tied securely to the trailer with the Forward Reverse handle in the NEUTRAL position the key switch in the OFF position and the park brake firmly engaged Because of the added length of the trailer use caution when making turns Do not transport the vehicle on a trailer with a load in the vehicle cargo bed Remove the vehicle windshield and secure seats before transporting on a trailer If the vehicle must be transported over long distances or on public highways it should be transported on an approved trailer that has an approved load rating of 2000 Ib 908 kg per vehicle being transported See fol lowing NOTE NOTE A two car trailer should be rated at 2 x 2000 Ib 4000 Ib 2 x 908 kg 1816 kg STORAGE See General Warnings on page 8 DANGER Do not attempt to drain fuel when the engine is hot or while it is running Clean up any spilled fuel before operating the vehicle Store fuel in an approved fuel container only Store in a well ventilated area away from sparks open flames heaters or heat sources Keep fuel out of the reach of children Do not siphon fuel from the vehicle A WARNING Turn the key switch to the OFF position remove the key and leave the Forward Reverse handle in the NEUTRAL position during storage This is to prevent unintentionally starting the vehicle or a fire hazard Gasoline vehicles only Turn fuel shut off valve to the closed OFF
87. trols and Indicators LOW OIL WARNING LIGHT The low oil warning light 9 is located on the instrument panel just to the left of the steering column Figure 4 and Figure 5 Page 11 If the warning light lights up oil should be checked and added to the engine as nec essary before vehicle use continues The vehicle should never be driven when the low oil warning light remains lit If the warning light alternately lights and darkens the vehicle may be driven but oil should be added at the first opportunity If the oil level is correct and the warning light remains lit have a trained techni cian check the vehicle See following CAUTION CAUTION Failure to add oil immediately when the low oil warning light remains lit may result in permanent engine damage FUEL GAUGE HOUR METER The fuel gauge and hour meter 8 are housed together on the right side of the instrument panel Figure 4 and Figure 5 Page 11 The fuel gauge operates when the key switch is in the ON position and allows the operator to monitor the fuel level in the vehicle The hour meter operates only when the engine is running and should be used by the trained technician to track vehicle usage and determine when periodic service proce dures are required See Periodic Service Schedule on page 29 HEADLIGHT CONTROL The headlight control 12 is located on the left side of the instrument panel Figure 4 and Figure 5 Page 11 Press the headlight rocker switch to turn the hea
88. uld be performed more often than recommended in the Periodic Ser vice and Lubrication Schedule Both the Periodic Service Schedule and the Periodic Lubrication Schedule must be followed to keep vehicle in optimum operating condition PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Daily service by owner Check engine oil level add if necessary or trained technician See Engine Oil Level Check on page 35 Engine Diesel vehicles Check engine coolant add if necessary See Engine Coolant Level Check on page 42 Diesel vehicles Drain water from fuel Fuel filters filter See Draining Water from Fuel Filter on page 45 Check brake fluid add if necessary Brakes Check brake pedal for proper operation See Performance Inspection on page 18 Periodic Service Schedule continued on next page 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Page 29 Periodic Service Schedule PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Monthly service by owner or trained technician Engine Check engine circulating air passage visually inspect unshrouded area around engine exhaust for grass and debris and clean if necessary Diesel vehicles Check for grass and debris around the radiator Tires Check air pressure and adjust if necessary See Vehicle Specifications on page 51 Transmission and differentials Check lubricant levels Add if necessary
89. y option or accessory is installed on the vehicle See following NOTE NOTE A standard vehicle with a cab accessory that weighs 235 Ib 107 kg must reduce its maximum payload capacity by 235 Ib 107 kg Refer to Figure 10 for the following specifications GASOLINE HUV 4421 VEHICLES WITH HIGH CAPACITY AND DIESEL OPTION VEHICLES A Maximum occupant capacity 400 Ib 181 kg 400 Ib 181 kg B C Maximum payload capacity 800 Ib 363 kg 1050 Ib 476 kg D Trailer tongue weight 150 Ib force 667 N 150 Ib force 667 N C Maximum vehicle capacity 1200 Ib 544 kg 1450 Ib 657 6 kg B Vehicle Weight Maximum gross 2750 Ib 1247 kg 3012 Ib 1366 kg vehicle weight 2007 HUV 4421 Gasoline and Diesel Vehicle Owner s Manual Page 23 Towing with the Vehicle Figure 10 Vehicle Load Capacity Two Passenger Vehicles TOWING WITH THE VEHICLE A WARNING Do not tow a vehicle or trailer on public streets or highways Normal vehicle operating speed should be reduced when towing Extreme caution should be used when towing Do not allow riders in the vehicle or trailer being towed Avoid sudden starts sudden stops and tight turns when towing Avoid stopping on a hill when towing If you must stop on a hill avoid sudden starts or rolling backwards and stopping suddenly Failure to heed this warning may cause vehicle to overturn possibly resulting in severe personal injury Towing

Husqvarna 4421-D User's Manual

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