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Husqvarna 4421-G/GX/GXL User's Manual

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1. 199 Figure 15 Lubrication Points Gasoline Vehicles 200 Figure 16 Lubrication Points Diesel Vehicles HUV 4421 Owner s Manual Page 37 Brake Fluid Reservoir BRAKE FLUID RESERVOIR 1 Full Level 2 Safe Level 3 Low Level 201 202 Figure 17 Brake Fluid and Coolant Access diesel vehicle Figure 18 Brake Fluid Reservoir shown The brake fluid reservoir 1 is located under the hood Figure 17 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 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 th
2. 193 Figure 7 Instrument Panel Diesel Vehicles Page 16 HUV 4421 Owner s Manual 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 6 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 key 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 When the key is turned to the OFF position the main vehicle systems are disabled The key switch may be used as an emergency stop The key
3. Place shift lever in NEUTRAL npt repair Firmly set park brake during operation Do not jump from vehicle Keep away from drop teep slopes and unstable surfaces cot 102961201 ect 102884301 Rotating Parts ect 102224001 NOTICE MAXIMUM TONGUE WEIGHT 150 Ibs CCI 1011553 CRUSH AREA STAY CLEAR We Crush area Can cause severe injury CCI 101609401 Stay clear when closing bed cries RIDING IN CARGO BED CAN CAUSE J Read owner s manual and warnings on dash PREVENT VEHICLE ROLL OVER SEVERE INJURY OR DEATH Maximum gross vehicle weight 3350 Ib 1520 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 8011000000000 000010000 CCI 103210501 Decal Trailer Hitch Tongue Weight Notice on 1 1011553 f i 7 102884401 Decal Rollover Warning on instrument panel trailer receiver hitch Decal Crush Area Warning behind seat near Decal Falling Off Warning behind and below front 101609401 102889201 cargo bed seats 102224001 Decal Rotating Parts Warning on fra
4. To avoid the possibility of fire clean up any spilled fuel before operating the vehicle 1 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 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 EN E C e e A a y Di ga F AS 219 220 Figure 34 Fuel Tank Gasoline Vehicles Figure 35 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 result from use of this fuel Page 48 HUV 4421 Owner s Manual Fueling Instructions 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 documented problems su
5. occurs when the gears make contact under load during vehicle operation The magnetic drain plug is included in the design to collect the metal particles 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 30 Tighten the drain plug to 108 in Ib 12 N m Use a funnel when filling the front differential through the lubricant level indicator hole 1 See Periodic Lubrication Schedule on page 36 Tighten the level indicator plug to 120 in Ib 14 N m Page 44 HUV 4421 Owner s Manual Gearcase Lubrication 215 216 Figure 30 Front Differential Lubrication Level Figure 31 Transmission Lubrication Level Transmission Clean and install the drain plug 2 before filling the transmission with new lubricant Figure 31 Tighten the drain plug to 96 in Ib 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 Periodic Lubrication Schedule on page 36 Apply Loctite 567 to the threads of the fill plug and tighten to 21 ft lb 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 t
6. 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 In the event that another pre printed warranty document and or certificate offered by or through Club Car at the time of sale of this vehicle each an Additional Warranty Document is deemed to conflict with the limitations or exclusions contained herein the limitations and exclusions contained herein shall continue to apply with respect to both this limited warranty statement and to the maximum extent permitted by law to each Additional Warranty Document 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 warranty gives you specific legal rights and you may also have other rights which vary from state to state 8 INFORMATION For further information customers in Europe and all other countries except for the US should go to www Husqvarna com Customers in the U S
7. 0 C 10 C 20 C 30 C 40 C 20 C 10 C 0 C 10 C 20 C 30 C 40 C ces i CEE KC saz gt a SAE 10W 30 SAE 10W 40 TA 32 F 50 F 68 86 F 104 F 4 F 14 F 32 50 68 F 86 F 104 F 213 214 Figure 28 Oil Viscosity Chart Gasoline Vehicles Figure 29 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 30 Figure 31 and Figure 32 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 30 Figure 31 or Figure 32 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 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
8. 4 Husqvarna HUV 4421 Owner s Manual 4421 G GX GXL Gas and 4421 D DX DXL Diesel Utility Vehicles Refer to back cover for applicable build code range NOTICE This manual is valid for vehicles manufactured in the build code range provided on the back cover of this manual If the vehicle build code is different from that shown on the back cover of this manual please contact your nearest dealer or go to www husqvarna com to retrieve the proper owner s manual for the vehicle See also Model Identification in this manual Warranty information appears at the end 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 Mo
9. 48 8 in 124 cm Weight 2 passenger gasoline with electric bed lift mud tires and without brush guard 1450 Ib 657 6 1597 Ib 724 2 1630 Ib 1734 Ib 2 passenger diesel with electric bed lift mud tires and brush guard kg kg 739 2 kg 786 4 kg 4 passenger gasoline with all terrain tires 4 passenger diesel with all terrain tires Forward speed 25 mph 40 km h Governed RPM 3825 Turning Radius 138 in 350 5 cm 204 in 518 2 cm Load bed height 34 in 86 4 cm 48 0 x 49 8 x 10 9 in Load bed size box bed inside dimensions 122 x 127 x 28 cm 15 3 cubic feet 800 Ib 363 kg Maximum payload capacity level surface only High capacity option 1050 800 Ib 363 kg lb 476 kg 1200 Ib 544 kg Vehicle rated capacity payload driver and passenger level surface only High capacity option 1450 1600 Ib 725 5 kg lb 658 kg 2750 Ib 1247 kg Maximum gross vehicle weight fully loaded vehicle including accessories High capacity option 3012 3350 Ib 1519 1 kg lb 1366 kg LIQUID CAPACITIES 1 qt and 19 oz 1 5 L Engine crankcase with filter SAE 10W 30 API classification CF 3at 2 8 L EE 3qt 2 8L Front differential Mobil 424 Exxon Hydraul 560 or Esso Hydraul 56 lubricant 5 oz 150 mL Engine Kawasaki crankcase with filter SAE 10W 30 API classification SJ HUV 4421 Owner s Manual Page 57 Vehicle Specifications HUV 4421 G HUV 4421 D HUV HUV SPECIFICATIONS
10. HUSQVARNA 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 HUSQVARNA will not be liable to warrant failures of warranted parts caused by the use of a non exempted add on or modified part HUSQVARNA its authorized dealers or a service agency approved by HUSQVARNA ITEMS COVERED BY THIS WARRANT Y The repair or replacement of any warranted part otherwise eligible for warranty coverage may be excluded from such warranty coverage if HUSQVARNA 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 HUV 4421 Owner s Manual Page 61 Warranties 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 Catalytic Converter Exhaust Manifold Air Induction Air filter housing air filter crankcase breather tube Ignition Flywheel magneto ignition pulse generator ignition coil assembly ignition control module
11. HUV 4421 HUV 4421 4421 GXL 4421 GXP DXP DXL 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 2 25 gal Engine coolant mixture of 55 propylene glycol and 45 water 2 gal 7 8 L n a 8 ae Brake fluid DOT 5 silicone brake fluid 8 oz 240 ml 17 9 oz 530 ml 6 5 gallons 6 5 gallons Fuel tank unleaded gasoline 24 6 L 24 6 L 6 5 gallons 6 5 gallons Fuel tank diesel grade no 2 with cetane rating of 45 or higher 24 6 L 24 6 L TIRE PRESSURE All terrain tread and mud tires 20 22 psi 1 38 1 52 Bars Page 58 HUV 4421 Owner s Manual Warranties WARRANTIES HUSQVARNA LIMITED TWO YEAR WARRANTY FOR TRANSPORTATION AND UTILITY VEHICLES 1 WARRANTY Husqvarna Inc Husqvarna hereby warrants to the Original Retail Purchaser that its new 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 starter generator gasoline vehicle motor transaxle assembly electric vehicle main frame assembly box
12. 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 7 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 continue to idle until the key is turned to the OFF position See previous WARNING CAUTION and NOTE FORWARD REVERSE CONTROL The Forward Reverse handle 6 is located on the right side of the instrument panel Figure 6 and Figure 7 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 15 This ve
13. erre nr rene nens 22 Drvirg Instr uvllons id tet 23 Bed Eatch and Prop ROd rite it tu onto bee aa eps 26 Loading and Unloading Cargo sssssssssssseses ene rre nn nnn erre enne nnne nens 27 Vehicle Load Gapacitl6s e a Hato e cio He eei ee elt et dte bee Lbs doble t ande aet ode baec bons eaa EAD 28 RIO vilsteRimurm lue e RA 29 Transponting on a Traller d rr e x Em Ex cate Fae aes Ex Coetus ax Cone x Cep en eee e eee pu pee AERE PS 29 SlOrage EU 30 Maintenance eves a DD N a 532 bad ined 32 P eniodic Service Schedule ici A Ao 33 Periodic Lubrication Schedule ecciesie A enden pred denn bind dinh ptt inh tbi se nA nha A Rake ad Arten id ATA 36 Brake Fa RESON iii e ra aeo a ont a 38 ISI 39 Gearcase Lubrication E Aia dai dida 44 Engine Coolant Diesel Vehicles ee eere EE E E EE beth di aA bh abe d nhi eben Ri 46 ESA ceccczcnec coecisaccdoechawkenned ee debe ETAU ERALAN AA ANA ESAE ORAETES AAR TTA VAR AOA TAIRO ahh apenas 47 FuelingInstr ctlolis 2 27 hot rote P Utd etd duit EE AEE AAEE AET A E E E 48 Baten eugen eiea A a el ended 50 Using A Booster Battery Jump Starting ec AET EA eene mme nnne nennen err n nennen nnns 52 Cleaning the Vehicle E oh ets 53 ACCOSSOLTOS edt eter rte rte facte face e b et d e nga ca we RE EE RAE 54 subsequent Owner Registrato lia ERadES 55 Vehicle Specifications E Warranties Page 4 HUV 4421 Owner s Manual Safety Decal and Feature Identificati
14. 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 following 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 11 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 position Figure 14 Do not attempt to charge frozen batteries or batteries with bulged cases Discard the battery Frozen batteries can explode A CAUTION Page 30 Batteries in a low state of charge will freeze at low temperatures HUV 4421 Owner s Manual Storage 1 Fuel Shut off Valve 2 Closed OFF 3 Open ON NOTE When selecting valve position ensure that it is fully opened or fully closed 449 Figure 14 Fuel Shut off Valve PREPARING THE VEHICLE FOR EXTEN
15. should contact HUSQVARNA PROFESSIONAL PRODUCTS INC WARRANTY SERVICES 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 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board CARB and Husqvarna HUSQVARNA are pleased to explain the emission control system warranty on your 2009 2010 vehicle engine the emission warranty In California new small off road engines SORE must be designed built and equipped to meet the State s stringent anti smog standards HUSQVARNA shall 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 the catalytic converter and related hoses belts connectors and other emission assemblies or components Where a warrantable condition exists as defined herein 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 tw
16. starts Diesel Vehicles Only If required turn key to PREHEAT and hold for 10 15 seconds TO OPERATE VEHICLE Ensure wheels are turned in desired direction and path is clear With vehicle stopped and engine at idle select vehicle direction DB Foward Neuiral p Reverse Buzzer will sound Release park brake and slowly press accelerator pedal to increase speed All wheel drive will automatically drive appropriate wheel s TO STOP VEHICLE Release accelerator pedal and push brake pedal BEFORE LEAVING VEHICLE Turn key to OFF and remove key Place shift lever in NEUTRAL Firmly set park brake CCI 102884301 Negative frame ground Can cause severe injury Do not contact positive battery post or cable to frame Disconnect negative battery cable first CAN CAUSE SEVERE BURNS Hot Surface CCI 102458901 CAN CAUSE SEVERE INJURY Rotating parts KEEP CLEAR Decal Gasoline Fuel Warning at fuel fill or on frame near fuel tank e 102459101 102459201 g 102459501 Decal Winch Safety Warning on vehicle body below seat Decal Hot Pressurized Fluid Warning on coolant reserve tank cap under hood Decal Hot Surface Warning on coolant pipes and underside of seats on bed seal 102884301 Decal Hot Manifold Warning on engine near manifold Page 6 HUV 4421 Owner s Manual CCI 102459101 CAN CAUSE SEVERE INJURY Hot manifold and muffler KEEP CLEAR CCI 102
17. the engine BE CAREFUL 1 2 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 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 4 Access the engine compartment by raising the cargo bed See WARNING For vehicles with cargo beds in General Warnings on page 11 Locate the vehicle battery on the driver s side of the vehicle under the cargo bed Figure 39 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 Explosive gases in General Warnings on page 11 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 Sit in the driver s seat and start the engine After the engine has started remove the frame ground cable 4 first Remove the cable from the positive terminal 2 Then remove the cables from the booster battery See following CAUTION Page 52 HUV 4421 Owner s Manual Cleaning the Vehicle CAUTION The alternator can be damaged if the following actions occur Engine is operated with battery cables disconnected Boost
18. 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 authorized 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 and maintenance information it contains Translated owner s manuals can be downloaded from the Husqvarna web site at www usa husqvarna com Page 2 HUV 4421 Owner s Manual TABLE OF CONTENTS Safety Decal and Feature Identification saroe ra rne KA ERE ENET TTEN AEE EAR EA E AARE NEE 5 Practice Safety O NN 10 Proposition 65 State of CalifOIMia ooooonoconnnnnnnccconncnconcncnnonnnoncnconnnnnonnncnn eeeeaeeesaaeeeeseeesaaeeeeaeeesaaeeesseeeesaeeesaeesesaeees 10 Safety Detalls I c eine Pde ie ed en MR Pv ee ee ee 11 ET TIMIDI 11 General OMAN D eaeaane ead 14 Model Identification em 14 Controlstand NCAA 15 Roll Over Protective Structure and Seat Belts eect eee ee eee etre eee eee eene ene mme n enne erre nens 20 Seat Latch and Adjustment 5 1 o E ob a E Rae E ee ea EE ee eee e ested Dodo er de o es 21 Pre Operation and Daily Safety Checklist ssssssessssse nemen nene e n nenne
19. with holes in the seat to achieve the desired seat position Install washers and bolts and tighten to 96 in Ib 10 8 N m Install the seat See preceding WARNING Make sure seat hinges and latch ex Boost 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 accepting 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 on page 23 and the Periodic Service Schedule on page 33 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 clamps 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 Safety Decal and Feature Identification on page 5 ROPS Check to ensure the ROPS is not damaged and all hardware is secure See Roll Over Protective Structure and Seat Belts on page 20 Seat belts Visually inspect for cuts fraying and loose parts See Roll Over Protective Structure and Seat
20. 1 5 L of oil per change Kubota diesel engines 3 qt 2 8 L of oil per change 2 Referto oil viscosity guidelines for selection of oil grade Figure 28 or Figure 29 See following CAUTION CAUTION Do not exceed recommended oil capacity Doing so will decrease engine performance or result in damage to the engine 3 Install the oil filler cap 4 Connect battery and spark plug Gas only wires See Connecting the Battery Gasoline Diesel Vehicle on page 13 5 With the Forward Reverse handle in the NEUTRAL position start and run the engine for three minutes and check for leaks Observe both the drain plug and the oil filter from under the vehicle and watch for oil leaks If the filter leaks tighten an additional 1 4 turn and retest If the oil drain plug leaks re torque and retest NOTE Wait a few minutes after turning off the engine before removing the dipstick 6 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 28 or Figure 29 See following NOTE HUV 4421 Owner s Manual Page 43 Gearcase Lubrication NOTE Use engine oil with API classification SJ for gasoline engines and CF for diesel engines Using multi grade oils SW 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
21. 1 Owner s Manual Page 41 Engine Oil NOTE An oil drip guard 1 can be used to prevent excess oil from dripping onto the engine base plate Figure 24 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 directed 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 26 27 Figure 24 Remove Engine Oil Filter Figure 25 Coat Rubber Seal Use a clean rag to wipe the oil filter mounting bracket surface clean where the oil filter gasket seats 5 Coat filter gasket with clean engine oil Figure 25 6 Install the new oil filter gas P N 603 00 00 06 diesel P N 603 00 00 41 See following NOTE NOTE Use only oil filters designed for your engine 7 Hand tighten 2 3 to 3 4 turn after the filter gasket contacts the mounting surface Page 42 HUV 4421 Owner s Manual Engine Oil Figure 26 Add Engine Oil Gasoline Vehicles Figure 27 Add Engine Oil Diesel Vehicles Engine Oil Filling 1 Add engine oil Figure 26 or Figure 27 With filter change the engine requires the following amounts Kawasaki gasoline engines 1 qt and 19 oz
22. 4 or Figure 35 2 1 Remove the plug from the fuel tank vent 2 2 Connect the vent tube to the fuel tank vent 3 Connect battery and spark plug Gas only wires See Connecting the Battery Gasoline Diesel Vehicle on page 13 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 4 Gasoline vehicles only Completely open the fuel shut off valve Figure 14 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 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 22 and the Performance Inspection on page 23 MAINTENANCE See General Warnings on page 11 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 22 the Performance Inspection on page 23 and the following Periodic Service Schedule and Periodic Lubricatio
23. 459501 Decal Ground Warning on vehicle frame near battery Decal Diesel Fuel Warning on frame near fuel tank Decal Rotating Hot Parts Warning on frame near battery Decal Operating Instructions on instrument panel Directional Arrow ALL HUV 4421 TWO PASSENGER MODELS ROLLOVER OR FALLING OFF MAY CAUSE DEATH Read owner s manual and operating instructions Fasten seat belts and remain seated while moving 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 Two 2 persons per bench seat maximum Safety Decal and Feature Identification YOUNG DRIVERS INCREASE CHANCE OF DEATH Young drivers may not be able to control vehicle No drivers younger than 16 years old Do not leave children unattended on vehicle cet 102459401 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 cei 102961201 One 1 person per bucket seat maximum Operate from driver side only and not on public roads Keep entire body inside vehicle while moving Do not operate while under the influence of alcohol or drugs Never attempt jumps and avoid
24. 9 model year It is also valid for vehicles with build codes between 54699 and the one indicated at the top of this page H Husqvarna www husqvarna com
25. 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 performance Have a dealer or a trained technician investigate anything unusual DRIVING INSTRUCTIONS A WARNING Only licensed drivers 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 handica
26. Belts on page 20 Tires Check for proper tire pressure Visually inspect tires for wear damage and proper inflation on a daily basis See Vehicle Specifications on page 56 Battery Check electrolyte to ensure it is at the proper level Figure 38 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 39 Check air filter and replace if necessary Fuel Check fuel level See Fueling Instructions on page 48 Check fuel tank 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 49 Exhaust system Check for leaks Hydraulic brakes Check fluid level Fill with DOT 5 brake fluid only See Brake Fluid Reservoir on page 38 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 pressure 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 Performance Inspection Inspect as instructed See Performance Inspection on page 23 Page 22 HUV 4421 Owner s Manual Driving Instructions PERFORMANCE INSPECTION After you have familiarized yourself with the veh
27. DED 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 battery is dead see Using A Booster Battery Jump Starting on page 52 3 Make sure the key switch is in the OFF position and the Forward Reverse handle is in the NEUTRAL position Chock the wheels 4 Gasoline vehicles 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 Bil 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 34 4 4 Plug the 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 6 Diesel vehicles If Biodiesel fuel is used see Biodiesel Fuel Diesel Vehicles Only on page 48 Prepare the fuel tank 6 1 Fill the fuel tank wit
28. EP CLEAR CCI 102459501 Safety Decal and Feature Identification ALL HUV 4421 FOUR PASSENGER MODELS OPERATING INSTRUCTIONS Read owner s manual and vehicle safety warnings Study and udderstand controls ROLLOVER OR FALLING OFF MAY CAUSE DEATH TO START ENGINE Read owner s manual and operating instructions Place shift lever in NEUTRAL and press brake pedal Fasten seat belts and remain seated while moving Tum key to START and hold until engine starts Diesel Vehicles Only f required turn key to PREHEAT and hold for 10 TO OPERATE VEHICLE e untila scans are seated heels are turne desired direction and path is clear icle stopped and ei I idle select vehicle direction Children requiring a child safety seat must not ride on vehicle Comply with state and local laws pertaining to child safety persons per bench seat maximum One 1 person per bucket seat maximum Neutral ee Buzzer will sound Operate from driver side only and not on public roads is park brake and Slowly press scc lerstor pedal o Keep entire body inside vehicle while moving increase speed Do not operate while under the influer cohol or drugs All wheel drive will automatically drive appropriate wheel s Never attempt jumps and avoid extreme braking in reverse TO STOP VEHICLE Relese nceslereinr pedal sd push bre pedal mw 0000000000 BEFORE LEAVING VEHICLE Turn key to OFF and remove key T clive Structure ROPS
29. OTE NOTE Dispose of water according to the environmental laws and regulations for your area 221 Figure 36 Fuel Filter BATTERY See General Warnings on page 11 A 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 e Battery Poison Contains acid Causes severe burns Avoid contact with skin eyes or clothing Antidotes External Flush with water Call a physician immediately nternal Drink large quantities of milk or water followed with milk of magnesia or vegetable oil Call a physician immediately DANGER CONTINUED ON NEXT PAGE Page 50 HUV 4421 Owner s Manual Battery DANGER Eyes Flush with water for 15 minutes Call a physician immediately Tools wires and metal objects can cause sparks when shorted across a battery WARNING Wear safety glasses or approved eye protection when servicing the 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 The batte
30. PERIODIC LUBRICATION SCHEDULE PERIODIC LUBRICATION SCHEDULE LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Gasoline vehicle Kawasaki engine First change 10 hours Diesel vehicle First change Gasoline Kawasaki engine vehicles 1 50 hours at and 19 oz 1 5L with filter Change engine oil and oil filter gt NA Additional change for all Diesel vehicles 3 qt 2 8 L with filter engines every 100 hours See Oil Viscosity on page 43 of operation or annually whichever comes first Monthly by owner or trained us Driveshaft Chassis Lube EP NLGI Grade 2 technician Semiannually by owner or trained technician or every 50 hours of operation whichever comes first Rear suspension 2 fittings Chassis Lube EP NLGI Grade 2 First change 50 hours additional change every 100 5 oz 150 mL Mobil 424 Exxon Hydraul Change front differential lubricant hours of operation or annually 560 or Esso Hydraul 56 lubricant whichever comes first i 20 oz 600 mL Mobil 424 Exxon Hydraul First change 50 hours Change rear differential lubricant y additional change every 300 560 or Esso Hydraul 56 lubricant hours of operation or annually n N a 20 oz 600 mL Mobil 424 Exxon Hydraul 3 ission lubri whichever comes first a 560 or Esso Hydraul 56 lubricant Page 36 HUV 4421 Owner s Manual Periodic Lubrication Schedule
31. See following WARNING 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 compression washer or sealing o ring remains on the drain plug Inspect the compression washer or the sealing o ring and replace if necessary Page 40 HUV 4421 Owner s Manual Engine Oil 7 Use a socket or wrench to replace the oil drain plug 1 Figure 21 or Figure 22 Turn the plug clockwise and tighten to 61 in Ib 6 9 N m for Kawasaki gas vehicles with plastic drain plugs 14 5 ft lb 20 N m for Kawasaki gas vehicles with metal drain plugs or 31 ft lb 42 Nm for diesel vehicles 207 208 Figure 21 Engine Oil Drain Plug and Pan Gasoline Figure 22 Engine Oil Drain Plug and Oil Filter Diesel Vehicles Vehicles 210 Figure 23 Replace Engine Oil Filter Kawasaki Gasoline Vehicles Engine Oil Filter Change 1 Drain the engine oil See Engine Oil Draining on page 40 2 Place the oil drain pan under the engine oil filter 2 Figure 22 or Figure 23 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 HUV 442
32. a 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 Side and rear body Plastic Cargo bed Powder coated steel or aluminum 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 brush guard 122 in 309 9 cm 154 in 391 2 cm Page 56 HUV 4421 Owner s Manual Vehicle Specifications HUV 4421 G HUV 4421 D HUV HUV SPECIFICATIONS HUV 4421 HUV 4421 4421 GXL 4421 GXP DXP DXL Overall width 58 5 in 148 5 cm 63 6 in 161 5 cm without mirror with mirror Overall height with ROPS with mud tires 82 3 in 209 cm 80 3 in 203 8 cm with all terrain tires Wheelbase 81 5 in 207 cm 114 in 289 5 cm Ground clearance 8 2 in 20 8 cm under differential Front and rear wheel tread
33. al The build code exists to enable the user to identify the correct owner s manual for a vehicle This owner s manual is valid for the build code range indicated on the back cover of this owner s manual Page 14 HUV 4421 Owner s Manual Controls and Indicators OR NEC M 3 SERIAL NUMBER PH0901 123456 BC54679 1400 Figure 5 Serial Number Decal CONTROLS AND INDICATORS See General Warnings on page 11 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 and 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 HUV 4421 Owner s Manual Page 15 Controls and Indicators S S 3 S 3 Y j LJ GN L 5
34. ance 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 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 HUSQVARNA SPECIFICATIONS THE WARRANTY IS 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
35. at 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 9 If the 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 194 Figure 9 Release Safety Belt Page 20 HUV 4421 Owner s Manual Seat Latch and Adjustment 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 seat belts provided to help prevent injury in the
36. ater 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 11 The bed latch Figure 10 has an automatically engaging prop rod and prop rod track Figure 11 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 deat
37. 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 material 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 drive buttons engine mounts mats and pads mainten
38. 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 HUSQVARNA 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 HUSQVARNA is liable for damages to other engine or equipment components proximately caused by a covered failure under warranty of any warranted part 8 Throughout the engine or equipment warranty period stated above HUSQVARNA 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 provided without charge to the owner Such use will not reduce the warranty obligations of
39. ch 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 damage 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 tube lines injectors injector pump and seals For more information on these fuel standards please contact your nearest Kubota dealer If biodiesel is used be sure to apply the following 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 39 Before vehicl
40. d After the trailer tires have been chocked engage the park brake TRANSPORTING ON A TRAILER WARNING Gasoline vehicles only Turn fuel shut off valve to the closed OFF position Figure 14 Do not allow riders in the trailer being towed Avoid sudden starts sudden stops and tight turns when towing WARNING CONTINUED ON NEXT PAGE HUV 4421 Owner s Manual Page 29 Storage 4 WARNING 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 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 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
41. dipstick gauge add oil to the engine until the level is between low and full levels safe level See following CAUTION CAUTION Do not exceed recommended oil capacity Doing so will decrease engine performance or result in damage to the engine HUV 4421 Owner s Manual Page 39 Engine Oil 1 Full Level 2 Safe Level 3 Low Level 1 Full Level 2 Safe Level 3 Low Level 205 204 Figure 19 Engine Oil Level Check Kawasaki Gasoline Figure 20 Engine Oil Level Check Diesel Vehicles Vehicles ENGINE OIL AND FILTER CHANGE The engine oil and oil filter should be changed at the following intervals Kawasaki gasoline engine after the first 10 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 battery and spark plug Gas only wires See Disconnecting the Battery Gasoline Diesel Vehicle on page 13 3 Remove the oil filler cap to allow the oil to drain properly Position a pan designed for oil changes under the drain plug Figure 21 or Figure 22 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
42. e Page 12 HUV 4421 Owner s Manual General Warnings DISCONNECTING THE BATTERY GASOLINE DIESEL VEHICLES 1 Disable the vehicle See Disabling the Vehicle on page 12 2 Disconnect the battery cables negative cable first as shown Figure 2 3 Gasoline Vehicles Only Disconnect the spark plug wire s from the spark plug s 1 Remove negative battery cable 2 Remove positive battery cable Connect battery cables in reverse order 188 189 Figure 2 Battery Cable Removal Figure 3 All Wheel Drive Warning CONNECTING THE BATTERY GASOLINE DIESEL VEHICLES Connect the battery cables positive cable first Tighten battery terminals to 80 in Ib 9 N m Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion Gasoline Vehicles Only Connect the spark plug wire s to the spark plug s moo oc RECYCLING LEAD ACID BATTERIES WARNING Lead acid batteries contain lead Pb other metals acids and other compounds If improperly handled they can contaminate both water and soil causing environmental damage and personal injury Lead acid batteries are identified by the symbol shown below and should be properly recycled Figure 4 They cannot be disposed as municipal waste and must be collected separately Responsibility for environmental protection must be shared not only by the manufacturers of the batteries but by people who use the batteries as well Please contact yo
43. e reservoir Figure 18 Also brake fluid should be clean with no residue in the bottom of the reservoir or other evidence of contamination 4 CAUTION Use only DOT 5 silicone brake fluid Use of any other type brake fluid is not recommended Page 38 HUV 4421 Owner s Manual Engine Oil 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 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 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 circulation design ENGINE OIL LEVEL CHECK 1 Remove the oil level dipstick from the oil filler tube and wipe oil from the dipstick Figure 19 and Figure 20 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 If the oil level is at or below the low level mark on the
44. e 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 31 See following 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 36 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 HUV 4421 Owner s Manual Page 49 Battery A WARNING 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 N
45. en 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 Use 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 This vehicle is not intended to be used where risk of falling objects exists If your vehicle will be used in such an environment contact your local dealer No one should drive the vehicle without first being instructed in the proper operation and use of vehicle controls 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 vehic
46. er cables are connected wrong 223 Figure 39 Jump Starting CLEANING THE VEHICLE Each vehicle is equipped with hand 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 A 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 damage 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 brush 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 HUV 4421 Owner s Manual Page 53 Accessories ACCESSORIES There is a complete line of accessory equipment available from our dealers di
47. event of sudden braking collision or roll over n 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 After inserting the tab make sure the tab and buckle are locked and that the belt is not twisted Loose fitting seat 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 single 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 Becareful 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 seat belts clean and dry If cleani
48. extreme braking in reverse oct 102884401 Rotating Parts CCI 102224001 CAN CAUSE SEVERE INJURY Rotating parts KEEP CLEAR CCI 102460201 NOTICE MAXIMUM TONGUE WEIGHT 150 Ibs CCI 1011553 CRUSH AREA STAY CLEAR CCI 101609401 Crush area Can cause severe injury Stay clear when closing bed mune PREVENT VEHICLE ROLL OVER Place cargo forward in the cargo bed and distribute RIDING IN CARGO BED CAN CAUSE J Read owner s manual and warnings on dash Maximum gross vehicle weight 2750 Ib 1247 kg SEVERE INJURY OR DEATH Do not ride in cargo bed Maximum cargo load 800 Ib 363 kg Includes cargo bed load and gross trailer weight Maximum cargo load is reduced by the weight of optional equipment Maximum trailer hitch tongue weight 150 Ib force 667 N evenly side to side Secure load On uneven or steep terrain reduce speed and load Avoid stopping on or backing down steep hills Avoid top heavy loads See owner s manual E 5 n RIDING IN CARGO BED CAN CAUSE Read owner s manual and warnings on dash PREVENT VEHICLE ROLL OVER SEVERE INJURY OR DEATH Do not ride in cargo bed Maximum gross vehicle weight 3012 Ib 1366 kg Maximum cargo load 1050 Ib 476 kg Includes cargo bed load and gross trailer weight Maximum cargo load is reduced by the weight of optional equipment Maximum trailer hitch tongue weight 150 Ib
49. force 667 N Place cargo forward in the cargo bed and distribute evenly side to side Secure load On uneven or steep terrain reduce speed and load Avoid stopping on or backing down steep hills Avoid top heavy loads See owner s manual A 21 Decal Trailer Hitch Tongue Weight Notice on P Decal Rollover Warning on instrument panel trailer receiver hitch 1011553 102884401 Decal Crush Area Warning behind seat near 101609401 102961201 cargo bed z 102224001 Decal Rotating Parts Warning on frame o 103202601 Decal Vehicle Loading Instructions on cargo bed Decal Bed Latch Warning on vehicle body below Decal Vehicle Loading Instructions on cargo bed 102459301 10 103210401 bed latch for vehicles with the high capacity option 102459401 Decal Young Driver Warning on ROPS I Serial Number Decal Rotating Parts Warning Diesel Only on 102460201 vehicle body under seat Decal ROPS Warning on ROPS HUV 4421 Owner s Manual Page 7 Safety Decal and Feature Identification ALL HUV 4421 FOUR PASSENGER MODELS DIESEL FUEL EXPLOSION FIRE Can cause severe injury or death No smoking sparks or open flame Stop engine allow to cool before refueling GASOLINE EXPLOSION FIRE Can cause severe injury or death No smoking sparks or open flame Stop engine allow to cool before refueling Turn fuel valve on during operation gt off during stora
50. ge or transport coii Hot Pressurized Fluid Can Cause Serious Burns Never Open Hot OPEN SLOWLY Ta psi ENGINE COOLANT Tvs CCI 102459201 WINCH CABLE FRACTURE COULD RESULT IN SERIOUS INJURY OR DEATH ow CCI 102458901 CAN CAUSE SEVERE INJURY Y Rotating parts KEEP CLEAR AAA Decal Ground Warning on vehicle frame near 102459101 battery Decal Diesel Fuel Warning on frame near fuel 102459201 tank Decal Rotating Hot Parts Warning on frame near 102459501 battery Decal Rotating Parts Warning Diesel Only on 102460201 vehicle body under seat S Directional Arrow Decal Gasoline Fuel Warning at fuel fill or on 1 101547601 frame near fuel tank Decal Winch Safety Warning on vehicle body 2 102231601 below seat Decal Hot Pressurized Fluid Warning on coolant 3 102427501 reserve tank cap under hood Decal Hot Surface Warning on coolant pipes and 4 102458901 underside of seats on bed seal Decal Hot Manifold Warning on engine near 5 102459001 manifold Page 8 HUV 4421 Owner s Manual CAN CAUSE SEVERE INJURY Rotating parts KEEP CLEAR CCI 102460201 CAN CAUSE SEVERE INJURY HOT manifold KEEP CLEAR CCI 102459001 Negative frame ground Can cause severe injury Do not contact positive battery post or cable to frame Disconnect negative battery cable first CCI 102459101 CAN CAUSE SEVERE INJURY Hot manifold and muffler KE
51. gh 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 7 The diesel engine is liquid cooled if the engine coolant has exceeded its HUV 4421 Owner s Manual Page 19 Roll Over Protective Structure and Seat Belts 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 Contact the dealer distributor or a trained technician See following WARNING 4 WARNING Allow the engine to cool before servicing the engine coolant system Engine coolant can cause severe burns ROLL OVER PROTECTIVE STRUCTURE AND SEAT BELTS HUV 4421 two passenger and four passenger vehicles are equipped with a Roll Over Protective Structure ROPS and seat 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 seat 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 se
52. h 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 WARNING CONTINUED ON NEXT PAGE Page 26 HUV 4421 Owner s Manual Loading and Unloading Cargo 4 WARNING 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 gas and diesel vehicles are equipped with an automatically engaging prop rod Figure 11 unless equipped with the electric bed lift accessory 195 178 Figure 10 Bed Latch Figure 11 Prop Rod LOADING AND UNLOADING CARGO 4 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 s
53. h 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 WARNING 4 WARNING f 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 clamp is properly tightened Tighten to 108 in Ib 12 2 N m A loose clamp 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 USING A BOOSTER BATTERY JUMP STARTING 4 WARNING 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 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 it is necessary to use a booster battery to start
54. h fresh fuel 6 2 Disconnect the fuel vent line from the fuel tank vent nipple Figure 35 6 3 Plug the fuel tank vent nipple so that it is air tight Husqvarna recommends using a slip on vinyl cap 7 All vehicles Change engine oil See Engine Oil and Filter Change on page 40 HUV 4421 Owner s Manual Page 31 Maintenance 8 Disconnect battery and spark plug Gas only wires See Disconnecting the Battery Gasoline Diesel Vehicle on page 13 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 Rinse 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 56 11 Perform semiannual periodic lubrication See Periodic Lubrication Schedule on page 36 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 3
55. hat only tires purchased 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 Registration HUV 4421 Owner s Manual Page 55 Vehicle Specifications VEHICLE SPECIFICATIONS HUV 4421 G HUV 4421 D HUV HUV SPECIFICATIONS HUV 4421 HUV 4421 4421 GXL 4421 DXP DXL GXP POWER SOURCE GASOLINE DIESEL Engine Kawasaki 4 cycle OHV 675 cc 23 0 maximum HP 943600 RPM per SAE J 1940 1349 twin cylinder air cooled with pressure lubrication system GASOLINE DIESEL 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 carburetor 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 Kawasaki engine internal to engine centrifugal ball Governor internal to engine mechanical centrifugal ball Ignition Transistorized magneto Ignition Compression PF Transmission Forward and reverse with neutral 5 39 1 forward 7 79 1 reverse Electrical system 12 volt 500 cc
56. he rear differential with new lubricant Figure 32 Tighten the drain plug to 96 in Ib 10 8 N m Use a funnel to fill the differential through the lubricant level indicator hole 1 See Periodic Lubrication Schedule on page 36 Apply Loctite 567 to the threads of the level indicator plug and tighten to 21 ft lb 28 N m HUV 4421 Owner s Manual Page 45 Engine Coolant Diesel Vehicles 217 Figure 32 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 17 Raise the hood to check the coolant level before every operation 1 Check the 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 technician See following WARNING A WARNING Hot Coolant reserve tank is pressurized Do not remove cap when engine is hot Page 46 HUV 4421 Owner s Manual Air Intake System AIR INTAKE 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 AIR FILTER REPLACEMENT The air filter should be inspected periodically and replaced when necessary Filter changes should not exceed the recommended interval See Period
57. hicle operates at a reduced speed in reverse If equipped with a reverse buzzer 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 6 and Figure 7 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 15 HUV 4421 Owner s Manual Page 17 Controls and Indicators BRAKE PEDAL The brake pedal 2 is located to the immediate left of the accelerator pedal Figure 6 and Figure 7 To slow or stop the vehicle press the brake pedal PARK BRAKE The park brake pedal 3 is located to the left of the brake pedal Figure 6 and Figure 7 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 8 See following WARNING 4 WARNING The park brake has multiple locking positions and should be firmly locked to prevent the vehicle from rolling 191 Figure 8 Park Brake Release STEERING ADJUSTMENT LOCK The steering wheel position is adjustable To adjust the steering wheel position press down on the steer
58. ic Service Schedule on page 33 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 Air Filter Removal 1 Raise the cargo bed and locate the air filter canister 2 Release both canister tab locks Figure 33 3 Pull the canister cap away from the canister 4 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 us 7 Q OUR W RT SN MASA 218 Figure 33 Air Filter Cartridge Air Filter Installation 1 Push the new air filter cartridge onto the nozzle inside the canister 2 Place the canister cap marked TOP on the top center of the canister 3 Secure the canister cap with both tab locks HUV 4421 Owner s Manual Page 47 Fueling Instructions FUELING INSTRUCTIONS See General Warnings on page 11 DANGER Turn the key switch to the OFF position before fueling Do not 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
59. icle capacity 1200 Ib 544 kg 1450 Ib 657 6 kg 1600 Ib 725 6 kg A B C Vehicle Weight Maximum gross vehicle eight 2750 lb 1247 kg 3012 Ib 1366 kg 3350 Ib 1519 1 kg wei Page 28 HUV 4421 Owner s Manual Towing with the Vehicle 1 197 98 Figure 12 Vehicle Load Capacity Two Passenger Figure 13 Vehicle Load Capacity Four Passenger Vehicles Vehicles TOWING WITH THE VEHICLE 4 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 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 28 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 loa
60. icle 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 technician e e Forward Reverse shifter Check for proper operation See Controls and Indicators on page 15 Brakes Be sure the brakes function properly When brake pedal is fully pressed under moderate pressure 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 the 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 If equipped with a 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
61. in either the FORWARD or REVERSE position The all wheel drive system will engage any wheel s front or rear with traction Figure 3 PERIODIC SERVICE SCHEDULE See General Warnings on page 11 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 should be performed more often than recommended in the Periodic Service and Lubrication Schedule Both the Periodic Service Schedule and the Periodic Lubrication Schedule must be followed to keep vehicle in optimum operating condition HUV 4421 Owner s Manual Page 33 Periodic Service Schedule PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE x See Pre Operation and Daily Safety Pre Operation and Daily Safety Checklist Daily service by owner Checklist on page 22 Performance Inspection See Performance Inspection on page 23 Check engine oil level add if necessary See Engine Oil Level Check on page 39 Engine Diesel vehicles Check engine coolant add if necessary See Engine Coolant Level Check on page 46 Daily service by owner or trained technician Diesel vehicles Drain water from fuel filter Fuel filters See Draining Water from Fuel Filter on page 49 Check brake fluid add if necessary Check Brakes brake pedal for proper operation See Performance Inspectio
62. ing adjustment lock lever 5 then move the steering wheel to the desired position Figure 6 and Figure 7 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 4 WARNING Ensure that the steering wheel lock is fully engaged before operating the vehicle Page 18 HUV 4421 Owner s Manual Controls and Indicators 12 VOLT ACCESSORY OUTLET The 12 volt accessory outlet 11 is located to the right of the key switch Figure 6 and Figure 7 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 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 6 and Figure 7 If the warning light lights up oil should be checked and added to the engine as necessary 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 technician check the vehicle See following CAUTION CAUTION Failure to add oil immediately when the low oil warning light stays on may re
63. ion in the Page 34 HUV 4421 Owner s Manual Periodic Service Schedule PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE appropriate maintenance and service manual Check for leaks around gaskets fill plugs etc Kawasaki gasoline engines Adjust valve clearance See Kawasaki FH680D Service Manual Gasoline vehicles Inspect clean and gap spark plug replace if necessary See f authorized dealer or trained technician for Engine service Diesel vehicles Check the v belt for proper tension or damage Adjust or replace if necessary Annual service by trained technician only or every 100 hours of operation whichever Diesel vehicles Change engine coolant See comes first Radiator and Cooling System Section in the maintenance and service manual Diesel vehicles Check clamps for tightness Radiator check hoses for cracks Replace if necessary Replace air filter element See Air Intake System on page 47 Engine air intake system Check clamps for tightness check hose for cracks Check for loose hardware and tighten if General vehicle necessary Fuel filters Replace Dispose of used filters properly WARNING f 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 HUV 4421 Owner s Manual Page 35 Periodic Lubrication Schedule
64. le STARTING THE VEHICLE PO Ie cm e Read safety and information decals located on the vehicle Be sure load if any is secure Study and understand all controls Be sure all passengers are seated with their seat belts fastened and are holding on to hand holds Driver should have both hands on the steering wheel 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 Page 24 HUV 4421 Owner s Manual Driving Instructions 7 Press and hold the brake pedal 8 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 key 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 8 2 Diesel vehicles To preheat glow plugs in cold weather turn the key to the PREHEAT position and hold it there 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
65. me o 102961201 Decal ROPS Warning on ROPS Decal Bed Latch Warning on vehicle body below 102459301 bed latch 10 103210501 Decal Vehicle Loading Instructions on cargo bed 102459401 Decal Young Driver Warning on ROPS Inf Serial Number 6 102884301 Decal Operating Instructions on instrument panel po HUV 4421 Owner s Manual Page 9 Practice Safety PRACTICE SAFETY N WARNING Rotating Parts 399 Figure 1 Practice Safety 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 4 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 10 HUV 4421 Owner s Manual Safety Details SAFETY DETAILS 4 WARNING This owner s manual should be read completely before attempting to drive or service the vehicle Failure to follow the i
66. n 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 and mechanical repair The appropriate instructions must be used when performing maintenance service or accessory installation WARNING CONTINUED ON NEXT PAGE Page 32 HUV 4421 Owner s Manual Periodic Service Schedule A WARNING f 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
67. n on page 23 Check engine circulating air passage visually inspect unshrouded area around engine 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 l S cas Monthly service by owner or trained See Vehicle Specifications on page 56 technician Check lubricant levels Add if necessary See Lubrication Level Check for Front Differential Transmission and Rear Differential on page 44 Transmission and differentials A Wash engine compartment and underside of General vehicle vehicle Do not wash engine when hot Clean terminals and wash dirt from casing check electrolyte level Add distilled water if necessary See page 50 Check and adjust if necessary See Steering n and Front Suspension Section in the Front wheel alignment and toe in appropriate maintenance and service manual Semiannual service by trained technician Electrical wiring and connections Check for tightness and damage only or every 50 hours of operation whichever comes first Inspect master cylinder brake lines and hoses for damage or leakage Check park brake cables for damage replace if necessary Brake system 7 3 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 22 See also Brake System Sect
68. ng is necessary use a mild soap and lukewarm water solution Do not use bleach dye or abrasive cleaners as they may severely weaken the seat belts Do not insert coins clip etc in the buckle as this may prevent the tab from locking into the buckle properly f 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 seat bottom and pull firmly in a forward upward direction See following WARNING 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 HUV 4421 Owner s Manual Page 21 Pre Operation and Daily Safety Checklist A WARNING Do not adjust the driver side seat while the vehicle is in motion To adjust the passenger side seat 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
69. nstructions 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 vehicle 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 WARNING AWARNING 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 GENERAL WARNINGS The following safety statements must be heeded whenever the vehicle is being operated repaired or serviced See Safety Decal and Feature Identification on page 5 Other specific safety statements appear throughout this manual and on the vehicle DANGER e Battery Explosive gases Do n
70. o years from the vehicles date of purchase If any emission related part on your HUSQVARNA SORE is defective the part will be repaired or replaced by HUSQVARNA OWNER S WARRANTY RESPONSIBILITIES Page 60 HUV 4421 Owner s Manual Warranties 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 Professional Products Inc 7349 STATESVILLE ROAD CHARLOTTE NC 28269 HUSQVARNA EXPLANATION OF EMISSION CONTROL WARRANTY 1 WARRANTY HUSQVARNA warrants to the ultimate purchaser and each subsequent purchaser that the SORE and related emissions equipment is designed built and equipped so a
71. on SAFETY DECAL AND FEATURE IDENTIFICATION The following pages contain safety decal and feature identification information For detailed information on specific features read the appropriate section in this manual HUV 4421 Owner s Manual Page 5 Safety Decal and Feature Identification ALL HUV 4421 TWO PASSENGER MODELS GASOLINE EXPLOSION FIRE Can cause severe injury or death No smoking sparks or open flame Stop engine allow to cool before refueling Tum fuel valve on during operation 3 off during storage or transport DIESEL FUEL EXPLOSION FIRE Can cause severe injury or death No smoking sparks or open flame Stop engine allow to cool before refueling oct 10r547601 CCI 102459201 Hot Pressurized Fluid Can Cause Serious Burns Never Open Hot OPEN SLOWLY 14 psi ENGINE COOLANT Tvs CAN CAUSE SEVERE INJURY HOT manifold KEEP CLEAR CCI 102459001 WINCH CABLE FRACTURE COULD RESULT IN SERIOUS INJURY OR DEATH Do not use winch while persons are seated on the vehicle 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 102231601 OPERATING INSTRUCTIONS Read owner s manual and vehicle safety warnings Study and understand controls TO START ENGINE Place shift lever in NEUTRAL and press brake pedal Tum key to START and hold until engine
72. 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 surfaces will significantly decrease the life of the mud tires Vehicle performance will also be reduced when driving on paved surfaces See following WARNING and CAUTION Page 54 HUV 4421 Owner s Manual Subsequent Owner Registration 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 drive system will not operate as intended and could result in severe personal injury or death Never install tires of different diameters on the vehicle CAUTION 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 t
73. ople 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 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 Only trained technicians should service or repair the vehicle Anyone doing even simple repairs or service sho
74. ot 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 e 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 HUV 4421 Owner s Manual Page 11 General Warnings 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 passenger must be restrained at all times with the seat 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 pe
75. 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 HUV 4421 Owner s Manual Page 59 Warranties 5 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 Husqvarna dealer 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
76. passenger side wheel The all wheel drive vehicle can adapt traction for a wide variety of driving surfaces and conditions See following WARNING 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 Figure 3 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 diameters on the vehicle Under most circumstances the driver will not need 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 conditions If the front differential becomes locked drive slowly in reverse for at least 10 feet 3 meters then brake gently See following WARNING HUV 4421 Owner s Manual Page 25 Bed Latch and Prop Rod 4 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 complete stop See following WARNING and CAUTION WARNING Driving through w
77. pped persons 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 WARNING CONTINUED ON NEXT PAGE HUV 4421 Owner s Manual Page 23 Driving Instructions A WARNING 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 safety 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 sudd
78. ry in this vehicle is a 12 volt low maintenance battery that requires infrequent checks Figure 37 Electrolyte level should be checked semiannually 1 Level Indicator 2 Cap 3 Plates Electrolyte level at least 1 2 inch 13 MM above plates or to level indicator 222 22 Figure 37 Battery Figure 38 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 in General Warnings on page 11 2 1 Remove the driver side seat 3 Disconnect battery and spark plug Gas only wires See Disconnecting the Battery Gasoline Diesel Vehicle on page 13 4 Use a flat blade screwdriver and carefully remove the battery cell caps from the battery See following WARNING HUV 4421 Owner s Manual Page 51 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 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 wit
79. s to conform with all applicable California environmental emission 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 HUSQVARNASs application for certification with CARB 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 from the date of purchase 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 HUSQVARNA according to subsection 4 below Any such part repaired or replaced under warranty will be warranted for the remainder of the original warranty 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 original warranty period 3 Any warranted part that is scheduled for replacement as required maintenance in the written instructions supplied is warranted for the period of time
80. shift handle in the desired position Figure 6 or Figure 7 The engine must be at idle before the shift handle is moved If equipped with a reverse buzzer the reverse 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 back 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 gas and diesel vehicles feature an all wheel drive AWD system The AWD system automatically 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
81. spark plug cap spark plug Positive Crankcase Ventilation PCV System PCV valve oil filler cap Evaporative System Fuel Tank Fuel Cap Fuel Lines Fuel Line Fittings Clamps Pressure Relief Valves Purge Valves Vapor Hoses Carbon Canister Canister Mounting Brackets Carbon Canister Purge Port Connector Misc Parts Belts hosing tubing fittings seals gaskets clamps and switches associated with the above systems Emission related parts will vary between vehicles therefore certain vehicles may not include all of the listed parts or may include equivalent parts 3 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 HUSQVARNA SPECIFICATIONS 4 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 HUSQVARNA dealer or send the defective component freight prepaid to WARRANTY SERVICES HUSQVARNA PROFESSIONAL PRODUCTS INC 7349 STATESVILLE ROAD CHARLOTTE NC 28269 Page 62 HUV 4421 Owner s Manual BC55503 Publication Part Number 103472526 Edition Code 0708D1010C This manual is valid for vehicles built during the 200
82. stributors 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 e 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 WARNING and CAUTION 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
83. sult 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 6 and Figure 7 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 procedures are required See Periodic Service Schedule on page 33 HEADLIGHT CONTROL The headlight control 12 is located on the left side of the instrument panel Figure 6 and Figure 7 Press the headlight rocker switch to turn the headlights 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 6 and Figure 7 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 hi
84. tops 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 WARNING CONTINUED ON NEXT PAGE HUV 4421 Owner s Manual Page 27 Vehicle Load Capacities 4 WARNING Unload cargo bed before raising vehicle with a 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 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 Vehicle Load Capacities on page 28 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 maxim
85. tor 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 If in English this manual is the Original Instructions provided by the manufacturer If in any language other than English this manual is a translation of the Original Instructions tj Husqvarna www husqvarna com Copyright O 2008 2009 HUV 4421 Owner s Manual Page 1 FOREWORD Thank you for choosing Husqvarna a world leader in 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
86. uld 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 and spark plug Gas only wires See Disconnecting the Battery Gasoline Diesel Vehicle on page 13 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 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 Figure 3 Page 13 DISABLING THE VEHICLE me qo Set the park brake Turn the key switch OFF and remove the key Place the Forward Reverse control in the NEUTRAL position In addition chock the wheels if servicing or repairing the vehicl
87. um 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 capacity 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 capacity The stated maximum gross vehicle weight must not be exceeded to maintain safe vehicle operation Maximum payload capacity must be reduced accordingly when any 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 12 and Figure 13 for the following specifications HUV 4421 HUV 4421 HUV 4421 Two Passenger Four Passenger Two Passenger Vehicles Gasoline and Diesel with High Capacity Option l Vehicles Vehicles A Maximum occupant capacity 400 Ib 181 kg 400 Ib 181 kg 800 Ib 363 kg Gasoline and Diesel B C Maximum payload capacity 800 Ib 363 kg 1050 Ib 476 kg 800 Ib 363 kg D Trailer tongue weight 150 Ib force 667 N 150 Ib force 667 N 150 Ib force 667 N A B C Maximum veh
88. ur nearest Husqvarna dealer or distributor for information on how to properly recycle your batteries HUV 4421 Owner s Manual Page 13 General Information 1403 Figure 4 Dispose of Lead acid Batteries Properly 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 GXP and DXP models have been renamed GX and DX respectively All operating procedures maintenance and regular servicing are identical unless otherwise noted MODEL IDENTIFICATION The serial number of each vehicle is printed on a bar code decal mounted either below the passenger side cup holder or above the accelerator or brake pedal Example PHO901 583947 Figure 5 The two letters 1 at the beginning of the serial number indicate the vehicle model The following four digits 2 indicate the model year and production week during which the vehicle was built The six digits 3 following the hyphen represent the unique sequential number assigned to each vehicle built within a given model year See following NOTE NOTE Have the vehicle serial number available when ordering parts or making inquiries A 17 digit Product Information Number PIN is included on this vehicle next to the serial number This number may be used to register the vehicle where required Build Code The build code 4 is a five digit number that appears on the vehicle serial number dec
89. 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 14 To avoid unintentionally starting the vehicle disconnect battery and spark plug Gas only wires See Disconnecting the Battery Gasoline Diesel Vehicle on page 13 f 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

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