Hauler 4X4 Diesel Crew Owner's Manual 646445-A

hauler 4x4 diesel crew owner’s manual 646445-a UTV-EZGO-Hauler 4X4 Diesel-00.in2 2 2015-05-26 오전 8:58:20 FOREWORD

Thank you for choosing HAULER 4X4 DIESEL CREW, our off-road diesel utility vehicle.

We are committed to provide the best quality products . It is strongly recommended for all customer to read this owner’s manual thoroughly before using HAULER 4X4 DIESEL CREW as the manual contains a lot of valuable information, such as safe driving guide, expla- nation for operations, maintenance interval, simple maintenance guide, trouble shootings and etc.

If you have any question about the product or manual, please feel free to contact us. We are always trying to deliver ultimate satisfaction and safety to customers.

< NOTE >  Make sure to read this manual carefully and keep it handy for future reference.  When leasing or transferring this vehicle, deliver this manual together with the vehicle.  The specifications in this manual are subject to change without notice.

UD120-OM-1600XD4-00.indd 1 2015-05-22 오전 8:59:09 ISO 3600 EU standards

This manual was compiled in compliance with ISO 3600, standards and instructions contained in this manual comply with the requirements of the Machinery Directive 2010/52/EU in force in the European Community. For tractors sold or used outside the European Community, local laws will prevail. Main protections on the tractors discussed in this manual. DESCRIPTION NON CANOPY CANOPY

1. ROPS (protection against overturning) Yes Yes

2. FOPS (protection against objects falling from above) No No

3. OPS (protection against penetration of objects from sides) No No protection against hazardous chemicals (CategoryⅠ) (CategoryⅠ)

UD120-OM-1600XD4-00.indd 2 2015-05-22 오전 8:59:09 TABLE OF CONTENTS

SAFETY PRECAUTIONS...... 1

VEHICLE IDENTIFICATIONS...... 2

SPECIFICATIONS...... 3

CONTROLS AND FEATURES...... 4

SECTION OPERATION...... 5

REPLACEMENT PARTS...... 6

MAINTENANCE...... 7

STORAGE AND DISPOSAL...... 8

TROUBLESHOOTING...... 9

INDEX...... 10

UD120-OM-1600XD4-00.indd 3 2015-05-22 오전 8:59:09 TABLE OF CONTENTS

SAFETY PRECAUTIONS...... 1-1 Vehicle Identification Number...... 2-2

Precautions before operation...... 1-2 Vehicle serial number...... 2-2 Engine serial number...... 2-2 General precautions...... 1-2 SPECIFICATIONS...... 3-1 Precautions during operation...... 1-4 SPECIFICATION...... 3-2 When starting the engine...... 1-4 When driving the vehicle...... 1-6 Exterior dimensions...... 3-2 When parking the vehicle...... 1-13 General specifications...... 3-3 OPTION List and FEATURES...... 3-5 Safety precautions during servicing...... 1-14 CONTROLS AND FEATURES...... 4-1

Safety precautions when Exterior view...... 4-3 using the ROPS...... 1-18 Hood...... 4-4 Safety decal...... 1-19 ELECTRIC COOLING FAN MOTOR...... 4-4 Suspension...... 4-5 mounting location...... 1-19 Headlamp...... 4-5 DeCALs...... 1-20 Rear hitch receiver...... 4-5 Cautions for decal maintenance...... 1-24 Rear wheel mudguard...... 4-6 Reflex Reflector...... 4-6 PRECAUTIONS BEFORE OPERATION...... 2-1

UD120-OM-1600XD4-00.indd 4 2015-05-22 오전 8:59:09 TABLE OF CONTENTS

Switches...... 4-7 Controls...... 4-19

Key switch...... 4-8 Shift lever...... 4-19 Combination switch...... 4-9 Differential lock lever (REAR WHEEL)...... 4-20 Hazard lamp switch...... 4-11 2WD/4WD shift lever...... 4-21 Spare switch panel...... 4-12 Brake pedal...... 4-21 12V power outlet...... 4-12 Parking brake lever...... 4-22 Accelerator pedal...... 4-23 Instrument panel...... 4-13 Seat...... 4-23

SPEEDOMETER / Hourmeter...... 4-14 Seat belt...... 4-23 Fuel gauge...... 4-14 ROPS ...... 4-24 Coolant temperature gauge...... 4-15 FRONT guard...... 4-25 Engine oil pressure warning lamp...... 4-15 SUN Canopy...... 4-25 Battery charging lamp...... 4-16 Cup holders and storage boxes...... 4-25 Head light high beam lamp...... 4-16 Cargo bed...... 4-26 Turn Signal Lamp...... 4-17 Cargo bed control lever (manual model)....4-26 Glow plug indicator...... 4-17 Fuel tank...... 4-27 Parking brake indicator...... 4-17 Fuel requirements...... 4-28 nEUTRAL indicator ...... 4-18 Engine inspection...... 4-28 Lower fUEL LEVEL WARNING INDICATOR ...... 4-18 Coolant, brake fluid and electrical devices...... 4-29 engine check warning lamp ...... 4-18 Tire...... 4-29

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tire tread patterns...... 4-30 Shifting...... 5-13 Proper inflation pressure...... 4-31 Driving on slippery surfaceS...... 5-14 Turning...... 5-15 OPERATION...... 5-1 Driving on slope...... 5-15 Driving in forest...... 5-17 PRE-OPERATION...... 5-2 Driving through water...... 5-17 Daily inspection...... 5-2 Driving backward...... 5-18 Driving on road...... 5-19 OPERATING THE ENGINE...... 5-2 Transporting cargo...... 5-19 Starting the engine...... 5-2 Unloading (manual model)...... 5-21 Checking warning lamps after Towing trailer...... 5-22 starting engine...... 5-5 Transporting...... 5-23 Operating principle of preheat system....5-6 4WD operation...... 5-24 Stopping the engine...... 5-6 DiffERENTIAL lock operation...... 5-25 Tailgate (back door)...... 5-26 OPERATING THE VEHICLE...... 5-7 REPLACEMEnT PARTS...... 6-1 HOW TO DRIVE...... 5-7 Warming up...... 5-10 Essential replacement part...... 6-2 Jump start...... 5-11 Oil and fluid...... 6-2 Stopping...... 5-12 Filters...... 6-2 Parking...... 5-12 Belts and rubber parts...... 6-3

UD120-OM-1600XD4-00.indd 6 2015-05-22 오전 8:59:09 TABLE OF CONTENTS

eLECTRIC PARTS ...... 6-3 Checking CVT driven pulley clutch buttons(K)...... 7-17 MAINTENANCE...... 7-1 Checking fuel FILTER(L)...... 7-17 BLEEDING FUEL LINE (M)...... 7-18 Maintenance check list...... 7-3 Checking injection nozzle and fuel injection pump (N)...... 7-19 Daily check chart...... 7-3 Cleaning radiator core (O)...... 7-20 MAINTENANCE interval table...... 7-4 Checking coolant in auxiliary coolant LUBRICANTS...... 7-6 tank (P)...... 7-21 Changing coolant (Q)...... 7-22 Daily inspection...... 7-7 Checking spark arrester of exhaust pipe (if equipped) (R)...... 7-24 Access for service...... 7-7 Checking and changing gearbox oil (S)....7-24 Opening inspection shield (A)...... 7-7 Checking and changing front axle oil (T).....7-26 Opening seat cushion (B)...... 7-8 Checking and changing rear axle oil (U)....7-27 Raising cargo bed (C)...... 7-8 Checking drive shaft and CV boots (V).....7-28 Applying grease (D)...... 7-9 Checking steering rack boots and Checking engine oil level (E)...... 7-10 ball joint (W)...... 7-29 Changing engine oil and filter (F)...... 7-11 Checking brake fluid (X)...... 7-30 dust valve (G)...... 7-13 Checking brake pedal free play (Y)...... 7-31 Replacing air filter (H)...... 7-13 Checking brake pad (Z)...... 7-31 Checking air hose and clamp(I)...... 7-14 Checking parking brake (AA)...... 7-32 Checking CVT belt (J)...... 7-14 Adjusting suspension (AB)...... 7-33

UD120-OM-1600XD4-00.indd 7 2015-05-22 오전 8:59:09 TABLE OF CONTENTS

Checking suspension shock absorber (AC).....7-34 Disposal...... 8-4 Battery (sealed) (AD)...... 7-35 Replacing headlamp bulb (AE)...... 7-37 TROUBLESHOOTING...... 9-1 Checking and replacing fuse (AF)...... 7-37 vehicle Troubleshooting...... 9-2 Main fuse (slow-blow fuse) (AG) ...... 7-38 Aligning wheel and checking wheel INDEX...... 10-1 nut (AH)...... 7-39 Checking differential lock cable (AI)...... 7-39 INDEX...... 10-2 Checking shift and 4WD cables (AJ)...... 7-40 Using Bio diesel (AK)...... 7-41 Adjusting belt tension (AL)...... 7-41 Washing (AM)...... 7-42 Protecting plastic and painted surface (AO) ...... 7-42

STROAGE AND DISPOSAL...... 8-1

vehicle sTORAGE...... 8-2

daily storage...... 8-2 Long-term storage...... 8-2 Using vehicle after long-term storage...8-3

UD120-OM-1600XD4-00.indd 8 2015-05-22 오전 8:59:09 SAFETY AND VEHICLE DAMAGE WARNING

This manual includes information titled as WARNING, CAUTION, IMPORTANT and NOTE. These titles indicate the following:

This indicates that a condition may result in harm, serious in- ! jury or death to you or other persons if the warning is not WARNING heeded. Follow the advice provided with the warning.

This indicates that a condition may result in damage to your vehicle or its equipment if the caution is not heeded. Follow CAUTION the advice provided with the caution.

This mark indicates emphasis on notable characteristics of working procedures, and information about technology for easier operation. IMPORTANT

This indicates that interesting or helpful information is being provided. NOTE

UD120-OM-1600XD4-00.indd 9 2015-05-22 오전 8:59:09 UNIVERSAL SYMBOLS

Various universal symbols have been used on the instruments and controls of your vehicle. Below is a list of the universal symbols and their meanings.

Fuel-Level low Differential Lock Preheat

Parking Brake Hazard Warning Lights N Neutral Position

Battery Charging Condition Headlight-Low Beam H High Speed Travel Light

Engine Oil-Pressure Headlight-High Beam L Low Speed Travel Light

Turn Signal Four-Wheel Drive-ON R Reverse Travel Light

CEL Engine Check Warning Lamp

UD120-OM-1600XD4-00.indd 10 2015-05-22 오전 8:59:09 SAFETY PRECAUTIONS

Precautions before operation...... 1-2 General precautions...... 1-2 1 Precautions during operation...... 1-4

When starting the engine...... 1-4 When driving the vehicle...... 1-6 When parking the vehicle...... 1-13

Safety precautions during servicing...... 1-14

Safety precautions when using the ROPS... 1-18

Safety decal...... 1-19

mounting location...... 1-19 DeCALs...... 1-20 Cautions for decal maintenance...... 1-24

UD120-OM-1600XD4-01.indd 1 2015-05-22 오전 8:50:27 1- HAULER 4X4 DIESEL CREW Precautions before operation General precautions

A careful operator is the best oper- 4. Replace any missing or damaged ator. Most accidents can be avoid- decals as soon as it is practical. ed by observing certain precautions. A list of decals is shown on page To help prevent accidents, use these 1-19~24. safety precautions, and pay attention 5. Keep safety decals clean of dirt to the job at hand. If you can prevent and debris. an accident, your time will have been well spent.

T66O101a

1. It is recommended that you read and understand this entire manual before operation of your new vehicle. Failure to do so could result in accidents or injury. 2. Only persons who are properly trained should be allowed to operate the vehicle. 3. Read and follow all warning labels and decals affixed to the vehicle.

UD120-OM-1600XD4-01.indd 2 2015-05-22 오전 8:50:27 SAFETY PRECAUTIONS 1-

driver's license 1

UUVO102A UUVO114A UUVO115A

6. Never operate this vehicle or any 8. This vehicle should be driven only 9. Never let anyone under 5 years of other agricultural equipment while by a driver with a valid driver’s li- age ride in the vehicle. If it is un- under the influence of alcohol, cense. avoidable, such child should be drugs or while fatigued. secured with special restraints 7. While working in cooperation with which are not available with this other vehicles always communi- vehicle. Both driver and passen- cate your intentions. gers should wear their seat belts at all times.

UD120-OM-1600XD4-01.indd 3 2015-05-22 오전 8:50:27 1- HAULER 4X4 DIESEL CREW Precautions during operation When starting the engine

UUVO116A UUVO123A UUVO108A

10. Never allow anyone to operate 11. It is recommended to wear a hel- 1. Do not operate your vehicle in this vehicle unless person has met whenever driving this vehi- an enclosed building without the read this manual and all decals cle in an aggressive manner. Eye proper ventilation. Inhalation of thoroughly. protection is recommended at all carbon monoxide can cause seri- times. ous injury or death.

UD120-OM-1600XD4-01.indd 4 2015-05-22 오전 8:50:27 SAFETY PRECAUTIONS 1-

UUVO103A UUVO105C56O164aA UUVO131A

2. When starting the vehicle make 4. Never start the engine while not 7. Make sure that wheel nuts have sure your path is clear of people to seated. been tightened to the specified avoid accidents caused by sudden 5. Keep bystanders away from the torque. movements. vehicle while in operation. 8. Always check the tire pressure be- 3. Before starting your vehicle you 6. Be sure to scrape off mud or soil fore starting the engine. For more should make sure that all shift le- from your shoes before riding in information about tire pressure, vers are in the neutral position and the vehicle. see chapter 4. parking brake is applied. 9. Make sure that all pressure lines are tight before starting the vehicle.

UD120-OM-1600XD4-01.indd 5 2015-05-22 오전 8:50:27 1- HAULER 4X4 DIESEL CREW

When driving the vehicle

UUVO133A UUVO122T66O127aA KUVO157A

10. Always activate the brake pedal 1. In some countries or states, it is 2. When driving on a public road, before releasing the park brake. illegal to drive a UTV on public make sure to install the "Safe- roads. Be aware of traffic laws be- ty lamp kit" supplied by us and fore driving. observe the applicable regulations and laws. If the vehicle is not equipped with the "Safety lamp kit", there will be no brake lamps, turn signal lamps and tail lamps on the vehicle. In this condition, it is very dangerous to drive on a public road.

UD120-OM-1600XD4-01.indd 6 2015-05-22 오전 8:50:27 SAFETY PRECAUTIONS 1-

KUVO158A UUVO112A UUVO125A

3. When the headlights are turned 4. Always slow the vehicle before 6. Do not apply the differential lock on, dim them when meeting an- turning. Turning at high speed may while traveling at road speeds. As other vehicle. tip the vehicle over or cause a loss the vehicle may run out of control. of control. 7. Do not use 4WD while traveling at 5. Drive at speeds that allow you to road speeds in a normal road con- maintain control at all times. dition. 8. Avoid sudden movements of the steering wheel as this can cause a loss of control of the vehicle. This risk is especially great when traveling at road speeds.

UD120-OM-1600XD4-01.indd 7 2015-05-22 오전 8:50:27 1- HAULER 4X4 DIESEL CREW

KUVO162A KUVO101A KUVO109C56O164aA

9. When working in groups, always 11. Watch where you are going at 13. For your safety ROPS with a seat let the others know what you are all times so that you are able to belt is recommended for all appli- going to do before you do it. avoid obstacles that can cause cations. 10. Do not operate near ditches, injury or damage to your vehicle. holes, embankments, or other 12. Before making reverse move- terrain features which may col- ments with your vehicle, you lapse under the vehicle's weight. should always check to see that The risk of vehicle upset is even the path is clear. higher when the ground is loose or wet.

UD120-OM-1600XD4-01.indd 8 2015-05-22 오전 8:50:27 SAFETY PRECAUTIONS 1-

UUVO109A UUVO110A UUVO121A

14. Watch front and rear to avoid ob- 15. Never try to get on or off a mov- 16. To minimize the risk of a rollover stacles at row ends, near trees ing vehicle. crash, be especially careful when and around other obstructions. driving over obstacles, on slopes and when braking on hills during turns.

UD120-OM-1600XD4-01.indd 9 2015-05-22 오전 8:50:27 1-10 HAULER 4X4 DIESEL CREW

UUVO124A UUVO125A UUVO126A

17. Never drive the vehicle at ex- 18. Never attempt wheelies, jumps 19. Always keep both hands on the cessive speeds. Always travel at or other stunts. steering wheel and both feet on speed proper for the terrain, visi- the floor of the vehicle during op- bility and operating conditions. eration. 20. Always keep arms and legs inside the cab frame while the vehicle is in motion.

UD120-OM-1600XD4-01.indd 10 2015-05-22 오전 8:50:27 SAFETY PRECAUTIONS 1-11

UUVO111A UUVO129A KUVO166A

21. Never drive in excessively rough, 23. Always follow proper procedures 24. Drive slowly across sloped ter- slippery or loose terrain. for climbing hills as described rain. Excessive speed can cause 22. Never operate on excessive- in this manual. Check the ter- vehicle to roll over leading to se- ly steep hills. Practice on small- rain carefully before attempting rious injury. er hills before attempting larger to climb any hill. Never climb hills 25. Driving across a slope with a hills. with excessively slippery or loose heavy load can cause the vehicle surfaces. Never open the throttle to roll over. suddenly or make sudden gear changes. Never go over the top of any hill at high speed.

UD120-OM-1600XD4-01.indd 11 2015-05-22 오전 8:50:28 1-12 HAULER 4X4 DIESEL CREW

UUVO110A UUVO130A UUVO132A

26. Always be careful of skidding 27 never operate your vehicle in 28. Never exceed the stated load or sliding. On slippery surfac- fast-flowing water or in water capacity for this vehicle. Car- es such as ice, travel slowly and deeper than that specified in this go should be properly distributed exercise caution to reduce the manual. Wet brakes may have and securely attached. Reduce chance of skidding or sliding out reduced stopping ability. Test speed and follow the instructions of control. your brakes after leaving water. in this manual for hauling cargo If necessary, apply them light- or pulling a trailer. Allow a great- ly several times to let friction dry er distance for braking. out the pads.

UD120-OM-1600XD4-01.indd 12 2015-05-22 오전 8:50:28 SAFETY PRECAUTIONS 1-13

When parking the vehicle

UUVO140A UUVO113A UUVO134A

(1) Rear hitch receiver

29. Pull only from the rear hitch re- 1. Place all control levers in the neu- 2. Always remove the ignition key ceiver. Pulling from any other lo- tral position, set the parking brake, when the vehicle is not in use to cation can cause the damage of stop the engine. prevent unauthorized use or acci- vehicle. dental starting. 3. Never leave the vehicle without setting the parking brake and shut- ting off the vehicle.

UD120-OM-1600XD4-01.indd 13 2015-05-22 오전 8:50:28 1-14 HAULER 4X4 DIESEL CREW

Safety precautions during servicing

UUVO107A KUVO127A UUVO117A

4. Never park on a slope with only 1. In order to service your vehicle 2. Do not smoke while working the transmission engaged. The ve- you must park it on a flat level sur- around the battery or when refuel- hicle may roll down, leading to an face, set the parking brake, place ing your vehicle. Keep all sparks accident. the gear shift lever in neutral and and flames away from the battery 5. If it is unavoidable to park on a stop the engine. and fuel tank. The battery pres- slope and leave the vehicle, apply ents an explosive hazard because the parking brake and chock the it gives off hydrogen and oxygen wheels. especially when recharging. 6. Never park the vehicle on a steep slope. A serious accident can occur.

UD120-OM-1600XD4-01.indd 14 2015-05-22 오전 8:50:28 SAFETY PRECAUTIONS 1-15

&OHJOFTUPQ

KUVO113A UUVO118A UUVO119A

3. You must always stop the engine 4. It is recommended to keep a first 5. Do not remove the radiator cap before refueling the vehicle. Avoid aid kit and fire extinguisher handy while the coolant is hot. When overfilling the vehicle or spilling at all times. cool, slowly rotate the cap to the the fuel. first stop and allow sufficient time for excess pressure to escape. Af- ter all the pressure is released remove the cap completely. If your vehicle is equipped with a coolant recovery tank, add coolant there rather than to the radiator. 6. Allow the vehicle time to cool off before servicing any part that may have become hot while the vehicle was running.

UD120-OM-1600XD4-01.indd 15 2015-05-22 오전 8:50:28 1-16 HAULER 4X4 DIESEL CREW

UUVO120A UUVO135A T66O130a

7. When working with your vehicles 10. Tire mounting should be done by 13. Fluid escaping from pinholes may electrical components, you must qualified professionals, with the be invisible. Do not use hands to first disconnect the battery cables. proper equipment. search for suspected leaks; 8. To ensure that there are no acci- 11. Maintaining correct tire pres- use a piece of cardboard or dents from sparks you must first sure is important for the life of wood, instead. Use of safety disconnect the negative battery your tires. Do not inflate the tires goggles or other eye protection cable. above the recommended pres- is also highly recommended. If 9. For jump starting a dead battery, sure specified in the owner’s injured by escaping fluid, see a read and follow all of the instruc- manual. medical doctor at once. This flu- tions. (Page 5-11) 12. Securely support the vehicle id can produce gangrene and/or when changing wheels. severe allergic reaction.

UD120-OM-1600XD4-01.indd 16 2015-05-22 오전 8:50:28 SAFETY PRECAUTIONS 1-17

UUVO104A UUVO139A

14. No alterations should be made to 15. Keep environmental pollution in your vehicle. mind. When replacing coolant or oil, dispose of it the right way. Be sure to observe all relevant regulations when you dispose of the engine oil, transmission oil, fuel, coolant, filters and battery.

UD120-OM-1600XD4-01.indd 17 2015-05-22 오전 8:50:28 1-18 HAULER 4X4 DIESEL CREW Safety precautions when using the ROPS

U12O101a UUVO143A UUVO104A

(1) ROPS

1. ROPS (Roll Over Protective Struc- IMPORTANT A ROPS should never be modified ture) is equipped to protect driver by welding, grinding or cutting, as  and passengers when the vehicle ROPS, Sun canopy or cabin this can weaken the ROPS structure. is rolled over. Always fasten your are not a FOPS (Falling Object If any component of the ROPS unit is seat belt. Protective structure). damaged, it must be replaced. It never can protect the riders failure to fasten your seat belt can If the ROPS unit is removed or loos- against falling objects. invalidate ROPS. ened for any reason, the parts should Aviod driving the vehicle into a be fitted back to their original posi- dangerous area such as falling tions and all bolts should be properly rocks zone. torqued.

UD120-OM-1600XD4-01.indd 18 2015-05-22 오전 8:50:28 SAFETY PRECAUTIONS 1-19 Safety decal mounting location

U12O102b

UD120-OM-1600XD4-01.indd 19 2015-05-22 오전 8:50:30 1-20 HAULER 4X4 DIESEL CREW

DeCALs

(1) Part No. : U3215-85691 (3) Part No. : U3215-85631 �� ݃ܡܠܟܣܛܦܣܤܧܟ MAX 7.3 INCH �� (185MM) �� ݃ܡܠܟܣܛܦܣܤܡܟ

(2) Part No. : U3215-85161 (4) Part No. : U3215-85641 (5) Part No. : U3215-85681 NOTICE ��  THIS ROPS IS 1. The owner's manual and warning labels contain important information on TESTED IN �� safe operation of this vehicle. You must read and fully understand the ACCORDANCE WITH owner's manual and warning labels before operating this vehicle. SAE J2194 METHOD �� 2. Use on public road is hazardous. �� This vehicle is designed and equipped for off-highway use only. MAXIMUM VEHICLE 3. Children may not have the skills and judgement to safely operate this vehicle. MASS INCLUDING ݃ܡܠܟܣܛܦܣܤܢܟ All operators should possess a valid driver's license or be 16 years of age or older. CARGO DECK AND 4. Carrying passengers outside the passenger compartment can be hazardous. PERMANENT This vehicle is designed to carry a maximum of 4 persons; 2 per bench seat ATTACHMENTS IS including the operator. 850kg(1874 lbs) 5. Protective head gear reduces the risk of head injuries. Use of helmet in rough terrain and a hard hat at construction sites is especially recommended. Trade Name : 6. Seat belts reduce injuries. Always fasten your seat belt. MEC2200 7. Alcohol and drugs impair reaction time and judgement. Never drink and ride. ROPS P/Number : 8. Failure to apply parking brake may result in vehicle moving inadvertently. U3215-2610 Apply parking brake before leaving vehicle. ݃ܡܠܟܣܛܦܣܤܦܟ܎

UD120-OM-1600XD4-01.indd 20 2015-05-22 오전 8:50:30 SAFETY PRECAUTIONS 1-21

(6) Part No. : U3215-85181 1 

SEVERE INJURY OR DEATH COULD OCCUR AS A RESULT OF RIDERS FALLING OFF, IMPROPER USE OF THE VEHICLE OR VEHICLE ROLLOVER. · Read the owner's manual · Familiarize yourself with all safety information · Fasten seat belts · Securely fasten all cargo · Inspect the tires for proper inflation (front/rear: 12/18psi.) · Navigate turns at reduced speeds · Apply brakes when going down slopes to prevent the vehicle from accelerating suddenly (freewheeling) · Reduce speeds on rough or uneven terrain · Turn engine off and apply parking brake before exiting the vehicle · Never operate the machine under the influence of alcohol or drugs · Never allow operators under the age of 16 or without a valid driver's license to operate this vehicle · Never carry passengers in the bed, or on the hood · Never exceed the gross vehicle weight rating (GVWR 3,285lbs, 1490kg) |ZYX\T_\X_X

UD120-OM-1600XD4-01.indd 21 2015-05-22 오전 8:50:30 1-22 HAULER 4X4 DIESEL CREW

(7) Part No. : U3215-85562 (9) Part No. : U3215-85171 �� 1. Never drive this utility vehicle unless you're 16 or older or have a driver's license. 2. This machine is designed for off-road use only. Never drive on public Roads and avoid paved surfaces as the handling characteristics of the machine may be adversely affected. UNDER · unless the road is part of a designated trail system · except to cross when safe and permitted. 3. Drive only in designated areas, at a safe speed, and use care when turning and operating on slopes or uneven terrain. 16 4. Never drive under the influence of alchol or other drugs. 5. Do not allow children to ride as a passenger in this vehicle. Children may not be able to sit safely in the passenger seat and use handholds properly. 6. Read and follow the operator's manual and warning labels. ݃ܡܠܟܣܛܦܣܣܤܠ

TO PREVENT PERSONAL (8) Part No. : U3215-85611 INJURY, 1. Always wear your seat belt. CAUTION In the event of a rollover, �� press your feet firmly against the floor board and keep hands • Check the hood latches before operating the vehicle on the steering wheel or hand • Do not operate the vehicle with the hood open or holds. unlatched 2. Do not remove the ROPS for • Operating the vehicle with the hood open or any reason. unlatched could lead to impaired visibility or the loss 3. Never modify or alter the ROPS. of vehicle control ݃ܡܠܟܣܛܦܣܟܥܟ • Turn engine off and apply parking brake before exiting the vehicle U3215-85611

UD120-OM-1600XD4-01.indd 22 2015-05-22 오전 8:50:30 SAFETY PRECAUTIONS 1-23

(10) Part No. : U3215-85861 (13) Part No. : U3215-85651 CAUTION �� 1 Driving UTV in “H” gear with heavy load could shorten the life time of the CVT belt. Please be to sure the use “L” gear rather than “H” gear when driving UTV in the following conditions. A. While driving on a steep slope. B. While driving with heavy load on the cargo deck. C. While towing or pulling implement, such as snow blade, etc. U3215-85861

(11) Part No. : U3215-85601 (12) Part No. : U3215-85721 CAUTION �� TO PREVENT DRIVETRAIN DAMAGE: �� · Do not shift ranges with the engine �� RPM's above idle Do not lock differential or turn with differential locked while operating ݃ܡܠܟܣܛܦܣܤܣܟ machine at high speed or on slopes · Do not shift ranges while the vehicle is ݃ܡܠܟܣܛܦܣܥܠܟ moving

· Do not engage the rear differential lock while the machine is moving |ZYX\T_\]WX

UD120-OM-1600XD4-01.indd 23 2015-05-22 오전 8:50:31 1-24 HAULER 4X4 DIESEL CREW

Cautions for decal maintenance

(14) Part No. : U3215-85661 Safety decals are attached to the ve- IMPORTANT hicle for safe operation. Make sure �� to follow the instruction on the decals  If a decal is damaged or lost, as well as the following instruction: contact your local dealer immediately to install a new de- CAUTION cal.  Keep the decals clean and in-  Make sure to attach the decal tact. If any decal is dirty, wash to the correct position cleanly it with soap and dry with a soft without bubbles after cleaning cloth. its mounting surface.  Never use a solvent, such as  If a decal is attached to a com- thinner or acetone, since it can ponent to be replaced, replace ruin the decals. the decal as well.  Do not spray high-pressure ݃ܡܠܟܣܛܦܣܤܤܟ water directly onto the decal. The decal may fall off the vehicle.

UD120-OM-1600XD4-01.indd 24 2015-05-22 오전 8:50:31 PRECAUTIONS BEFORE OPERATION

Vehicle Identification Number...... 2-2 2 Vehicle serial number...... 2-2 2 Engine serial number...... 2-2

UD120-OM-1600XD4-02.indd 1 2015-05-22 오전 8:50:44 2- HAULER 4X4 DIESEL CREW PRECAUTIONS BEFORE OPERATION 2-PB Vehicle Identification Number Vehicle serial number Engine serial number

Have the vehicle serial number and engine serial number with you when ordering parts or asking for service information. Fill in the following boxes with appro- priate information as the vehicle serial number and engine serial number should be submitted to the dealer during service.

U12O201a U12O202a  Vehicle Serial No.

(1) Vehicle Serial Number (1) Engine Serial Number  Engine Serial No. This vehicle serial number is located The engine serial number is stamped on the structure frame where the bat- on the engine cylinder block where  Date of Purchase tery is installed. the injection pump is installed.

To be filled in by purchaser

UD120-OM-1600XD4-02.indd 2 2015-05-22 오전 8:50:44 SPECIFICATIONS

SPECIFICATION...... 3-2 Exterior dimensions...... 3-2 3 General specifications...... 3-3 3 OPTION List and FEATURES...... 3-5

UD120-OM-1600XD4-03.indd 1 2015-05-22 오전 8:50:56 3- HAULER 4X4 DIESEL CREW SPECIFICATION Exterior dimensions

C C

D E, F

A B U12O301a

in. (mm) Overall length Overall width Overall height Wheel base Front wheel tread Rear wheel tread Ground clearance (A) (B) (C) (D) (E) (F) (G) 144.6 60.7 76.4 108.7 49.7 48.30 12 (3,672) (1,543) (1,940) (2,760) (1,262) (1,228) (304)

UD120-OM-1600XD4-03.indd 2 2015-05-22 오전 8:50:56 SPECIFICATIONS 3-

General specifications

ITEMS HAULER 4X4 DIESEL CREW REMARKS Model 3C100LFU-U Number of cylinders 3 Total displacement cc 1,007 Fuel Diesel Engine Gross HP/KW 22/16.40 Rated speed rpm 2,800 3 Engine oil U.S.Gal.(L) 0.85 (3.2) Fuel tank U.S.Gal.(L) 7.40 (28.0) Gear box oil U.S.Gal.(L) 0.24 (0.9) Front differential case oil U.S.Gal.(L) 0.16 (0.6) C apacity Rear differential case oil U.S.Gal.(L) 0.21 (0.8) Coolant U.S.Gal.(L) 1.66 (6.3)

Main shift CVT (Continuous Variable Transmission with belt)

Range shift High / Low / Neutral / Reverse

If equipped with standard tires at maximum Max. speed M/h(Km/h) 25 (40) engine speed D riving unit

Brake Hydraulic dry type with caliper disc

- Front suspension MacPherson Strut us S

pension Rear suspension Double A-arm (Independent) Steering type Power Steering

UD120-OM-1600XD4-03.indd 3 2015-05-22 오전 8:50:56 3- HAULER 4X4 DIESEL CREW

ITEMS HAULER 4X4 DIESEL CREW REMARKS Front wheel 25 x 10-12 (Worksite) ire T

Rear wheel 25 x 10-12 (Worksite) 38.6 x 56.2 x 11.5 Dimension (L x W x H) in.(mm) (980 x 1,427 x 293) bed C argo Load capacity lbs(kg) 661.5 (300) Min. turning radius ft(m) 17.7(5.4) Gross Weight lbs(kg) 1,852(840) Trailer pulling capacity lbs(kg) 1,300 (590) Payload capacity lbs(kg) 1,325(600) Seat 2 Seat Bench X 2 Cargo dumping Manual Front guard Standard Speedometer Standard ROPS Standard Instrument cluster Standard Tachometer, fuel gauge, odometer

O thers Gas Spring Kit Standard Combination switch Standard For lamps and horn Safety Light Kit Standard Tail Light, Brake light, Turn signal, Hazard Switch, Horn Parking Brake Buzzer Kit (Safety) Standard Alarm, SYS Back-Lamp Kit Standard

※ Notes: Some option kits are installed as a standard in a certain country.

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OPTION List and FEATURES

ITEM DESCRIPTION REMARKS Wind Shield (Saftety With Wiper) Body Color Ornage / Green / Blue Hydraulic cargo dumping kit with hydraulic pump, oil Hydraulic Bed Lift tank, cylinder, valve, hoses and control lever Hydraulic Utility Valve Beacon Light 3 Winch MTG Bracket Sun Canopy Plastic moulding canopy Wind Shield Acrylic windshield kit Wiper Kit 2-inch front hitch Receiver 2 inch square type Remove lower screen of brush guard for installation Swing-Drawbar kit (EEC) Hand Throttle Hand throttle lever and cable Oil-Cooler Kit Sprayer Kit Skid Plate To protect important components underside vehicle Highly recommended for recrational driving Rear Screen Protection for rear area for operator Highly recommended for worksite using with cargo Suspension (CV Joint) Dust Guard Rear and front suspension guard Recommended to protect CV joints Horn Fog Light (two) Fog lamps, switch Headrest (two) Height adjustable with 2 steps

UD120-OM-1600XD4-03.indd 5 2015-05-22 오전 8:50:56 3- HAULER 4X4 DIESEL CREW

ITEM DESCRIPTION REMARKS Rear View Mirror Kit (two) Convex rear view mirror Strongly recommended for public road driving License Plate For mounting vehicle license plate Working Lamp Kit (ROPS) 2 Lamps Add on to the sun canopy Deck Extension Kit (Cargo) Cargo bed extension kit in height made by metal pipes Soft Cabin Kit (Four, OEM-One) Beacon Light Kit High-Mount Brake Lamp Kit

※ Notes: Some option kits are not available at the time of printing. The specifications are subject to change without notice. Some option kits are installed as a standard in a certain country.

UD120-OM-1600XD4-03.indd 6 2015-05-22 오전 8:50:56 CONTROLS AND FEATURES

Exterior view...... 4-3 Engine oil pressure warning lamp....4-15 Battery charging lamp...... 4-16 Hood...... 4-4 Head light high beam lamp...... 4-16 ELECTRIC COOLING FAN MOTOR...... 4-4 Turn Signal Lamp...... 4-17 Suspension...... 4-5 Glow plug indicator...... 4-17 4 Headlamp...... 4-5 Parking brake indicator...... 4-17 Rear hitch receiver...... 4-5 nEUTRAL indicator ...... 4-18 Rear wheel mudguard...... 4-6 Lower fUEL LEVEL WARNING INDICATOR..4-18 Reflex Reflector...... 4-6 4 engine check warning lamp...... 4-18

Switches...... 4-7 Controls...... 4-19 Key switch...... 4-8 Shift lever...... 4-19 Combination switch...... 4-9 Differential lock lever (REAR WHEEL)....4-20 Hazard lamp switch...... 4-11 2WD/4WD shift lever...... 4-21 Spare switch panel...... 4-12 Brake pedal...... 4-21 12V power outlet...... 4-12 Parking brake lever...... 4-22 Accelerator pedal...... 4-23 Instrument panel...... 4-13 Seat...... 4-23 SPEEDOMETER / Hourmeter...... 4-14 Seat belt...... 4-23 Fuel gauge...... 4-14 ROPS ...... 4-24 Coolant temperature gauge...... 4-15 FRONT guard...... 4-25

UD120-OM-Hauler 4X4 Diesel Crew-1 1 2015-05-22 오후 3:25:53 CONTROLS AND FEATURES

SUN Canopy...... 4-25 Cup holders and storage boxes.....4-25 Cargo bed...... 4-26 Cargo bed control lever . (manual model)...... 4-26 Fuel tank...... 4-27 Fuel requirements...... 4-28 Engine inspection...... 4-28 Coolant, brake fluid and . electrical devices...... 4-29 Tire...... 4-29 tire tread patterns...... 4-30 Proper inflation pressure...... 4-31

UD120-OM-Hauler 4X4 Diesel Crew-2 2 2015-05-22 오후 3:25:53 CONTROLS AND FEATURES 4-

CONTROLS AND FEATURES Exterior view

U12O401a

(1) Seat Back (6) ROPS (11) Rear Reflex Reflector (2) Seat (7) Steering Handle (12) Cargo Bed (3). dumping Handle (8) Hood (13) Rear Hitch Receiver (4). dumping Latch (9) Headlamp (14) Rear Wheel Mudguard (5) Fuel Tank Cap (10). brush Guard (15) Sun Canopy

UD120-OM-Hauler 4X4 Diesel Crew-3 3 2015-05-22 오후 3:25:54 4- HAULER 4X4 DIESEL CREW

Hood ELECTRIC COOLING FAN MOTOR

The fan motor runs when the coolant temperature raises over 80℃ and stops when the coolant temperature drops below 75℃. The 5℃ gap between two points is to prevent contin- ual “ON” and “OFF” operation of fan motor. The fan motor can run even when the engine is stopped if the key is in “ON” position and the coolant is still hot.

U12O402A UUVO452A To prevent engine failure, the fan motor keeps running even if there is (1) Hood (A) Hook (1) Hood Support any short-circuit or disconnected wire on the temperature signal circuit.

The hood is secured with two rubber CAUTION hooks. Always make sure the hooks  are latched before operating the ve- Make sure that there is noth- hicle. ing around or between the vehicle and the hood before clos- WARNING ing the hood.  Make sure that the hood is firmly closed and the hooks are latched before driving. If not, it may open during driving, resulting in an accident.

UD120-OM-Hauler 4X4 Diesel Crew-4 4 2015-05-22 오후 3:25:55 CONTROLS AND FEATURES 4-

Suspension Headlamp Rear hitch receiver

U12O405a U12O404a U12O406A 4

(1) Front Axle (2) Rear Axle (1) Headlamp (LH) (2) Headlamp (RH) (1) Rear Hitch Receiver

The Mcpherson strut type suspen- The headlamps consist of Halogen This vehicle is equipped with the rear sion for front wheel and adjustable lamps for high beam and low beam. hitch receiver as standard. dual A-arm (wishbone) type suspen- Their reflective mirrors are chrome- The rear hitch receiver is a 2-inch sion for rear wheel provide smooth- plated and have black bezel covers, square boss type and is used to in- est ride off road, empty or at full load. featuring refined design. stall a trailer or 3-point hitch implement. Make sure to observe the WARNING following precautions in order to pre-  Driving with high beam head- vent injuries and damage to proper- lamps disturbs the approaching ties. driver’s visibility for safe driving. Use high beams only if necessary.

UD120-OM-Hauler 4X4 Diesel Crew-5 5 2015-05-22 오후 3:25:55 4- HAULER 4X4 DIESEL CREW

Rear wheel mudguard Reflex Reflector

WARNING  Never drive this vehicle with a person in the trailer or cargo bed.  Do not apply vertical load for more than 59 Kg (130 lbs) onto the towing bracket.  When towing, do not exceed the driving speed of 16 km/h (10 mph). U12O407A U12O408A  Remember that the stopping (1) Rear Wheel Mudguard (1) Reflex Reflector (LH) distance becomes longer while (2) Reflex Reflector (RH) towing a trailer.  When towing a trailer, make The rear wheel mudguard is installed Two round reflectors are installed on sure the gross weight of the under the cargo bed. the rear wheel fender. trailer, including cargo weight, does not exceed 590 kg (1,300 lbs).  When connecting a trailer, attach it only to the trailer hitch bracket.  Never connect a trailer to any point other than the specified. Otherwise, you can lose control of the vehicle during driving, resulting in a possible accident.

UD120-OM-Hauler 4X4 Diesel Crew-6 6 2015-05-22 오후 3:25:56 CONTROLS AND FEATURES 4- Switches

CAUTION  Make sure that the reflectors are clean before driving the vehicle. Driving with dirty reflectors, especially in cloudy weather or at night can cause an accident.  In some counties and states, it is illegal to drive UTV in the public road. Be aware the traf- 4 fic law before driving.

KUVO410C

(1) Combination Switch (3) Spare Switch Panel (2) Hazard Lamp Switch (4) 12V Power Outlet

UD120-OM-Hauler 4X4 Diesel Crew-7 7 2015-05-22 오후 3:25:56 4- HAULER 4X4 DIESEL CREW

Key switch

ACC (B) used in very cold weather to pre- When the key switch is turned to heat the engine manually for extra the position “B”, only electrical period of time. Using this position power outlet and brake lights can for more than 30 seconds con- be operated. secutively can reduce the preheat system’s life. ON (C) The position “C” indicates the “ON” IGN (E) position. As soon as the key switch The position “E” indicates the is turned to this position, the oil “Start”. In order to start the engine, pressure warning lamp and bat- U12O411A the shift lever should be in the tery charge warning lamp comes neutral position. As soon as the (1) Key switch (A) OFF (B) ACC on (These become off after the engine is started, release the key (C) ON (D) HEAT (E) IGN engine is started). The preheat then the key switch is returned to operation is automatically started. the position “C”. There are five positions for the ig- The automatic preheat operation nition key switch as follow. The key is indicated by the glow plug in- NOTE dicator. Make sure to preheat the can be removed from the key switch  The automatic preheating sys- engine until the glow plug indica- only if it is in the "OFF" position. tor goes off (Approx. 9 seconds) in tem is not activated and the pre- cold weather. heating indicator doesn’t come OFF (A) on when the engine temperature When the key switch is in position HEAT (D) is 30℃ or higher. In this case, “A”, the engine and all electrical The position “D” indicates the strut the engine right away with- devices in the vehicle stop except “manual preheat” position, which out preheating. horn, hazard lamps and turn sig- is not used in normal conditions. nal. This position is a self-return type, so the key should be held there while using. This position can be

UD120-OM-Hauler 4X4 Diesel Crew-8 8 2015-05-22 오후 3:25:57 CONTROLS AND FEATURES 4-

Combination switch

CAUTION NOTE  Stop the engine immediately if  The ignition key is not directional the oil pressure warning lamp and can be inserted in any direc- does not go off after the en- tion. Also, be careful not to leave gine is started. The engine can the vehicle unattended as the be seriously damaged. same key is used for all vehicles.  If the battery charge warn- It can be stolen. ing lamp does not go off after the engine is started, check the electrical systems, such UUVO412A 4 as the alternator, for damage. (1) Turn Signal Lamp Switch Continuing to use the engine (2) Headlamp Switch under this condition can dis- (3) Horn Switch charge the battery or damage The combination switch consists of other electrical devices. the head light, turn signal light, and  By leaving the vehicle with the horn switches. key in the ignition switch, an unauthorized person can operate the vehicle and cause a serious accident and even death. Make sure to keep the key with you when leaving the vehicle.

UD120-OM-Hauler 4X4 Diesel Crew-9 9 2015-05-22 오후 3:25:57 4 -10 HAULER 4X4 DIESEL CREW

Headlamp switch Turn signal lamp switch WARNING  Driving with high beam headlights makes it difficult for the driver of an on coming vehicle to see. Use high beams only if necessary.

UUVO413A UUVO414A

(1) Headlamp Switch (1) Turn Signal Lamp Switch (A) OFF : Headlamps Off (A) : Turn signal lamps On (B) : Low Beam ON (C) : High Beam ON Pulling the lever up blinks the right The headlamp switch can be operat- turn signal lamp while pushing the le- ed while the key switch is in the "ON" ver down blinks the left turn signal position then head lights, tail lights (if lamp. equipped) and dash lights come on. The turn signal lamp switch is to op- Turning on the headlamps for an ex- erate the turn signal lamps, which tended period of time with the engine is included in the "Safety lamp kit" off can discharge the battery. as an option. Check if the safety lamp kit is installed before using this switch.

UD120-OM-Hauler 4X4 Diesel Crew-10 10 2015-05-22 오후 3:25:58 CONTROLS AND FEATURES 4 -11

Hazard lamp switch Horn switch NOTE  The turn signal lamp lever is not the self-return type. Therefore, make sure to return the lever manually after turning the vehicle.  The turn signal lamps and flasher can be operated even with the key switch in the "OFF" position. Leaving the turn signal lamps UUVO455A UUVO4154A flashing with the key switch in the (1) Horn Switch (1) Hazard Lamp Switch "OFF" position can discharge the (A) ON (B) OFF battery. The horn switch can be operated This switch can be used to warn without the key in the key switch. other vehicles when malfunction oc- Pressing this switch sounds the horn. curs in the vehicle while driving on a public road.. pressing this switch up blinks the hazard lamp and returning it turns off the lamp. The turn signal lights cannot be operated while this switch is pressed up to operate the hazard lamps.

UD120-OM-Hauler 4X4 Diesel Crew-11 11 2015-05-22 오후 3:25:59 4 -12 HAULER 4X4 DIESEL CREW

Spare switch panel 12V power outlet

CAUTION  The hazard lamp can be operated without the key inserted.  If the hazard lamps are turned on for an extended period of time while the engine is stopped, the battery can be discharged. Therefore, use them only in emergency. U12O462A U12O416A

(1) Spare Switch Panel (1) 12V Power Outlet

The spare switch panel is for the op- This 12 V power outlet operates with tional items available for installa- the key in the “ACC” or "ON" position. tion on this vehicle such as the wind- Using the power outlet for an extend- shield wipers and other items. ed period of time with the engine off or connecting an electric device with its capacity over the limit into the power outlet can discharge the battery.

UD120-OM-Hauler 4X4 Diesel Crew-12 12 2015-05-22 오후 3:26:00 CONTROLS AND FEATURES 4 -13 Instrument panel

WARNING  Do not wear a headphone to listen to the radio or music during driving.  Use only D.C. electric devices with its capacity of 12V 10A or less.  Never use an electric heater. It can cause a fire. 4

U12O417A

(1) Fuel Gauge (8) Preheating Indicator (2) Speedometer (9) Hourmeter (3) Coolant Temperature Gauge (10) Battery Charge Warning Lamp (4) Turn Signal Indicator (LH) (11) Parking Brake Indicator (5) Neutral Indicator (12) Engine Oil Pressure Warning Lamp (6) High Beam Indicator (13) Turn Signal Indicator (RH) (7) Lower Fuel Level Warning Indicator (14) Engine Check Warning Lamp

UD120-OM-Hauler 4X4 Diesel Crew-13 13 2015-05-22 오후 3:26:01 4 -14 HAULER 4X4 DIESEL CREW

SPEEDOMETER / Hourmeter Fuel gauge

This is due to air entered into the fuel supply system. In this case, the system should be bled. (For details, refer to page 7-18 "Bleeding fuel system" in the chapter "Maintenance".)

NOTE  Make sure that good quality fuel is used, poor quality fuel can cause damage to the engine. U12O418A T46O568A  Use fuel formulated for cold (1) Speedometer (2) Hourmeter (1) Fuel Gauge weather during the winter, the en- “E”: Empty “F”: Full gine will start easier.

The speedmeter operates correctly This indicates the remaining fuel lev- when the specified tires with the cor- el after the key switch is turned to the rect inflation pressure are installed. “ON” position. Refer to the chapter "Maintenance" F : Fuel is completely filled. for the correct tire inflation pressure. The hourmeter indicates the total us- E : Replenish the fuel tank. age time of the vehicle in digits. If driving is continued with the nee- The hourmeter does not operate if dle below the position "E", the warn- the engine is stopped even though ing lamp of out of fuel( ) turns on. the key switch is in the "ON " posi- If the vehicle is run completely out of tion. fuel, it may be hard to restart the en- Check the hourmeter to service the gine after refilling the fuel tank. vehicle at the correct interval.

UD120-OM-Hauler 4X4 Diesel Crew-14 14 2015-05-22 오후 3:26:01 CONTROLS AND FEATURES 4 -15

Coolant temperature gauge Engine oil pressure warning lamp Stop the vehicle or operation for a while without stopping the engine until the engine is cooled down. If the engine temperature does not drop, open the hood and check if the radiator fan is operating. If the fan is not operating, stop the engine and have your vehicle checked by your dealer. CAUTION H11O425A  Make sure to control the work U12O419A 4 (1) Coolant Temperature Gauge load so that the pointer is not (2) Normal Driving Range in the red zone. “C”: Cold “H”: Hot  If the pointer stays in the red This gauge indicates the coolant zone, do not stop the engine This lamp comes on when the en- temperature after the key switch is immediately. Instead, reduce gine oil pressure or oil level is low. turned to the "ON" position. the work load to cool down the This lamp comes on when initial- C : Coolant is cold. engine before stopping the en- ly turning the key switch to the "ON" gine. position. It goes off as soon as the H : Coolant is hot.  Make sure to keep the front engine is started. If this lamp comes The range marked “2” in the figure grill clean so that air is sucked on while driving, stop the engine im- indicates the normal engine temper- through it freely for fast cool- mediately and check the engine oil ature (normal driving range). ing. level.  If the needle is in the "H" zone dur- Never open the radiator cap If this lamp comes on even with the ing driving, it indicates the engine is when it is hot. You can get specified engine oil level, have your overheated. burnt badly. vehicle checked by your local dealer or workshop immediately.

UD120-OM-Hauler 4X4 Diesel Crew-15 15 2015-05-22 오후 3:26:02 4 -16 HAULER 4X4 DIESEL CREW

Battery charging lamp Head light high beam lamp

CAUTION  If the oil level is below the specified range, the engine can seize.  The engine can be severely damaged if driving or operating the vehicle with the engine oil warning lamp ON.

U12O420A U12O421A

This lamp is lit when the key switch This blue lamp is lit when the head- is turned to the. oN position before light switch is set to high beam. Driv- starting the engine. Once the engine ing with high beam headlights makes is started the lamp will turn off. it difficult for the driver of an on coming vehicle to see.. use high beams CAUTION only if necessary.  If this warning lamp comes on while driving, the charging system, such as the alternator, is malfunctioning. Therefore, turn off all electrical devices and have the vehicle checked by your local Dealer or workshop as soon as possible.

UD120-OM-Hauler 4X4 Diesel Crew-16 16 2015-05-22 오후 3:26:02 CONTROLS AND FEATURES 4 -17

Turn Signal Lamp Glow plug indicator Parking brake indicator

U12O422A U12O423A U12O424A 4

Operating the turn signal lamp This indicates the operating condi- This lamp comes on in red when the switch, up or down, will turn on the tion of the preheat system. When the parking brake is engaged. corresponding green arrow light. key switch is turned to the "ON" position, this indicator comes on for ap- CAUTION prox. 9 seconds. It is recommended  If this indicator is ON even with to start the engine as soon as this in- the parking brake released, dicator goes off for best starting per- have the vehicle checked by formance. This indicator may not turn your local dealer or workshop on if the engine is warm. In this case, immediately. the engine can be started without the preheat operation.

UD120-OM-Hauler 4X4 Diesel Crew-17 17 2015-05-22 오후 3:26:03 4 -18 HAULER 4X4 DIESEL CREW

nEUTRAL indicator Lower fUEL LEVEL WARN- engine check warning lamp ING INDICATOR

U12O425A U12O426A U12O452A

If the shift lever is in neutral position, This lamp comes on when the fuel This comes on when any major elec- this lamp turns green. tank is approaching empty. When it tric device or engine fuel system is Engine can be started only when this comes on, you should add fuel as malfunctioning. lamp is ON. soon as possible. Driving with the this lamp on or with the fuel level below “E” can cause the engine to mis- fire and damage the engine parts. If the air enters into the fuel system refer to maintenance chapter page 7-17 for "Bleeding fuel line".

UD120-OM-Hauler 4X4 Diesel Crew-18 18 2015-05-22 오후 3:26:03 CONTROLS AND FEATURES 4 -19

Controls Shift lever

UUVO428A 4

(1) Shift lever H: High speed L: Low speed N: Neutral R: Reverse The shift lever has four positions; "H"

U12O427A (High speed), "L" (Low speed), "N" (Neutral) and "R" (Reverse). (1) Steering Wheel (4) 2WD/4WD Shift Lever (2) Differential Lock Lever (5) Brake Pedal This vehicle is equipped with the in- (3) Shift Lever (6) Accelerator Pedal line type shift lever system for conve- nient control. Also, there is a stopper between the "H" and "N" positions to ensure safe shift between the forward and reverse operation.

UD120-OM-Hauler 4X4 Diesel Crew-19 19 2015-05-22 오후 3:26:05 4 -20 HAULER 4X4 DIESEL CREW

Differential lock lever (REAR WHEEL)

IMPORTANT [Differential lock system] The differential lock system is to con-  This vehicle is equipped with nect the wheel on the left and right a CVT (Continuous Variable mechanically to rotate them at the Transmission). same speed regardless of friction ap-  Make sure to stop the vehi- plied to them even on a slippery or cle before moving the shift le- bumpy road for better traction. ver into the "H", "L" or "R" position. Shifting during driving CAUTION can damage parts in the gear-  The differential lock lever box. UUVO429A  Shift the lever into the "L" (Low should always be returned to (1) Differential Lock Lever speed) position when driv- the "UNLOCK" position after (A) Upper Position: Unlock use. Leaving the differential ing on a hill or a bumpy area (B) Lower Position: Lock so that the vehicle can utilize lock in the "LOCK" position On hard firm ground, the differential more power and enhance du- when driving on normal roads system should be unlocked to secure rability of the CVT belt and pul- or trails will cause the gears to safe turning. ley. wear more quickly. When the wheel on one side is on a  make sure to set the steering slippery surface, such as mud or icy wheel in the straight ahead po- road, the wheels on a slippery sur- sition and drive at a low speed face lose traction and rotate fast while the differential lock lever while the wheel on a normal surface is in the "Lock" position. Oth- do not rotate, resulting in the vehi- erwise, you can lose control of cle stuck into its position. In order the vehicle or damage the dif- to prevent this situation, this vehicle ferential system, resulting in is equipped with the differential lock an accident. system.

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2WD/4WD shift lever Brake pedal

CAUTION  make sure to move the differential lock lever to the "unlock" position while the vehicle is stationary. Moving the lever during driving can affect the life of the differential system.

UUVO430A UUVO431A 4 LSD Differential Lock (Front Wheel) (1) 2WD/4WD Shift Lever (2) Lock (1) Brake Pedal (A) Depress (A) 2WD Position (B) 4WD Position The LSD (Limited Slip Device) is installed on the front axle. The 2WD/4WD shift lever is equipped The brake pedal is located on the left The LSD differential lock system will with a lock which should be pulled up of the accelerator pedal. Press the automatically adjust the wheel rota- by a finger in order to operate the le- brake pedal slowly to slow and stop tion speed to compensate for differ- ver. (So does diff. lock lever) the vehicle. ent traction conditions. 4WD should be engaged only when Press the pedal before starting needed to travel on slippery surfac- downhill to prevent the vehicle from es, loose soil, rocky terrain or steep gaining too much speed. slopes. IMPORTANT The gears in the vehicle can be stressed and steerability can be de-  Press the brake pedal light- teriorated if using the 4WD unneces- ly several times to dry the disc sarily. bakes after driving through water or mud.

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Parking brake lever

WARNING WARNING To avoid possible injury, death  An unauthorized person or or loss of property from a ma- child can move or operate the chine runaway: vehicle. Therefore, make sure  With the engine off, unexpect- to apply the parking brake and ed machine movement could carry the key with you when result regardless of the gear leaving the vehicle.  shift position. This vehicle is equipped with the CVT (Continuous Variable  Before dismounting the ma- U12O432A Transmission). Therefore, the chine, apply the parking brake vehicle may roll down a slope (1) Parking Brake Lever to prevent machine runaway. if the parking brake is not en- (A) Down to release with pushing ※ Only CVT model. (B) Pull up to set button. gaged even though the shift le- The parking brake lever is similar to ver is in the "H", "L" or "R" po- the one installed in cars. Make sure sition. Make sure to apply the that the parking brake is released be- parking brake before leaving fore driving. your vehicle.

UD120-OM-Hauler 4X4 Diesel Crew-22 22 2015-05-22 오후 3:26:07 CONTROLS AND FEATURES 4 -23

Accelerator pedal Seat Seat belt

UUVO433A U12O434A UUVO435c 4

(1) Accelerator Pedal (A) Depress (1) Seat Back (2) Seat Cushion (1) Seat Belt

The accelerator pedal is located on The vehicle is equipped with two The seat belts for the driver and pas- the right of the brake pedal. Make bench seats. Each seat is intended sengers are 3-point retractable lap sure not to press the brake pedal in- for two occupants. The front seat is and shoulder belts. stead of the accelerator pedal and for the driver and one passenger. 1. Make sure the seat belt is not vice versa by mistake. Removing the seat cushion will gain twisted and insert the latch plate access to the engine compartment. into the buckle until a clicking sound is heard. 2. Press the red button to un-buckle.

UD120-OM-Hauler 4X4 Diesel Crew-23 23 2015-05-22 오후 3:26:07 4 -24 HAULER 4X4 DIESEL CREW

ROPS

WARNING WARNING  As the safety belt can reduce  The ROPS is to protect you in or prevent injuries in an acci- a rollover accident, not to pro- dent, make sure to wear the tect you from falling objects. seat belt during driving. Also, Never drive in a dangerous be sure the seat belt is not or construction area that may twisted as the seat belt may have falling objects. Occu- not protect an occupant prop- pants can be seriously injured. erly, leading to an accident.  Fasten the seat belt firmly U12O437A NOTE when seated in the vehicle. (1) ROPS  ROPS: Roll. over. protective  The seat belt should go around Structure your pelvis or as low as pos-  FOPS: Falling. object. protec- sible, not your waist or abdo- The ROPS (Roll. over. protective tive Structure (installed mainly to men. Otherwise, the seat belt Structure) is a unit made of robust construction machinery) cannot protect you properly. metal tubes in order to protect the  Children under age 5 should driver and occupants in an accident. never be on this vehicle. The ROPS installed complies with various regulations. (OSHA, OECD, EEC, ASAE, etc.) WARNING  Make sure to fasten the seat belt during driving. The ROPS cannot protect you if not wear-

ing the seat belt. UUVO438A

UD120-OM-Hauler 4X4 Diesel Crew-24 24 2015-05-22 오후 3:26:08 CONTROLS AND FEATURES 4 -25

FRONT guard SUN Canopy Cup holders and storage boxes

KUVO403A U12O439a U12O453a 4

(1) Front Guard (1) Sun Canopy

The brush guard is made of strong The sun canopy is available for this metal tubes to protect the headlamps vehicle as an option. This is to im- and radiator. It has a winch installa- prove the driver's comfort in rain or tion hole so that the WARN ® winch sunlight. can be installed to the vehicle. CAUTION  When entering a garage, make U12O454A sure that the vehicle does not (1) Cup Holders hit the ceiling or entrance of (2) Glovebox (Driver Side) the garage. (3) Glovebox (Center) (4) Glovebox (Passenger Side) (5) Glovebox (under the Front Seat)

UD120-OM-Hauler 4X4 Diesel Crew-25 25 2015-05-22 오후 3:26:08 4 -26 HAULER 4X4 DIESEL CREW

Cargo bed Cargo bed control lever (manual model) There are 3 cup holders, 2 up front and one in the back.

U12O446a

(1) Dumping Latch (2) Dumping Handle (A) Turn (B) Pull Up

To raise the cargo bed, pull up the handle with one hand while turning the dumping latch lever with the other hand. Take your hand off the handle after the support rod is set into

UUVO445A the lock groove securely. (1) Door (2) Latch Handle (3) Wire Rope CAUTION (A) Close (B) Open  Never drive your vehicle with To open the back door of the cargo the cargo weight over the bed, rotate and pull the handles on the both sides simultaneously. Also, make specified max. load limit. sure the latch handles are securely locked after closing the back door. Max. load: 500 Kg (1,102 lbs)

UD120-OM-Hauler 4X4 Diesel Crew-26 26 2015-05-22 오후 3:26:09 CONTROLS AND FEATURES 4 -27

Fuel tank

WARNING  When raising or lowering the cargo bed, be careful not to let any part of your body, such as a hand or foot, stay between the cargo bed and cab frame. Grip only the handle to prevent injuries.

U12O470A UUVO449A 4

(1) Cargo Bed Support (1) Fuel Tank

WARNING The fuel tank is installed under the right side of the cargo bed and its ca-  Never let anyone ride on the pacity is 7.4 gallons (28 liters). Since cargo bed during driving. He/ this vehicle is equipped with the die- she can fall off the bed and be sel engine make sure to fill the fuel seriously injured. tank with clean diesel fuel for optimal  It is dangerous to drive with performance. the cargo bed raised. Make sure to lower the cargo bed Make sure to keep the following to its original position and en- safety precautions when fueling. gage the latch before driving. 1. Make sure that the fuel to be filled into the tank is diesel fuel.

UD120-OM-Hauler 4X4 Diesel Crew-27 27 2015-05-22 오후 3:26:10 4 -28 HAULER 4X4 DIESEL CREW

Fuel requirements Engine inspection

2. Avoid using electrical devices, Make sure to use high quality diesel such as a cellular phone, during fuel for durability and performance fueling. of the engine. The cetane number of 3. The fuel is highly flammable and the fuel should be at least 40 (ASTM even explosive in certain condi- D975) in any circumstance. It is rec- tions. Make sure to stop the en- ommended to use fuel with higher gine and remove the key before cetane number when driving in cold fueling. weather or at an altitude of 1,500 m (5,000 ft) or above. 4. Never smoke while fueling. Add It is recommended to use diesel fuel fuel in a well-ventilated area and U12O450A keep away from spark and flame. with high cetane number in order to 5. Do not fill the tank with fuel up to enhance power and starting of the the top. The fuel can expand by engine in a cold weather. heat, resulting in leakage through CAUTION the bleeding hole in the fuel tank filler cap.  Adding gasoline or kerosene to the fuel tank can damage 6. Make sure to close the tank filler the fuel system severely. cap firmly after fueling. If fuel overflows, wipe it with a rag immediately.

U12O471A (1) Inspection Shield

It is possible to inspect the engine for most items by removing the seat

UD120-OM-Hauler 4X4 Diesel Crew-28 28 2015-05-22 오후 3:26:10 CONTROLS AND FEATURES 4 -29

Coolant, brake fluid and Tire electrical devices cushion and raising the cargo bed. For engine oil level check, just remove the inspection shield on the lower section of the seat.

UUVO451A T56O530A 4

(1) Radiator Cap (2) Drain Plug (A) Insufficient (B) Standard (C) Excessive

The coolant, radiator cooling fan and Though the tire inflation pressure is brake fluid can be checked by open- factory-set to the prescribed level, it ing the hood. naturally drops slowly in the course Also, various relays and controls for of time. Thus, check it everyday and electrical devices can be checked in inflate as necessary. this location. The coolant reservoir tank can be inspected without opening hood, right behind the right front wheel.

UD120-OM-Hauler 4X4 Diesel Crew-29 29 2015-05-22 오후 3:26:10 4 -30 HAULER 4X4 DIESEL CREW

tire tread patterns

Standard tire for worksite Turf

UUVO458A

UUVO460A UUVO457A

All terrain (recreatiONal) 1. Always check the tire inflation pressure before driving. It is possible to check the inflation pressure roughly by checking the tires visually and tapping them (refer to the figure above). 2. Check if the wheel nuts are firmly tightened and tighten them as necessary before driving.. driving with loose wheel nuts can lead to a serious accident. UUVO456A

UD120-OM-Hauler 4X4 Diesel Crew-30 30 2015-05-22 오후 3:26:11 CONTROLS AND FEATURES 4 -31

Proper inflation pressure

WARNING Always maintain the proper tire inflation pressure. Make sure the tire pressure does not exceed the pressure recommended in the manual.  Do not use tires larger or Inflation Wheel nut smaller than specified. Item Type Remarks  Do not disassemble or assem- pressure torque 4.0~4.6 kgf.m ble the tire. If it is necessary to Work site 25x10-12(6PR) 12 PSI Standard disassemble/assemble the tire, 28.9~33.3 lb.ft Front 4.0~4.6 kgf.m let a qualified service person All terrain 25x10-12(4PR) 12 PSI Option perform the work. wheel 28.9~33.3 lb.ft  4.0~4.6 kgf.m The tire rims can fall out of the Turf 25x10-12(4PR) 12 PSI Option tires. Therefore, stay out of its 28.9~33.3 lb.ft 4 4.0~4.6 kgf.m way when checking or inflating Work site 25x11-12(6PR) 18 PSI Standard tires. 28.9~33.3 lb.ft Rear 4.0~4.6 kgf.m All terrain 25x11-12(6PR) 18 PSI Option wheel 28.9~33.3 lb.ft 4.0~4.6 kgf.m Turf 25x11-12(6PR) 18 PSI Option 28.9~33.3 lb.ft

NOTE  If tires with a different size from the ones specified are installed, contact the dealer for the front/rear wheel speed ratio. Improper front/rear wheel speed ratio can result in excessive wear of the tires.

UD120-OM-Hauler 4X4 Diesel Crew-31 31 2015-05-22 오후 3:26:11 4 -32 HAULER 4X4 DIESEL CREW

UUVO459A

WARNING  Do not weld or apply heat to the tire rim or disc. The tire can explode due to the rapidly increased pressure in the tire.  Check tires for inflation pressure, damage, deformation, and extended wear on lug and damage of the rim and disc. Also, check if the wheel bolts, rim bolts, and nuts are loose.

UD120-OM-Hauler 4X4 Diesel Crew-32 32 2015-05-22 오후 3:26:12 OPERATION

PRE-OPERATION...... 5-2 Driving in forest...... 5-17 Driving through water...... 5-17 Daily inspection...... 5-2 Driving backward...... 5-18 Driving on road...... 5-19 OPERATING THE ENGINE...... 5-2 Transporting cargo...... 5-19 5 Starting the engine...... 5-2 Unloading (manual model)...... 5-21 Checking warning lamps Towing trailer...... 5-22 after starting engine...... 5-5 Transporting...... 5-23 Operating principle of preheat system...... 5-6 4WD operation...... 5-24 Stopping the engine...... 5-6 DiffERENTIAL lock operation...... 5-25 Tailgate (back door)...... 5-26 5 OPERATING THE VEHICLE...... 5-7

HOW TO DRIVE...... 5-7 Warming up...... 5-10 Jump start...... 5-11 Stopping...... 5-12 Parking...... 5-12 Shifting...... 5-13 Driving on slippery surfaceS...... 5-14 Turning...... 5-15 Driving on slope...... 5-15

UD120-OM-Hauler 4X4 Diesel Crew-1 1 2015-05-26 오전 9:55:19 5- HAULER 4X4 DIESEL CREW PRE-OPERATION OPERATING THE ENGINE Daily inspection Starting the engine Check item  It is a good practice to know the con- Check the engine oil level. WARNING dition of your vehicle before you start  Check the engine coolant level. it. You should do routine check be- To avoid accidents:  Clean the radiator grille.  fore each use. Be sure to read and under-  Check the air cleaner filter. stand the warning and cau- CAUTION  Check the brake pedal. tion decals on the vehicle thor-  oughly. Stop the vehicle on level  Check the gauges and indicators  ground, stop the engine and on the instrument panel. Run the engine only in a well- ventilated area, or you can be apply the parking brake before  Check the headlamps and turn checking or servicing the vehi- suffocated by exhaust gas. signal lamps.  cle. Never start the engine unless  Check the fuel level.  For refueling, refer to the chap- you are on the driver's seat. ter "Maintenance."  Visually check the tire inflation The vehicle can abruptly start  Read information titled as pressure and wheel nut tightness. off, resulting in an injury or ac- "Danger", "Warning", and For more information, refer to the cident. "Caution" thoroughly for the chapter "Maintenance." safe operation. IMPORTANT  Using an additive so the engine will start more easily can damage the engine. And it will not be covered by warranty.  To protect the start motor and battery from damage, never try to start the engine for over 10 seconds consecutively.

UD120-OM-Hauler 4X4 Diesel Crew-2 2 2015-05-26 오전 9:55:19 OPERATION 5-

1. Make sure there is no obstacle around the vehicle. 2. Make sure to fasten your seat belt on the driver's seat and apply the parking brake firmly. NOTE  The parking brake indicator on the instrument panel comes on while the parking brake is en- UUVO501A H11O503a gaged. It goes off when the parking brake is released. (1) Shift Lever  The buzzer sounds when operat- 5 ing the shift lever without releasing the parking brake. Make sure 3. Check that the shift lever is in the to release the parking brake be- "N" (Neutral) position. fore starting off. Failure to do so could reduce the life of the park- NOTE ing brake disk.  The vehicle is equipped with the safety switch for starting at the "N" position. Therefore, the en- UUVO502D gine can be started only when (1) Brake Pedal (2) Parking Brake the shift lever is in the "N" posi- (A) Depressing (B) Push tion. (C) Pull

UD120-OM-Hauler 4X4 Diesel Crew-3 3 2015-05-26 오전 9:55:20 5- HAULER 4X4 DIESEL CREW

WARNING  Never operate the start motor for 10 consecutive seconds as it consumes a lot of battery power. If the engine cannot be started within 10 seconds, wait for 30 seconds and try again.  When trying to start the engine again, make sure that the fly- U12O411A U12O504A wheel is stopped in advance.  Do not turn the key switch to (1) Key Switch (A) Stop (B) ACC (1) Glow Plug Indicator (C) ON (D) Heat (E) Start (2) Battery Charge Warning Lamp the "START" position while the (3) Oil Pressure Warning Lamp engine is running. 4. Insert the key into the key switch 5. Check that the following lamps are 7. When the engine is started, re- and turn it to the "ON" position. turned ON. lease the key. The key switch is  Charge warning lamp automatically returned to the "ON" position.  Oil pressure warning lamp 8. After the engine is started, let the  Glow plug indicator (9 sec.) engine run for approx. 3 to 4 min- 6. Turn the key to the "START" posi- utes (10 minutes in cold weath- tion as soon as the glow plug indi- er) to warm up the engine. (Refer cator goes off. to "Warming up" page 5-10 for details)

UD120-OM-Hauler 4X4 Diesel Crew-4 4 2015-05-26 오전 9:55:21 OPERATION 5-

Checking warning lamps after starting engine

9. Check to see that all the warning 1. If the oil pressure warning lamp WARNING lamps on the instrument cluster does not go off in 4 to 5 seconds  turn "OFF". If any lamp remains after the engine is properly start- Driving the vehicle for an ex- ON, immediately stop the engine, ed, stop the engine immediate- tended period of time with the and contact your local dealer for ly and check the engine oil level. charge warning lamp ON, the assistance. If the engine oil level is within safe battery can be discharged and operating limits, contact your local the vehicle's electrical system IMPORTANT Dealer. can be damaged.

 It is not recommended to oper- WARNING ate the vehicle full speed or ex-  cessive load when new. Doing so The engine can be severely can harm the overall service life damaged if it is run with the oil of the vehicle. pressure warning lamp ON. 5 break in the vehicle by driving 2. If the charge warning lamp does with light work loads or at a maxi- not go off in 4 to 5 seconds after mum of 3/4 throttle for the first 20 the engine is properly started, it hours. means that the battery is not being properly charged. Have the charging system, such as the battery and alternator, serviced. 3. Refer to "Instrument panel" in chapter 4 for detailed information about other indicators and lamps.

UD120-OM-Hauler 4X4 Diesel Crew-5 5 2015-05-26 오전 9:55:21 5- HAULER 4X4 DIESEL CREW

Operating principle of Stopping the engine preheat system 1. When the key switch is turned to 1. Make sure to reduce the engine CAUTION the “ON” position, the glow plug rpm before stopping the engine.  Apply the parking brake and indicator comes on for 9 seconds 2. Put the shift lever in the neutral remove the key from the key and then goes off . The engine position. should be started within 3 seconds switch before leaving your ve- 3. Apply the parking brake. after the glow plug indicator goes hicle. An unauthorized person off. 4. Run the engine at idle speed for or child can move or operate approx. 2 to 3 minutes, and then the vehicle, resulting in an in- 2. After the engine is started, post- turn the key switch to the “OFF” jury or accident. heat is performed without any indi- position to stop the engine.  This vehicle is equipped with cating lamp on. The post-heating a CVT (Continuous Variable function keeps the glow plugs ac- 5. Remove the ignition key. Transmission). Therefore, the tivated for approx. 20 seconds af- vehicle may roll down a slope ter the engine is started in order to WARNING  if the parking brake is not en- enhance the engine combustion Never touch the muffler or heat gaged even though the shift le- performance and reduce harmful shield until the engine is suffi- ver is in the "H", "L" or "R" po- emissions right after engine starts. ciently cooled down. Failure to do so could result in sition. 3. The preheat/post-heat function serious injury on burns. and glow plug indicator do not op- IMPORTANT erate when the coolant temper-  If the vehicle is operated for an ature is 30℃ (86℉) or higher. In extended period of time, idle this case, the engine can be start- the engine at low speed for 2 ed without the preheat operation. to 3 minutes in order to cool 4. In case extra preheating is needed, down the engine before shut- hold the key in ( )position . Do not down. preheat more than 30 seconds.

UD120-OM-Hauler 4X4 Diesel Crew-6 6 2015-05-26 오전 9:55:21 OPERATION 5- OPERATING THE VEHICLE HOW TO DRIVE

IMPORTANT WARNING  When leaving the vehicle,  Fasten the seat belt firmly make sure to remove the key when you are seated in the ve- after turning off all the electri- hicle. cal systems.  The seat belt can reduce or  Also, be careful not to leave the prevent injuries in an accident. utility vehicle unattended as Make sure to wear the seat belt the same key is used for all ve- during driving. Also, be sure hicles. It can be stolen. the seat belt is not twisted. A  The horn, turn signal lamps and UUVO435c twisted or improperly fastened hazard warning lamps can be seat belt may not protect an (1) Seat Belt operated without the key in the occupant properly, in an acci- 5 key switch. Therefore, special dent. care must be taken to prevent  1. Sit down on the seat and fasten The seat belt should go around the battery from discharging. the seat belt. your pelvis or as low as possible, not your waist or abdo- men. Otherwise, the seat belt cannot protect you properly.  Children under age 16 or who doesn’t have a driver’s license should not drive this vehicle.  Childrem under age 5 should not ride on this vehicle even in the passanger seat.

UD120-OM-Hauler 4X4 Diesel Crew-7 7 2015-05-26 오전 9:55:22 5- HAULER 4X4 DIESEL CREW

UUVO503A U12O505a UUVO506A

(1) Shift Lever (1) Parking Brake (1) Shift Lever h: High Speed (A) Push (B) Release L: Low Speed n: Neutral R: Reverse 2. Start the engine after checking 3. Release the parking brake. 4. Place the shift lever to the "H" that the shift lever is in the neutral (High speed) or "L" (Low speed). position. 5. Press the accelerator pedal gradu- ally to start off the vehicle. 6. The 4WD system can be used as necessary.

UD120-OM-Hauler 4X4 Diesel Crew-8 8 2015-05-26 오전 9:55:22 OPERATION 5-

CAUTION IMPORTANT  Avoid abrupt acceleration or  Do not shift the gear when the braking for safe driving. vehicle is moving or the en-  When driving on a steep hill or gine is running at a high idling loading or unloading the vehi- speed. To stop the vehicle, cle from the transportation ve- press the brake pedal, and hicle, set the shift lever into then move the shift lever. the "L" position or the 4WD/  Shifting at a high idling speed 2WD lever into the "4WD" po- can wear the gears. sition in advance. UUVO507A  Practice starting and stopping (1) Brake Pedal (2) Accelerator Pedal the vehicle with the pedals and (A) Depressed levers until getting used to 5 these controls. 7. To stop the vehicle, release the  Place the shift lever into the accelerator pedal and press the "L" position when driving on a brake pedal. soft or bumpy surface or carrying a heavy load.

UD120-OM-Hauler 4X4 Diesel Crew-9 9 2015-05-26 오전 9:55:23 5 -10 HAULER 4X4 DIESEL CREW

Warming up

It is recommended always to warm 5. The engine is sufficiently warmed up the engine before driving in order up when the temperature gauge to maintain the durability of the en- on the instrument panel indicates gine and prevent malfunction of the 1/4 of the normal temperature engine. range, regardless of the warming- Warming up the engine can ensure up time. that each part in the engine is prop- 6. Do not increase the work load or erly lubricated and each hydraulic driving speed rapidly after starting part is in a perfect condition in order work. to prevent malfunction in the engine 7. Run the engine without load or idle as well as the hydraulic system. UUVO504A for approx. 2 to 3 minutes before stopping the engine after work. How to warm up engine 1. Start the engine and run it at a low WARNING speed and without load for approx.  Warming up the engine exces- CAUTION 3 to 4 minutes. sively increases fuel consump-  Avoid running the engine in an 2. In cold weather, increase the tion and affects the durability enclosed area. Inhaling emis- warming up time to 10 minutes. of the vehicle negatively. sions can harm your health.  3. If it is very cold, warm up the en- Never warm up the engine and  If it is unavoidable to run the gine for approx. 15 minutes. leave the vehicle for an extend- engine in an enclosed area, 4. The engine throttle can be open ed period of time. It can cause make sure to ventilate the area for 50 % in order to shorten the fire and an accident. properly and take proper ac- warming up time. tions to avoid inhaling emissions.

UD120-OM-Hauler 4X4 Diesel Crew-10 10 2015-05-26 오전 9:55:23 OPERATION 5 -11

Jump start

1. Check that the voltage of the dis- 6. start the engine of the vehicle charged battery is the same as with the normal battery. the voltage of the other vehicle for 7. start the engine of the vehicle jump start (specification for this with the discharged battery. vehicle: 12 V). 8. Disconnect the black cable from 2. Check the length of the jumper ca- the negative battery terminals of bles and position another vehi- both of the vehicles. cle near the vehicle with the dis- 9. Disconnect the red cable. charged battery. Then, put the shift lever in the neutral position, 10. Run the engine for at least 30 UUVO508A apply the parking brake, and stop minutes to charge the discharged (1) Battery the engine. battery. 3. Wear protective glasses and 11. If the battery is discharged again, 5 gloves and open the battery cover replace it or check the charging If the battery is discharged and the of both vehicles. Remove the bat- system, such as the alternator. engine cannot be started, it is possi- tery terminal cover as necessary. ble to start the engine by connecting 4. Connect the alligator clips on both the discharged battery to a battery ends of the red positive cable to the from another vehicle or other extra positive terminals of both batteries. battery. 5. Connect one clip of the black negative cable to the negative terminal of the normal battery and the other clip to the vehicle body with the discharged battery. Make sure to connect the clip to the body part without paint.

UD120-OM-Hauler 4X4 Diesel Crew-11 11 2015-05-26 오전 9:55:23 5 -12 HAULER 4X4 DIESEL CREW

Stopping Parking

Press the brake pedal to control the NOTE driving speed.  This vehicle does not have an 1. Release the accelerator pedal engine brake function. Always completely. check the brake function before 2. Press the brake pedal evenly and operating the vehicle. firmly.  This vehicle is equipped with the parking brake system and main WARNING brake system separately for safe-  The stopping distance increas- ty. The parking brake should be es when loaded with cargo or used in an emergency, such as towing a trailer. In this case, brake pedal failure. drive at a low speed and al-  Never press the accelerator and ways consider the actual stop- brake pedals simultaneously. ping distance.

U12O509e (1) Chock (2) Parking Brake Lever (A) Push (B) Pull

UD120-OM-Hauler 4X4 Diesel Crew-12 12 2015-05-26 오전 9:55:23 OPERATION 5 -13

Shifting

When parking, make sure to pull up WARNING This vehicle is equipped with the the parking brake fully. CVT (Continuous Variable Transmis- To avoid possible injury, death The parking brake in the vehicle is sion) and the shifting operation is au- or loss of property from a ma- equipped with separate disc and pad tomatic according to the accelerator chine runaway: in order to enhance safety. Make pedal operation and outer load con- sure to use the parking brake in  With the engine off, unexpect- dition. emergencies, such as brake pedal ed machine movement could Make sure to move the shift lever to malfunction, during driving. result regardless of the gear the "H", "L" or "R" position when the shift position. vehicle is stationary. In order to stop WARNING  Before dismounting the ma- the vehicle, release the accelerator  Never park on a slope with chine, apply the parking brake pedal and depress the brake pedal only the transmission en- to prevent machine runaway. as necessary. gaged. The vehicle may roll ※ Only CVT model. 5 down, leading to an accident. WARNING  If it is unavoidable to park on  If moving the shift lever to a slope and leave the vehicle, the "H", "L" or "R" position apply the parking brake and while the vehicle is moving or chock the wheels. the accelerator pedal is de-  Never park the vehicle on a pressed, the internal gears re- steep slope. A serious acci- lated to the shifting operation dent can occur. can be severely damaged.

UD120-OM-Hauler 4X4 Diesel Crew-13 13 2015-05-26 오전 9:55:23 5 -14 HAULER 4X4 DIESEL CREW

Driving on slippery surfaceS

3. Avoid abrupt acceleration and WARNING turning during driving on a slippery  road. It is recommended to use the 4WD on a slippery road. Using 4. If the vehicle cannot move for- the 4WD can increase the driv- ward due to spinning wheels, stop ing force of the wheels as well the vehicle, engage the differential as the braking performance lock lever and then try again. on a slippery road. Also, it re- WARNING duces a chance of the vehicle skidding at abrupt braking.  Abrupt braking or acceleration UUVO510A  It is a best measure to drive at in the 2WD operation on a slip- a low speed with the 4WD and pery surface can make the rear low gear position selected on wheels slide to one side, re- a slippery surface. Otherwise, sulting in the vehicle skidding. the vehicle can roll over or col- It is possible that the vehicle can skid Make sure to use the 4WD in lide. with its rear side sliding to one side advance in this case. when driving on a muddy, icy or slip-  When the vehicle starts to pery road. Therefore, when driving skid with the rear wheels spin- in this circumstance, observe the fol- ning, release the accelerator or lowing: brake pedal and turn the steer- 1. Slow down before you enter a slip- ing wheel to the spinning di- pery area. rection immediately.  2. Before entering a slippery area, If it is necessary to brake the move the shift lever to the "L" po- vehicle abruptly on an icy or sition and 2WD/4WD lever to the slippery road, depress the "4WD" position as necessary. brake pedal for several times.

UD120-OM-Hauler 4X4 Diesel Crew-14 14 2015-05-26 오전 9:55:23 OPERATION 5 -15

Turning Driving on slope Uphill and downhill Before entering a curved road, slow WARNING down your speed. Turning at a high speed can lead the vehicle off the To prevent an accident due to course, resulting in a severe acci- loss of steering control: dent.  If turning at a high speed, the vehicle can turn over. Be careful not to lose balance during  Never use the differential lock turning. The driver and all occupants system when turning at a should wear the seat belts. If the dif- high speed and even at a low ferential lock system is used during 15 Maximum speed. A serious accident can turning on a normal road with suffi- occur. UUVO511A cient friction, the durability of the internal gears related to the differential system can be damaged. Also, there 5 is a high chance that the vehicle can over turn due to poor steerability. 1. Move the shift lever into the "L" If cargo is loaded onto the cargo bed position before driving uphill. Also, too high, the center of gravity of the select the 4WD as necessary de- vehicle gets high and the centrifugal pending on road surface condi- force increases when turning. There- tions. fore, drive slower when turning. 2. Avoid driving on a slope of 15° or more. Drive the vehicle at a low speed so that the engine is not applied with excessive load.

UD120-OM-Hauler 4X4 Diesel Crew-15 15 2015-05-26 오전 9:55:24 5 -16 HAULER 4X4 DIESEL CREW

Hill inclined sideward 3. It is hard to steer the vehicle 1. When driving on a road inclined WARNING and the front section of the ve- sideward, be extra careful not to hicle can be lifted off the ground let the vehicle overturn sideward.  When driving on a road inclined vertically or sideward, when driving on a slope with ex- 2. The best measure to prevent over- make sure to drive at a low cessive cargo loaded in the vehi- turn on a road inclined sideward is speed. Otherwise, the vehicle cle. In the worst case, the vehicle driving at a low speed. may roll over down the hill. There- can roll over, leading to a seri- 3. Never drive on a road inclined fore, avoid carrying excessive load ous accident. sideward for 12° or more. when driving on a slope and drive  Driving with excessive load on backward uphill if necessary. 4. If starting to lose balance while a slope can lead to overturn. driving forward on a road inclined  Always wear the seatbelt and 4. This vehicle is equipped with the sideward, turn the steering wheel safety gears, such as a helmet, CVT (Continuous Variable Trans- to the downhill direction to gain when driving on a slope. mission), there is no engine brake control of the vehicle again. function. Therefore, make sure to press the brake pedal to reduce 5. Be extra careful when driving with the speed when driving downhill. cargo loaded. 5. Never drive backward downhill with cargo loaded. The vehicle can roll over.

UD120-OM-Hauler 4X4 Diesel Crew-16 16 2015-05-26 오전 9:55:24 OPERATION 5 -17

Driving in forest Driving through water

Consider the following when driving through water: 1. Check the depth and speed of water or water flow before entering it. 2. Avoid a steep path when driving through water. 3. Be careful not to hit a rock or obstacle and drive at a low speed. 4. Drive slowly with 4WD. UUVO512A UUV513A 5. After driving through water, press the brake pedal several times to dry the brake disc for normal 5 brake operation. 1. Drive at a low speed when driving This vehicle can go through water as in a mountainous area or through high as the floor of the vehicle. WARNING a forest. Make sure to check the depth of wa-  Driving through water without 2. Wear protective gear, such as ter before entering. When driving knowing depth, speed and bot- a helmet to avoid an injury by through deep water, the wheels may tom condition of waterflow is branches. lose traction so that you cannot con- very dangerous and can lead 3. Be sure to wear the seat belt to trol the vehicle, leading to an acci- to a drowning accident.  minimize a chance of injury by col- dent. Make sure to observe the spec- If driving on a slope or at a lision with a tree or rock. ified water depth limit. high speed with the brake wet Never drive through swift water flow after driving through water, the even though its depth is below the brake system may not function height of the vehicle floor. properly, leading to an accident.

UD120-OM-Hauler 4X4 Diesel Crew-17 17 2015-05-26 오전 9:55:24 5 -18 HAULER 4X4 DIESEL CREW

Driving backward

CAUTION WARNING  Salty water corrodes paint and  If precautions are not taken exterior parts of the vehicle. during driving backward, a se- Make sure to wash the vehicle rious accident can occur. thoroughly with tap water. Check if there is any obstacle  If any part is corroded by salty or person behind the vehicle (sea) water, it may not be cov- before driving backward. Also, ered by warranty. keep the speed slow.

NOTE H11O515A  It is required to service the vehicle after driving through water. Pay special attention to the engine oil, transmission fluid, front/ Consider the following when driving rear differential gear cases and backward: grease fittings. 1. Drive backward at a low speed. To stop the vehicle, press the brake pedal gently. 2. Avoid abrupt turning and driving down the slope backward. 3. Never press the accelerator pedal abruptly and pay close attention to the surroundings before driving backward.

UD120-OM-Hauler 4X4 Diesel Crew-18 18 2015-05-26 오전 9:55:24 OPERATION 5 -19

Driving on road Transporting cargo

Observe the following when driving WARNING 1. Distribute cargo evenly onto the on a road: cargo bed when driving.  When driving on a road, make 1. It is recommended to attach the 2. For the vehicle without the hy- sure to install the "Safety lamp "Safety lamp kit" (optional) from draulic dump kit (optional), it is kit" supplied by dealer and ob- dealer when driving on a public hard to raise the cargo bed if the serve the applicable regula- road. load is concentrated to the front tions and laws. If the vehicle is side of the vehicle. 2. If the vehicle is equipped with the not equipped with the "Safe- turn signal lamps, use them during ty lamp kit", there will be no 3. The max. load limit for the vehicle driving. If not, inform other driv- brake lamps, turn signal lamps is 500 kg (1100 lbs). Make sure ers of your intended direction with and tail lamps on the vehicle. to keep under this specified limit. hand signals. In this condition, it is very dan- Otherwise, steerability and brak- 3. It is strongly recommended to in- ing performance are degraded gerous to drive on a road. 5 stall the "Safety lamp kit" when  In some countries or states, and you may lose control of the driving on a road at night. it is illegal to drive a UTV on vehicle, leading to a severe accident. 4. Driving with high beam headlights public roads. Be aware of traf- makes it difficult for the driver of fic laws before driving. 4. Load cargo only up to half of the an on coming vehicle to see. Use load limit when driving on a steep, high beams only if necessary. bumpy or slippery road. 5. When loading wide or long objects, secure them with ropes firmly. The vehicle should be equipped with the rear screen (option) so that such objects do not hit the back of the driver.

UD120-OM-Hauler 4X4 Diesel Crew-19 19 2015-05-26 오전 9:55:24 5 -20 HAULER 4X4 DIESEL CREW

6. When loading heavy material, 11. If an object, such as a rock, is such as sand and earth, distribute loaded, but not secured onto the it evenly in the cargo bed and do cargo bed, driving on a slope, not pile it over the side frame of abrupt starting-off or abrupt brak- the cargo bed. ing can damage the cargo bed 7. Wet sand weighs at least twice as parts and lead to an accident due much as dry sand. Therefore, load to the object rolling on the car- sand less if it is wet. go bed. Make sure to secure any cargo firmly. 8. Make sure to distribute cargo evenly in the cargo bed. Other- UUVO515A WARNING wise, the vehicle can overturn. 9. Never let anyone ride on the car-  If loading cargo excessive- go bed. It can lead to a serious ly or unevenly, you can lose accident. steerability and braking con- 10. The brake system is applied with trol, resulting in a severe acci- excessive load when driving on dent. Make sure to keep under a slope with excessive cargo. the specified load limit and ob- Therefore, load only up to half serve relevant regulations.  of the specified load limit when Avoid overspeed driving, driving on a slope. abrupt acceleration and abrupt starting-off in order to prevent accidents when the vehicle is loaded.  M a k e s u r e t o s e c u r e c a r - go firmly so that it does not hit the driver. Install the rear screen (optional) if necessary.

UD120-OM-Hauler 4X4 Diesel Crew-20 20 2015-05-26 오전 9:55:24 OPERATION 5 -21

Unloading (manual model)

1. Open the tailgate with both hands. 4. After raising the cargo bed, make Be careful as the tailgate can open sure support is latched in the abruptly due to cargo on the cargo groove (A) firmly. bed. 5. Never drive the vehicle with the 2. To raise the cargo bed, pull up the cargo bed raised. If the support handle with one hand while turn- rod comes off the groove by vibra- ing the latch lever with the other tion, the cargo bed will fall, leading hand. to an accident. 3. Never apply excessive force to 6. To lower the cargo bed, place the

raise the cargo bed as you may U12O446a support rod off the groove and get injured. In this case, unload lower the cargo bed slowly. some cargo on the front with a (1) Duping Ratchet (2) Duping Handle (A) Turn (B) Pull Up 7. The hydraulic dump kit can be shovel or other tools, before trying used as an option. This kit is ide- 5 again. al for vehicles which carry heavy loads often.

U12O516A

(1) Cargo Support (A) Support Groove

UD120-OM-Hauler 4X4 Diesel Crew-21 21 2015-05-26 오전 9:55:25 5 -22 HAULER 4X4 DIESEL CREW

Towing trailer

WARNING This vehicle is equipped with a 2-inch square hitch receiver in the back as  A part of your body may get standard. Be careful of the following between the vehicle body and when towing a trailer cargo bed or your waist can 1. This vehicle can tow a trailer and get injured while raising or cargo with their weight of up to lowering the cargo bed. Never 590 kg (1300 lbs). You can lose apply excessive force to raise control of the vehicle, leading to the bed and pay special atten- an accident if towing more than tion to install the support rod specified. UUVO517A properly. 2. The max. vertical load applica- WARNING ble to the tow hitch is 59 kg (130 lbs) which is 10% of the total tow-  Make sure to check the ground ing load limit. If this specification is condition before driving back- not met, the vehicle can turn over wards to unload. backward.  Apply the parking brake firmly 3. It is very hard to drive backward before unloading. with a trailer connected. Keep the  Never drive the vehicle with speed low. the cargo bed raised. The cargo bed can fall accidentally, resulting in an accident.

UD120-OM-Hauler 4X4 Diesel Crew-22 22 2015-05-26 오전 9:55:25 OPERATION 5 -23

Transporting

[Tips for driving backward with trailer] If a trailer is about to go out of a cor- A rect course during driving backward, turn the steering wheel to the direc-

tion which the trailer goes then the A trailer returns to its original course.

UUVO518A UUVO519A

4. When driving over an excessive- 1. Check the width of the cargo bed ly concave or convex surface, ex- of a transporting vehicle or trailer. cessive stress is applied to the 2. Set ramps to the transporting vehi- hitch connection. A ball-type hitch cle firmly. (A) is recommended in this case. 3. It is recommended to drive backward onto the transporting vehicle to drive out of it more easily later. 4. Make sure to set the shift lever to the "L" position and the 2WD/4WD lever in the "4WD" position.

UD120-OM-Hauler 4X4 Diesel Crew-23 23 2015-05-26 오전 9:55:25 5 -24 HAULER 4X4 DIESEL CREW

4WD operation

5. After getting onto the transporting WARNING vehicle, apply the parking brake firmly and secure the vehicle onto  Make sure to secure the vehi- the body frame or bracket of the cle firmly during transporta- transporting vehicle with chains or tion. belts.  The canopy, windshield or other components, which can be 6. When transporting the vehicle on accidentally removed by wind a road, set applicable decals to during transportation, should keep local regulations. be removed in advance before 7. Always keep the total height in transportation and transported UUVO520A mind so that the vehicle top does separately. (1) 2WD/4WD Shift Lever not hit under a bridge or the top of  The above precautions should (A) 2WD (B) 4WD a tunnel. be kept in order to avoid a serious accident during trans- The rear wheels are driven in the portation. 2WD mode while all the wheels are driven in the 4WD mode. Keep the following instructions to use the 4WD correctly: 1. It is recommended to use the 4WD when driving on a slippery, muddy or icy road, driving through water or driving to load or unload the vehicle to the transporting vehicle.

UD120-OM-Hauler 4X4 Diesel Crew-24 24 2015-05-26 오전 9:55:26 OPERATION 5 -25

DiffERENTIAL lock operation

2. When moving the 2WD/4WD le- 5. In some cases, it may be hard to ver, push up the detent knob with move the 2WD/4WD shift lever out a finger and then move the lever. of the "4WD" position. This is be- 3. To operate the shift lever, depress cause parts related to the shift- the brake pedal and stop the ve- ing operation are firmly engaged. hicle completely. It is hard to shift These parts can be released easi- when the vehicle is moving or the ly by changing the driving direction engine is running at a high idling (forward or backward). speed. Moreover, abnormal noise may occur and parts related to WARNING the shifting operation can be dam-  Never try to shift the gear UUVO521A aged. while the vehicle is moving or (1) Differential Lock Lever 4. Move the 2WD/4WD lever back to the engine is running at a high (A) Unlock (B) Lock 5 the "2WD" position as soon as the speed. The power transfer sys- 4WD is not necessary. Prolonged tem can be severely damaged On hard firm ground, the differential use of the 4WD in a normal con- and an accident can occur. system should be unlocked to secure dition can increase the fuel con- safe turning. sumption and decrease the dura- When the wheel on one side is on a bility of parts related to the power slippery surface, such as mud or icy transfer system. It also affects the road, the wheels on a slippery sur- steering performance negatively. face lose traction and rotate fast while the wheel on a normal surface do not rotate, resulting in the vehicle stuck into its position. In order to prevent this situation, this vehicle is equipped with the differential lock system.

UD120-OM-Hauler 4X4 Diesel Crew-25 25 2015-05-26 오전 9:55:26 5 -26 HAULER 4X4 DIESEL CREW

Tailgate (back door)

[Differential lock system] The differential lock system is to connect the wheel on the left and right mechanically to rotate them at the same speed regardless of friction applied to them even on a slippery or bumpy road for better traction.

H11O585AU12O522A H11O585AU12O523A

(1) Latch Lever (1) Gate

1. When opening the tailgate, it can 2. Keep your feet as far as possible open abruptly due to cargo on the as any object can fall off the car- cargo bed. Therefore, support the go bed when the tailgate opens upper side of it with both hands abruptly. when pushing the latch lever.

UD120-OM-Hauler 4X4 Diesel Crew-26 26 2015-05-26 오전 9:55:26 REPLACEMEnT PARTS

Essential replacement part..... 6-2 Oil and fluid...... 6-2 6 Filters...... 6-2 Belts and rubber parts...... 6-3 eLECTRIC PARTS ...... 6-3

UD120-OM-1600XD4-06.indd 1 2015-05-22 오전 8:52:47 6- HAULER 4X4 DIESEL CREW REPLACEMENT PARTS 6- Essential replacement part Oil and fluid Filters U.S.Gal.(L)

NO ITEM SPECIFICATION CAPACITY

Engine 1 SAE 15W40 8.45 (30) Oil Gear DAEDONG 2 0.23 (0.9) Box UTF55 Front Exxonmobil 3 0.16 (0.6) Differ. Mobilfluid 424 Exxonmobil Rear 4 Hydraulic 560 0.21(0.8) Differ. Shell:Donax TD UUVO601A SAE multifunc- UUVO602A 5 Grease A little tional Anti- Ethylene glycol There are various types of oil and flu- 6 1.66 (6.3) The various filters and air cleaner are ids used in this vehicle for the opera- freeze and water (50:50) consumable to filter foreign materials Brake tion, lubrication, cooling and anti-cor- 7 DOT 3 - from oil and air. Make sure to check rosion of the vehicle. Oil or replace these parts when chang- If any oil or fluid is insufficient, de- ing oil. graded or contaminated, it can cause incorrect operation and seizure, resulting in damage of the vehicle. In order to protect the vehicle properly and keep it in a perfect condition, make sure to refill or change the oil and fluid specified in accordance with the maintenance intervals. Refer to chapter 7 "Maintenance".

UD120-OM-1600XD4-06.indd 2 2015-05-22 오전 8:52:47 6- HAULER 4X4 DIESEL CREW REPLACEMENT PARTS 6-

Belts and rubber parts eLECTRIC PARTS

N0 PART NO DESCRIPTION QTY

1 E5205-32091 Engine Oil Filter 1

2 84612-4316-0 Fuel Filter Element 1

3 T2350-11641 Air Filter 1

UUVO603A UUVO604A

Rubber belts, hoses and boots get N0 PART NO DESCRIPTION QTY tender and cracked as they age. con- tinuos use of a belt, hose or boot in 1 2350-69571 Headlight Bulb 1 poor condition can result in pact fail- 6 ure, causing a serious problem to the 2 52794-42421 Slow Blow Fuse 1 vehicle. Make sure to replace such 3 T2185-33651 Fuse 5A 3 parts at the specified intervals in order to prevent accidents. 4 T4260-33631 Fuse 10A 3 5 35820-7556-1 Fuse 15A 4 N0 PART NO DESCRIPTION QTY 6 36919-5665-0 Fuse 20A 2 1 E5760-72532 Fan Belt 1 7 36919-5666-1 Fuse 25A 2 2 U3215-29081 CVT Belt 1

3 U3215-40001001 Brake pad 8

UD120-OM-1600XD4-06.indd 3 2015-05-22 오전 8:52:48 MEMO

UD120-OM-1600XD4-06.indd 4 2015-05-22 오전 8:52:48 MAINTENANCE

Maintenance check list...... 7-3 BLEEDING FUEL LINE (M)...... 7-18 Checking injection nozzle Daily check chart...... 7-3 and fuel injection pump (N)...... 7-19 MAINTENANCE interval table...... 7-4 Cleaning radiator core (O)...... 7-20 Checking coolant in auxiliary coolant tank (P)...... 7-21 7 LUBRICANTS...... 7-6 Changing coolant (Q)...... 7-22 Daily inspection...... 7-7 Checking spark arrester of exhaust pipe (if equipped) (R)...... 7-24 Access for service...... 7-7 Checking and changing Opening inspection shield (A)...... 7-7 gearbox oil (S)...... 7-24 Opening seat cushion (B)...... 7-8 Checking and changing front axle oil (T)...... 7-26 Raising cargo bed (C)...... 7-8 Checking and changing rear Applying grease (D)...... 7-9 axle oil (U)...... 7-27 Checking engine oil level (E)...... 7-10 Checking drive shaft and Changing engine oil and filter (F)..... 7-11 CV boots (V)...... 7-28 dust valve (G)...... 7-13 Checking steering rack 7 boots and ball joint (W)...... 7-29 Replacing air filter (H)...... 7-13 Checking brake fluid (X)...... 7-30 Checking air hose and clamp(I)...... 7-14 Checking brake pedal free play (Y).... 7-31 Checking CVT belt (J)...... 7-14 Checking brake pad (Z)...... 7-31 Checking CVT driven pulley clutch buttons(K)...... 7-17 Checking parking brake (AA)...... 7-32 Checking fuel FILTER(L)...... 7-17 Adjusting suspension (AB)...... 7-33

UD120-OM-1600XD4-07.indd 1 2015-05-22 오전 8:53:08 MAINTENANCE

Checking suspension shock absorber (AC)...... 7-34 Battery (sealed) (AD)...... 7-35 Replacing headlamp bulb (AE)...... 7-37 Checking and replacing fuse (AF).....7-37 Main fuse (slow-blow fuse) (AG)...7-38 Aligning wheel and checking wheel nut (AH)...... 7-39 Checking differential lock cable (AI)...... 7-39 Checking shift and 4WD cables (AJ).....7-40 Using Biodiesel (AK)...... 7-41 Adjusting belt tension (AL)...... 7-41 Washing (AM)...... 7-42 Protecting plastic and painted surface(AO) ...... 7-42

UD120-OM-1600XD4-07.indd 2 2015-05-22 오전 8:53:08 MAINTENANCE 7- Maintenance check list Daily check chart

SERVICE SCHEDULE MAINTENANCE ITEM SERVICE REQUIRED CODES Clean debris from radiator, screen and grills. Check coolant level in the reser- Engine Cooling System O, P ,Q voir tank. Seat Belt Check the condition of seat belt and mounting hardware. Check for wear, damaged tires and air pressure. Tires Check wheel hub nuts are tightened. Parking Brake condition Check operation and adjust if required. AA

Brake condition Check operation and adjust if required.

Clean Pedals Clean brake pedals, travel control pedal, and footrest area. Y

Check for loose or broken parts, instrument General Items AE, AF, AG, AH operation, oil leaks and damaged or missing signs (decals).

※ For detailed information about maintenance codes, refer to the corresponding section in each chapter. 7

UD120-OM-1600XD4-07.indd 3 2015-05-22 오전 8:53:08 7- HAULER 4X4 DIESEL CREW

MAINTENANCE interval table ※ ⊙: Just once initially, ○: In every interval

INTERVAL RUN HOUR RUN AGE MAINTENANCE NO CHECK ITEM 10 50 100 200 300 400 800 1000 1YEAR 2YEAR codes 1 Engine oil and filter Replace ⊙ ○ F

2 Fuel filter Replace ○ L 3 Fuel line and hose connection Check ⊙ ○ M 4 Fuel tank and its filler cap Check ○ L, M

Check ○ 5 Air cleaner filter H Replace ○ Air intake hose connection 6 Check ⊙ ○ I and filter body anti-dust valve 7 Valve clearance Check ○ 8 Injection nozzle Check ○ N 9 Spark arrester Check ○ R 10 Coolant Replace ○ P

Cooling system (radiator grill, Check ⊙ ○ 11 coolant hose, cooling fan) O, P, Q 12 CVT belt Replace ○ J 13 CVT pulley and system Check ○ J. K

Check ⊙ ○ 14 Gearbox and front/rear axle oil S, T, U Replace ○

UD120-OM-1600XD4-07.indd 4 2015-05-22 오전 8:53:08 MAINTENANCE 7-

※ ⊙: Just once initially, ○: In every interval

INTERVAL RUN HOUR RUN AGE MAINTENANCE NO CHECK ITEM 10 50 100 200 300 400 800 1000 1YEAR 2YEAR codes Hydraulic oil 15 Replace ⊙ ○ S (if equipped with hydraulic kit) Pump, cylinder, levers, oil tank 16 and hoses related to hydraulic Check ○ kit (if equipped) 17 Brake fluid level Check ⊙ ○ X

18 Front/rear wheel and parking Check ○ brake pads AA, AC Suspension mounting bushing 19 Check ○ AC play and mounting rubber 20 Leakage from shock absorber Check ○ AC 21 Wheel hub bearing clearance Check ○

22 Wheel hub bolt tightness Check ⊙ ○ 23 Other bolt tightness Check ○ 7 24 Battery Check ○ AD 25 Steering rack and pinion, ball joint Check ○ W 26 Drive shaft and CV boots Check ○ 27 ROPS and safety belt Check ⊙ ○ 28 Greasing drive shaft Check ○ D

UD120-OM-1600XD4-07.indd 5 2015-05-22 오전 8:53:08 7- HAULER 4X4 DIESEL CREW LUBRICANTS To prevent serious equipment damage, use only indicated fluids, oils and greases, or equivalents.

NO. ITEM Capacity [ U.S. gal (L) ] LUBRICANTS 1 Fuel 7.4 (28.0) Diesel fuel Antifreezing solution (Ethylene glycol) + Pure 2 Coolant 1.7 (6.3) water (50:50) 3 Engine oil 0.9 (3.2) SAE 15W40

4 Gear Box Oil 0.24 (0.9) DAEDONG UTF55 Exxonmobil 5 Front differential case oil 0.16 (0.6) Mobilfluid 424 Exxonmobil Hydraulic 560 6 Rear differential case oil 0.2(0.8) Shell:Donax TD Grease 7  Rear axle drive shaft Small amount NLGI grade NO.2 or equivalent  Front wheel hubstrut

Optional hydraulic tank -Exxon: Mobil fluid 423 or 424, 8 oil for dumping kit and 4.76 (18) Exxon Hydraul 550 remote hydraulic kit -Shell: DONAX-TD

9 Brake Fluid - DOT3

WARNING  Check the oil level regularly. Correct the oil level, if needed, before operating.  Always check and add oil with the vehicle on a flat, level surface.

UD120-OM-1600XD4-07.indd 6 2015-05-22 오전 8:53:08 MAINTENANCE 7- Daily inspection Access for service Opening inspection shield (A)

This vehicle is designed so that it is easy to access the inspection points for service. Most of regular services can be performed by opening the inspection shield under the seat, seat and cargo bed.

U12O471A UUVO702A

(1) Inspection shield (1) Engine oil dipstick (2) Oil filter

To check the engine oil, unscrew It is possible to check the engine oil the mounting bolts of the inspection dipstick, oil filter, fan belt tension, shield under the seat and then open start motor power connection, etc. the inspection shield. after opening the inspection shield. 7

UD120-OM-1600XD4-07.indd 7 2015-05-22 오전 8:53:09 7- HAULER 4X4 DIESEL CREW

Opening seat cushion (B) Raising cargo bed (C)

UUVO703A U12O704A U12O446a

(1) Seat (1) Pin (1) Ratchet Lever (2) Lever Lock Bracket (A) Up (B) Down

To close the seat cushion, align It is possible to check the gearbox oil, the pins under the cushion with CVT, muffler, air filter, fuel strainer, the holes and then push down the parking brake pad for wear and play, cushion gently. shift lever cable and differential lock Most of the engine services, includ- cable play by raising the cargo bed. ing engine oil change and head Also, most of the service items can be cover repair, can be performed by inspected by lifting the cargo bed and opening the seat cushion. removing the seat cushion.

KUVO704A To open the seat cushion, lift its rear side slightly and then raise both sides with both hands as shown in the figure.

UD120-OM-1600XD4-07.indd 8 2015-05-22 오전 8:53:10 MAINTENANCE 7-

Applying grease (D)

UUVO707b UUVO775A U12O776a

(1) Grease fitting (Rear axle drive shaft) (1) Grease fitting (Front wheel hub strut) (1) Grease Fitting (Front Axle Drive Shaft Around Gear Box)

There are sixteen greasing points. The another two are located on the It is located on the spline area of Two of them are located on both front wheel knuckle. Remove the front axle drive shaft around the gear ends of the universal joint which con- front wheels to give grease. box. Raise up the cargo bet to feed nects the gearbox and rear axle. the grease to this fitting. 7 Raise the cargo bed and then apply grease to the greasing points. It is recommended to use NLGI grade No. 2 grease.

UD120-OM-1600XD4-07.indd 9 2015-05-22 오전 8:53:10 7 -10 HAULER 4X4 DIESEL CREW

Checking engine oil level (E)

The remaining 12 are located in the rear suspension section. Remove the rear wheels to add grease.

UUVO778a UUVO708A

(1) Oil dipstick

1. Park the vehicle on level ground and apply the parking brake firmly. 2. Stop the engine and wait at least for 5 minutes. 3. Unscrew the mounting bolts of the inspection shield from under the seat cushion. UUVO779a 4. Pull out the engine oil dipstick and (1) Grease fitting wipe it clean. 5. Insert the dipstick into the end, and then pull it out to check the engine oil level.

UD120-OM-1600XD4-07.indd 10 2015-05-22 오전 8:53:10 MAINTENANCE 7 -11

Changing engine oil and filter (F)

IMPORTANT 1. Warm up the engine oil by operating the engine for approx. 10 min-  The engine oil should be utes or driving the vehicle. checked regularly. Driving 2. Park the vehicle on level ground, without sufficient engine oil stop the engine and apply the can lead to severe engine dam- parking brake firmly. age.  It is recommended to inspect 3. Remove the inspection shield and the engine when it is cold be- seat cushion. fore starting it. H11O606A  The oil level should always be between the MAX and MIN lim- (1) Oil dipstick (A) MAX limit (B) MIN limit its.  Be sure to stop the engine 6. If the oil level is below the MIN lim- to prevent an accident when it, add some oil. If the oil level is checking the engine oil or re- above the MAX limit, drain some fueling. oil through the drain plug. 7 7. Insert the dipstick to its end and UUVO709A close the inspection shield. (1) Drain plug

4. Place a container under the drain plug and remove the drain plug to drain the oil to the container. Be careful as the engine oil may be hot.

UD120-OM-1600XD4-07.indd 11 2015-05-22 오전 8:53:11 7 -12 HAULER 4X4 DIESEL CREW

12. Stop the engine and wait for approx. 5 minutes. Then, check the oil level and add oil as necessary. 13. Install the seat cushion and inspection shield to their original positions.

IMPORTANT  UUVO710A U12O711A Do not overfill the oil. Over- filled oil applies excessive (1) Oil filter (1) Filler Cap stress to the crankshaft, leading to serious malfunction.  Trying to drain the oil while it 5. Remove the oil filter through the 8. Open the filler cap and slowly add is hot may cause serious skin inspection shield and discard it. new oil. burn. 6. Apply a thin film of oil to the rub- 9. The engine oil capacity for this ve- ber O-ring of a new oil filter. Then, hicle is as follow. install it by tightening it firmly to its end by hand. Oil Capacity 0.85 U.S.gal. (3.2 L) 7. Install the drain plug firmly. 10. Install the filler cap. 11. Start the engine and run it at a low speed without load. Then, check if any oil has leaked.

UD120-OM-1600XD4-07.indd 12 2015-05-22 오전 8:53:11 MAINTENANCE 7 -13

dust valve (G) Replacing air filter (H)

It is necessary to remove dust from 4. Check if the anti-dust valve is torn the anti-dust valve of the air filter fre- or damaged and replace it as nec- quently. essary.

IMPORTANT  Do not operate the engine without the anti-dust valve or air filter. The engine can be damaged.

U12O713A

(1) Filter (2) Cap (3) Evacuator Valve U12O712A

(1) Anti-dust valve 1. Park the vehicle on level ground and apply the parking brake firmly. 1. Park the vehicle on level ground 2. Stop the engine and raise the car- and apply the parking brake firmly. go bed. 7 2. Stop the engine and raise the car- 3. Open the cover of the air filter can- go bed. (In case the hydraulic ister to replace the filter. dumping kit is installed, raise the 4. Make sure to fit the filter to the car go bed before stopping the en- center of the canister. gine.) 5. Install the canister cover after 3. Press the corner of the anti-dust checking that the anti-dust valve is valve to remove foreign materials facing downward without any gap. accumulated inside as shown in the figure.

UD120-OM-1600XD4-07.indd 13 2015-05-22 오전 8:53:11 7 -14 HAULER 4X4 DIESEL CREW

Checking air hose and clamp(I) Checking CVT belt (J)

If there is a tiny gap caused by a It is not easy to inspect the CVT on loose connecting clamp on the air your own. It is recommended to have hose, air without passing through the it inspected by your Dealer. air filter could enter the system for a 1. Park the vehicle on level ground long period of time, resulting in short- and apply the parking brake firmly. ening the service life of the engine. Carry out the check according to the service intervals in this manual as follows.

UUVo714a

(1) Clamp 1 (2) Clamp 2

1. Park the vehicle on level ground and apply the parking brake firmly.

2. Stop the engine, remove the seat (1) Rear cover U12O715B cushion and raise the cargo bed. (In case the hydraulic dumping kit 2. Stop the engine, remove the seat is installed, raise the car go bed cushion and remove the rear cov- before stopping the engine.) er on the left of the vehicle. 3. Check if the clamps (1 and 2) are loose. If so, tighten them. 4. Check if there is tiny cracks or flaws on the rubber hose and replace it if necessary.

UD120-OM-1600XD4-07.indd 14 2015-05-22 오전 8:53:12 MAINTENANCE 7 -15

UUVO716A U12O717A UUVO718A

(1) Battery (1) Heat shield cover 1 (1) Exhaust pipe (2) Muffler (2) Heat shield cover 2

3. Remove the battery. 4. Remove the heat shield covers (1 5. Remove the exhaust pipe, but and 2). leave the muffler in place. WARNING  You can get burnt by touching 7 hot parts, such as the muffler. Wait until hot parts are cooled down after stopping the engine.

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U12O719A UUVO720A UUVO721A

(1) Air hose 1 (2) Air hose 2 (1) CTV cover (1) CTV belt

6. Remove the air hoses (1 and 2) 7. Remove the CVT cover. 8. Measure the width of the CVT from the CVT cover. belt. Replace it with a new one if it has been used for more than 300 hours or its width is 1 in. (25 mm) or less. For replacement, contact your Dealer.

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Checking CVT driven pul- Checking fuel FILTER(L) ley clutch buttons(K) NOTE 1. Remove the relevant parts such as the CVT cover by following the  The width of a new belt is 29 mm same procedure as for the CVT belt (1 9/64 in.). Its max. speed re- service (see "Checking CVT belt"). duction ratio is 3.55 while its min. speed reduction ratio is 0.68. As- suming that its width is reduced to 1 in. due to wear, the speed reduction ratio would be 3.22 and 0.76 respectively. There- fore, the maximum speed would U12O760A be reduced by 10% and the max. (1) Fuel Filter (2) Drain Plug torque at a low speed would be reduced by 9%. UUVO722A 9. If foreign materials are caught in 1. Water and dust in fuel are accu- the components such as the CVT (1) Clutch button 1 (2) Clutch button 2 mulated in the filter. Remove the belt or CVT pulley or there is dust plug from the bottom of the fuel fil- inside the CVT cover, clean thor- 2. Check the CVT driven pulley clutch ter to drain any impurities. buttons (1 and 2) for wear. 7 oughly with vaccum cleaner and 2. Tighten the filter with a hand (not 3. If they should need replacement reassemble them. a tool) after drainage. due to excessive wear, contact your IMPORTANT Dealer. 3. Start the engine and check for fuel leakage.  Never apply grease, oil, or sim- 4. If foreign materials are caught in the ilar fluids on the surface of the components such as the CVT belt or CVT pulley or there is dust inside the belt and pulley. CVT cover, clean thoroughly with vaccum cleaner and reassemble them.

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BLEEDING FUEL LINE (M) Replacing fuel filter 1. Wipe the surface of the fuel filter CAUTION clean.  Do not operate the start motor 2. Unscrew the plug on the bottom of for more than 5 seconds con- the fuel filter to drain fuel. tinuously. Instead, operate it 3. Remove the fuel filter. for several times within 5 sec- 4. Remove foreign materials, such onds each time. as dirt, thoroughly and replace the fuel filter with a new one. NOTE  It is not necessary to bleed the U12O761A system if filling the tank with fuel (1) Pump (2) Air Plug before installing the fuel port.

3. When fuel is visible through the 1. Make sure that the amount of fuel bleeding bolt, tighten the bolt and in the fuel tank is sufficient. start the engine. 2. If there is air in the fuel filter, turn the filter cock to the air side and turn the ignition key to turn the start motor. Then, the air in the filter port is discharged through the bleeding hose as shown in the figure.

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Checking injection nozzle and fuel injection pump (N) IMPORTANT CAUTION The injection nozzle and injection pump can be inspected only by a To protect the catalyst filter,  Never bleed the fuel system qualified service personnel. For de- keep the followings: while the engine is hot. tailed information, contact your Deal-  Make sure to use only genuine er. fuel. IMPORTANT  Keep the engine oil replace- IMPORTANT  After bleeding, fuel without air ment schedule. bubbles is filtered by the fuel  Modifying sealed parts in the  Check the engine oil level fre- filter and is transferred to the fuel system, such as the flow quently to keep it to the speci- fuel injection pump. Maintain limit bolt and engine rpm lim- fied level. the proper fuel level in the fuel it bolt, is strictly prohibited by  Avoid any unnecessary engine tank before the fuel tank be- the emission regulations. If idling. comes empty. If all fuel is com- such regulations are not fol-  Never stop the engine during pletely consumed in a Diesel lowed, it will not be covered by driving. engine, fuel should be added warrant and will void any war-  Never place the shift lever in to the fuel tank and then the ranty. the neutral position when driv- fuel system should be bled. ing downhill.  Do not use any engine oil ad- 7 ditive or fuel additive. NOTE  Avoid driving with any warn-  If the engine cannot be started ing lamp illuminated. even after bleeding the fuel sys-  Do not allow any flammable tem, contact your local Dealer. materials, such as dry grass and paper, to come near the catalyst filter while parked.

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Cleaning radiator core (O)

1. Park the vehicle on level ground IMPORTANT and apply the parking brake firmly.  2. Stop the engine, open the hood Driving with the radiator core and support it. clogged by foreign materials can deteriorate heat radiation performance, resulting in the overheated engine.  If the distorted or clogged area of the radiator core is over 30% of its total area, it is rec- UUVO727A ommended to replace it with (1) Radiator a new one. For replacement, contact your Dealer.

UUVO726A 4. Spray compressed air or water to the radiator from its inside toward (1) Brush guard (High) (3) Brush guard (Low) outside to remove any foreign ma- (2) Brush guard (Middle) terials stuck in the radiator core. 3. Remove the three grilles from the WARNING brush guard.  Do not remove the radiator cap while the engine is hot. You can get burnt by hot steam. Make sure to remove it after the engine and radiator have cooled down enough.

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Checking coolant in auxiliary coolant tank (P)

When the coolant in the radiator ex- 1. Park the vehicle on level ground IMPORTANT pands by heat, it overflows into the and apply the parking brake firmly.  auxiliary coolant tank. On the other 2. Check the coolant level through If you have to keep adding hand, when the coolant temperature the sight glass of the auxiliary water to the auxiliary cool- in the radiator decreases, the radi- coolant tank. It is located on the ant tank, the coolant becomes ator is depressurized and the cool- inner side of the right front wheel diluted and the radiator can ant in the auxiliary coolant tank flows well. burst in cold weather. Contact to the radiator to keep the amount of your Dealer to find the cause 3. If the engine is hot, the coolant the coolant in the radiator consistent. and have fixed. level may be higher than normal. Perform the following steps to check In this case, run the engine at a the auxiliary coolant tank. low speed without a load until the coolant in the radiator is cooled down and the coolant in the auxiliary coolant tank flows to the radiator. 4. When the coolant is cooled down sufficiently, add water and anti- freeze mix to the auxiliary cool- 7 ant tank so that the coolant level is between the MAX and MIN limits.

UUVO728A 5. If the coolant level decreases con- tinuously, have your vehicle in- (1) Auxiliary coolant tank (A) MAX limit (B) MIN limit spected by your Dealer.

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Changing coolant (Q)

WARNING 4. After confirming the radiator cap is not hot, unscrew it counterclock-  Do not remove the radiator cap wise slowly pressing it down. Un- while the engine is hot. You screw it in several steps to remove can get burnt by hot steam. any inner pressure safely. Make sure to remove it after 5. Remove the cap after the inner the engine and radiator have pressure is removed. cooled down enough. 1. Park the vehicle on level ground

and apply the parking brake firmly. UUVO731A 2. Stop the engine and let the engine cool down sufficiently. (1) Coolant Drain Plug Of Radiator 3. Open the hood. 7. Place a container with wide opening under the vehicle and open the drain plug to drain the coolant. UUVO730A (1) Brush guard (Upper) (2) Brush guard (Middle) (3) Brush guard (Lower) 6. Remove the lowest grille from the brush guard.

UUVO729A (1) Radiator Cap

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13. Make sure to install the drain plugs for radiator and engine before filling new coolant. 14. Fill the tank with water and anti-freeze (Ethylene glycol) in ratio of 50:50. 15. Slowly add the new coolant and water through the radiator filler 2 with the air bleeder bolt loosened

UUVO732A U12O733A to allow the air to bleed from the sytem. (1) Engine Coolant Drain Plug (1) Air Bleeder Bolt (2) Engine Oil Filter 16. Squeeze the coolant rubber hoses several time before tightening the bleeder bolt to make sure no 8. Now drain the coolant from the en- 9. loosen the air bleeder bolt for air left in hoses. gine by removing the engine cool- fast drain. 17. Make sure all plugs and caps for ant drain plug. 10. Disconnect the hose from the the cooling system have been re- bottom of the auxiliary coolant placed and tightened. 7 tank to drain the coolant in it. 18. Test run the engine to find any 11. Flush the cooling system with leakage. clean water 2 to 3 times as necessary until clean water is pres- 19. The coolant mixture ratio may ent. differ by local climate. Therefore, contact your Dealer for the cor- 12. Reconnect the hose to the auxil- rect mixture ratio. iary coolant tank.

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Checking spark arrester of Checking and changing exhaust pipe (if equipped) (R) gearbox oil (S) 1. Park the vehicle on level ground 1. Park the vehicle on level ground 1.7 U.S Gal. (6.3 L) Coolant Water+Ethylene glycol and apply the parking brake firmly. and apply the parking brake firmly. Capacity 50:50 2. Stop the engine and let the engine 2. Stop the engine and let the engine cooled down sufficiently. cooled down sufficiently. 20. If a different type of anti-freeze is to be used, fill the cooling sys- 3. Loosen the fixing bolt and then re- 3. Raise the cargo bed and support it tem with clean water, run the en- move the spark arrester. with the support rod. gine for approx. 5 minutes and 4. Apply WD-40 or equivalent to the drain the water. Repeat this 2 to inner side and blow any residual 3 times before adding new anti- with compressed air. Do not blow freeze. with compressed air too closely, or the filter can be damaged. 5. If the filter is damaged, replace the spark arrester with a new one. WARNING

 You can get burnt by touch- UUVO734A ing hot parts, such as the muffler. Wait until hot parts have (1) Filler plug cooled down after stopping the engine. 4. Clean around filler plug, then remove the filler plug. 5. Check that the gearbox surface is not hot. Then, check the oil level and condition with a finger bent slightly. If you cannot reach the oil, it means the oil level is low. Add oil

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as needed to fill. WARNING 6. If the color or viscosity of the oil is  You can get burnt badly by not normal or it is at the oil change interval, change the oil. hot oil. Make sure to work on it after it is sufficiently cooled down.

UUVO765A

(1) Funnel

UUVO735A Oil Capacity 0.2 U.S Gal. (0.9 L) (1) Drain plug 10. Check the oil level by performing the step 5 in the previous page. If 7. To change oil, place a container the oil level is normal, install the 7 with wide opening under the drain filler plug. plug. Then, remove the drain plug. 11. Wipe the gearbox and is sur- 8. After draining all the oil, install the rounding with a rag thoroughly. drain plug firmly. 12. Test drive the vehicle for 5 to 10 9. When adding new oil, add it minutes to check for leakage. through a long hose into the fill plug location. Fill till oil starts to spill out of filler plug hole.

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Checking and changing front axle oil (T)

1. Park the vehicle on level ground 6. If the color or viscosity of the oil is and apply the parking brake firmly. not normal or it is at the oil change 2. Stop the engine and let the engine interval, change the oil. cool down sufficiently. 3. Raise the hood and support it with the support rod

UUVO762A

(1) Funnel

UUVO737A

(1) Drain Plug 9. When adding new oil, add it through a long hose into the filler plug location. Fill till oil starts to UUVO736A 7. To change oil, place a container spill out of filler plug hole. (1) Filler Plug with wide opening under the drain plug. Then, remove the drain plug. 4. Clean around filler plug, then re- Oil Capacity 0.16 U.S Gal. (0.6 L) move the filler plug. 8. After draining all the oil, install the drain plug firmly. 10. Check the oil level by performing 5. Check that the differential case the step 5 in the previous page. If surface is not hot. Then, check the the oil level is normal, install the oil level and condition with a finger filler plug. bent slightly. If you cannot reach the oil, it means the oil level is low. Add oil as needed.

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Checking and changing rear axle oil (U)

11. Wipe the differential case and its 1. Park the vehicle on level ground 5. If the color or viscosity of the oil is surrounding with a rag thoroughly. and apply the parking brake firmly. not normal or it is at the oil change 12. Test drive the vehicle for 5 to 10 2. Stop the engine and let the engine interval, change the oil. minutes to check for leakage. cool down sufficiently. WARNING  You can get burnt badly by hot oil. Make sure to work on it after it is sufficiently cooled down.

UUVO739A UUVO738A (1) Drain Plug (1) Filler Plug 6. To change oil, place a container 3. Clean around filler plug, then re- with wide opening under the drain 7 move the filler plug. plug. Then, remove the drain plug. 4. Check that the differential case 7. After draining all the oil, install the surface is not hot. Then, check the drain plug firmly. oil level and condition with a finger bent slightly. If you cannot reach the oil, it means the oil level is low. Add some oil.

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Checking drive shaft and CV boots (V) 10. Wipe the differential case and its 1. Park the vehicle on level ground surrounding with a rag thorough- and apply the parking brake firmly. ly. 2. Stop the engine. 11. Test drive the vehicle for 5 to 10 minutes to check for leakage.

WARNING  You can get burnt badly by hot oil. Make sure to work on

UUVO763A it after it is sufficiently cooled (1) Funnel down.

UUVO740A 8. When adding new oil, add it (1) CV Boots (Front Wheel) through a long hose into the fill plug location. Fill till oil starts to spill out of filler plug hole. 3. Check if the CV boots of the drive shaft for the front wheels are torn Oil Capacity 0.21 U.S Gal. (0.8 L) or have a sign of leakage.

9. Check the oil level by performing the step 4 in the previous page. If the oil level is normal, install the filler plug.

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Checking steering rack boots and ball joint (W)

1. Park the vehicle on level ground and apply the parking brake firmly. 2. Stop the engine. 3. Open the hood and support it.

UUVO741A UUVO743A

(1) CV Boots (Rear Wheel) (1) Tie Rod End

4. Check if the CV boots of the drive UUVO742A 5. Turn steering wheel fully to the shaft for the rear wheels are torn right and inspect the boots of the or have a sign of leakage. (1) Steering Rack Boot tie rod end and nut, then turn 5. If the CV boots should be re- wheel fully to the left and inspect 7 placed, contact your Dealer. 4. Check the steering rack boots, to boot of the tie rod end and nut. see if torn or have a sign of leak- 6. If the above components should age. be replaced, contact your Dealer.

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Checking brake fluid (X)

1. Park the vehicle on level ground IMPORTANT Brake fluid DOT 3 and apply the parking brake firmly.  The components related to 2. Stop the engine, open the hood 6. If the brake fluid is severely con- the steering operation direct- and support the hood. taminated or insufficient, contact ly affect your safety. If a condi- your Dealer. tion of such components is in doubt, contact your Dealer immediately.

UUVO744A

(1) Brake Fluid Tank (A) MAX Limit (B) MIN Limit 3. Clean the brake fluid tank and its surrounding thoroughly. 4. Check the brake fluid level is between the MAX and MIN limits. 5. If the level is below or close to the MIN limit, fill the tank with the brake fluid to the MAX limit.

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Checking brake pedal Checking brake pad (Z) free play (Y) The master cylinder rod of the vehi- 1. Park the vehicle on level ground cle is adjusted so that the brake ped- and apply the parking brake firmly. al free play is 0.59 ~ 0.79 in. (15 ~ 20 mm) at factory. If the free play of the brake pedal should be adjusted, perform the following steps. 1. Park the vehicle on level ground and apply the parking brake firmly. 2. Stop the engine, open the hood and support the hood.

UUVO746A (1) Wheel Nut

2. Unscrew the nuts of the wheel to be checked only 1 turn. 3. Lift the vehicle with a hydraulic 7 jack and then support the vehicle

UUVO745A with the safety stand. Then, lower UUVO747A the hydraulic jack so that the vehi- (1) Master Cylinder Rod cle chassis sits on the stand. (1) Brake Pad 3. Measure the free play of the brake 4. Unscrew the wheel nuts complete- pedal. According to the measure- ly to remove the wheel. ment, adjust the length of the master cylinder rod(1).

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Checking parking brake (AA)

5. If any of the brake pads on either NOTE side of the disc is too thin, close to  0.04 in. (1 mm), both pads for that The vehicle should be stopped disc as well as the pads for the on a slope (up to 10 degrees) wheel on the other side should be when the parking brake is ful- replaced. ly applied. With cargo loaded. When driving the vehicle downhill 6. Check the brake pads on the oth- without depressing the accelera- er axle, using the same procedure. tor pedal, there should be no fric- 7. Check if the brake disc is abnor- tion resistance. In order to keep mally worn. the parking brake in the best con- UUVO748A 8. If the brake pads should be re- dition, check the parking brake (1) Parking Brake Cable placed with new ones or abnormal with the following procedure. wear is found on the disc, contact your Dealer. 1. Park the vehicle on level ground 3. Adjust the length of the parking 9. When reinstalling the wheel after and apply the parking brake firmly. brake cable. Test the cable ac- inspection, tighten the wheel nuts 2. Stop the engine, raise the cargo cording to the procedures de- firmly. bed and support it with the support scribed previously and then adjust its length as necessary. WARNING rod (In case the hydraulic dumping kit is installed, raise the car go bed  Driving with loose wheel nuts before stopping the engine.). is very dangerous and can lead to overturn and collision. Make sure that they are firmly tightened.

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Adjusting suspension (AB)

7. If the parking brake pads should The rear suspension equipped on be replaced with new ones or ab- this vehicle is adjustable, to allow for normal wear is found on the disc, ride quality and weight hauling. To contact your Dealer. adjust the suspension, perform the following steps: 1. Park the vehicle on level ground and apply the parking brake firmly.

UUVO749A

(1) Disc Pad

4. Measure the thickness of the pads on the sides of the parking brake disc If any of the pads are close to 0.04 inch (1 mm), both pads UUVO746A 7 should be replaced. (1) Wheel Nut 5. After replacing the pads, test the parking brake and adjust the cable 2. Unscrew the nuts of one of the length accordingly. rear wheels only 1 turn. 6. Check if the parking brake disc is 3. Lift the vehicle with a hydraulic not worn abnormally. jack and then support the vehicle with the safety stand. Then, lower the hydraulic jack so that the vehicle chassis sits on the stand.

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Checking suspension shock absorber (AC) 4. Unscrew the wheel nuts complete- 6. After adjustment, install the wheel If the shock absorber is malfunc- ly to remove the wheel. and tighten the wheel nuts firmly. tioning, your riding comfort can be harmed. In this case, check the WARNING shock absorber as follows  Driving with loose wheel nuts 1. Park the vehicle on level ground is very dangerous and can and apply the parking brake firmly. lead to overturn and collision. 2. Stop the engine. Make sure that the nuts are firmly tightened.

UUVO750A (1) Hole

5. Fit a special service tool to the hole and turn it to adjust the spring load and stroke. UUVO751A (1) Shock Absorber NOTE A direction(soft): suitable for 3. Check for any sign of oil leakage driving mountainous area fre- on the shock absorbers for the quently. front and rear wheels and their B direction(hard): suitable for surrounding. transporting cargo frequently. 4. If the shock absorbers should be replaced, contact your distributor/ Dealer.

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Battery (sealed) (AD) Inspection Replacement Never open or service the battery IMPORTANT 1. Park the vehicle on level ground and never add electrolyte to the bat- and apply the parking brake firmly.  tery. Doing so will not be covered The battery discharges natu- 2. Stop the engine. by your warranty. Therefore, when rally if the vehicle is stored for checking the battery, observe the fol- an extended period of time. lowing: When storing the vehicle for 1. Keep the battery and its terminals a long period of time, run the clean. engine for approx. 30 minutes monthly to charge the battery. 2. Connect the battery cables firmly. Never leave the vehicle with 3. Make sure the battery vent hole is the engine running. not clogged. 4. Fit the battery to the vehicle body

firmly. U12O715B

(1) Side Cover

3. Remove the side cover (LH). 7

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CALIFORNIA BATTERY WARNING WARNING  The battery terminals and ca-  The battery gas is dangerous bles contains lead. The body enough to cause explosion. accumulates lead which can  Do not smoke near the battery. cause cancer. Make sure to  Do not leave the battery near wash your hands after han- flame or spark. dling these parts.  Do not touch the both terminals of the battery with a metal WARNING object simultaneously. UUVO753A  When disconnecting the bat-  The battery has acid that can tery, disconnect the negative (1) Battery Cover burn your skin. battery cable first. (A) Positive (+) Cable  Make sure to wear protective (B) Negative (-) Cable  When connecting the battery, glasses and gloves. connect the positive battery 4. Remove the battery cover and dis-  Wear long sleeves to protect cable first. connect the negative battery cable. your skin. 5. Disconnect the positive battery ca-  If you accidentally inhaled ble. acid, see your doctor immedi- 6. Remove the battery mounting ately.  bracket. If acid got in your eyes, flush with water for 15 to 30 minutes 7. When connecting cables, connect and get medical attention im- the positive cable first, and then mediately. the negative cable.  If acid got on your skin, flush with water immediately and see your doctor.

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Replacing headlamp bulb (AE) Checking and replacing fuse (AF) 1. Park the vehicle on level ground 1. Park the vehicle on level ground and apply the parking brake firmly. and apply the parking brake firmly. 2. Stop the engine, open the hood 2. Stop the engine, open the hood and support the hood. and support the hood.

UUVO755A (1) Bulb (2) Rubber Cover (A) Pull Out

UUVO754A 4. Hold and pull the socket section to UUVO756A pull out the bulb. (1) Connector (2) Rubber Cover (1) Fuse Box 5. When installing a new bulb, be careful not to touch its glass. Dura- 7 3. Remove the rubber cover. Then, bility of a bulb can be deteriorated. 3. Open the fuse box cover. There remove the mounting screws with are spare fuses and fuse tongs in 6. Tighten the mounting screws and a phillip’s head screwdriver. the center of the box. install the rubber cover firmly.

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Main fuse (slow-blow fuse) (AG)

4. Wrap the fuse with insulation tape 30A 5A 5A 20A 20A 10A ENGINE ALTER- after replacement. Make sure that HEAD FOG STOP NATOR / DISPLAY RADIATOR LAMP LAMP SOLENOD HOLD COIL UNIT FAN the inspection shield is visible. SPARE 15A 20A 30A 5. If this fuse is repeatedly blown, 10A 5A 20A 20A 15A contact your Dealer. FUSE COMBI- WASHER HORN / WORKING BRAKE PULLER NATION / WIPER FLASHER LAMP LAMP METER MOTOR UNIT

2CTV0Q 7 USE ONLY RATED FUSE.

U12O774A UUVO758A (1) Slow-blow Fuse

If the start motor and all electrical devices do not operate at all when turning the key the switch to the "START" position, the first thing to inspect is the main fuse. 1. Remove the engine inspection UUVO757A shield. (1) Fuse Tong 2. Check if the yellow slow blow fuse 4. Check or replace the fuse with the installed to the positive start motor fuse tongs. cable is blown. 5. If fuses are blown repeatedly, con- 3. Remove the tape and replace the tact your Dealer. fuse with a new one if necessary.

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Aligning wheel and checking wheel nut (AH) Checking differential lock cable (AI) 1. Park the vehicle on level ground 5. After reinstalling the wheel after and apply the parking brake firmly. inspection, tighten the wheel nuts firmly. WARNING  Driving with loose wheel nuts is very dangerous and can lead to overturn and collision. Make sure that they are firmly tightened. UUVO759A IMPORTANT (1) Differential Lock Cable UUVO746A (2) Nut  The tire inflation pressure and (1) Wheel nut wheel nut tightness should be inspected daily. 1. Park the vehicle on level ground and apply the parking brake firmly. 2. Unscrew the nuts on the wheel to be replaced for only 1 turn. 2. Stop the engine, raise the cargo bed and support it with the support 3. Lift the vehicle with a hydraulic 7 rod. (In case the hydraulic dump- jack and then support the vehicle ing kit is installed, raise the car go with the safety stand. Then, lower bed before stopping the engine.) the hydraulic jack so that the vehicle chassis sits on the stand. 4. Unscrew the wheel nuts completely to remove the wheel.

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Checking shift and 4WD cables (AJ)

WARNING 3. Unscrew nut 1 and adjust the length of the shift cable.  You can get burnt by touching 4. Unscrew nut 3 and adjust the hot parts, such as the muffler. 4WD cable. Make sure the vehicle is not hot before starting servicing. 5. To check 4WD operation, lift the front and rear axles completely off 3. Unscrew the nut and adjust the the ground and support with jack cable length. stands. 4. To check the differential lock oper- 6. Start the engine and move the

ation, lift the rear axle with a jack UUVO760A 2WD/4WD lever to "4WD" and so that the rear wheels are off the "2WD" positions to check rotation (1) Shift Cable (2) Nut 1 ground. (3) 4WD Cable (4) Nut 2 of each wheel. 5. Set the differential lock lever to the WARNING "Lock" position and rotate one of 1. Park the vehicle on level ground  the wheels manually. It is normal and apply the parking brake firmly. Make sure that no one, especially children, near the vehi- that the other wheel rotates in the 2. Stop the engine, raise the cargo cle. same direction. bed and support it. 6. Set the differential lock lever to the "Unlock" position and rotate one of WARNING the wheels manually. It is normal  You can get burnt by touching that the other wheel rotates in the hot parts, such as the muffler. opposite direction. Make sure the vehicle is not hot before starting servicing.

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Using Biodiesel (AK) Adjusting belt tension (AL)

1. It is allowed to use 5% biodiesel The engine belt drives the alterna- fuel. If biodiesel fuel of higher ratio tor and coolant pump. If the tension is used, the engine can be dam- of this belt is below the specification, aged and this will not be covered the alternator efficiency decreases, by warranty. resulting in insufficient battery charge 2. The biodiesel fuel should meet level and low coolant circulation effi- ASTM D6751, EN14214 and ciency. equivalent standards. If the tension of this belt is too high, 3. For details about biodiesel use, it wears rapidly and service life of the contact your Dealer. coolant pump bearing is shortened. NOTE  In this vehicle, the electric fan is not installed to the engine, but to the radiator under the hood. 1. Park the vehicle on level ground and apply the parking brake firmly. 2. Stop the engine and remove the 7 engine inspection shield and seat cushion UUVO761A (1) Adjusting Bolt (A) Belt Tension

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Washing (AM) Protecting plastic and painted surface(AO) 3. Loosen the adjusting bolt on the It is recommended to wash your ve- Do not wipe any plastic parts if they top of the alternator as well as the hicle with water of moderate pres- are not washed. hinge bolt on the bottom of the al- sure and with or without soap. When Spraying insecticide can damage the ternator. washing your vehicle in a car wash, plastic and painted surface. Never make sure high-pressure water is not 4. Leverage the alternator toward the spray insecticide near the vehicle. outside. directly sprayed to the following components: Do not spill the brake fluid on the 5. Fix the upper adjusting bolt and vehicle parts. It can damage the push down the section A of the IMPORTANT painted surface. If the brake fluid is belt to measure the tension. spilled, wipe it immediately.  Never spray high-pressure wa- Standard Never spill fuel on the vehicle com- 1 in. (25 mm) when pressing ter to the radiator core, spark belt tension center of belt arrester, various warning de- ponents. It can damage the surface. (A) cals, air cleaner inlet, CVT If it is spilled, wipe it immediately. 6. If necessary, loosen the adjusting cover air inlet and outlet, key bolt and make adjustment. Then, switch, instrument panel, air measure the tension again. breather of gearbox and dif- 7. After adjustment, tighten the hinge ferential case, CV boots and bolt firmly. Check the adjusting steering rack boots, alternator, bolt is tightened as well. various wiring connections, electric sensors and switches. WARNING  If getting too close to rotating parts, such as the belt, during the engine is running, your clothes or part of your body can be caught.

UD120-OM-1600XD4-07.indd 42 2015-05-22 오전 8:53:21 STROAGE AND DISPOSAL

vehicle sTORAGE...... 8-2 daily storage...... 8-2 8 Long-term storage...... 8-2 Using vehicle after long-term storage...... 8-3

Disposal...... 8-4

UD120-OM-1600XD4-08.indd 1 2015-05-22 오전 8:56:50 8- HAULER 4X4 DIESEL CREW vehicle sTORAGE daily storage Long-term storage

1. Keep the vehicle clean when it is Follow the instructions below if the 6. Keep the vehicle in a dry place stored. Make sure to wash it after vehicle is not to be used for a long where the vehicle is sheltered work. period of time. This is to operate the from rain. Cover the vehicle. 2. Store it indoors if possible. If it vehicle again with minimum prepara- 7. the vehicle should be stored in should be kept outside, cover it. tion after long-term storage. an enclosed area to avoid direct sunlight or heat. Make sure the WARNING IMPORTANT tires are not exposed to sunlight   When operating the vehicle in If the vehicle is not used for an and heat directly. extended period of time, fol- an enclosed area, ventilate the 8. Keep the vehicle, including the low the instructions below to area to release exhaust gas to engine components, clean. the outside. The exhaust gas prevent corrosion and perfor- is colorless and not visible, mance deterioration of the ve- 9. Apply grease to every grease fit- but is harmful. hicle while it is stored. ting as needed.  In an area that exhaust gas can 10. Apply grease to the exposed cyl- come in contact with a flame 1. Check the bolts and nuts for loose- inder rod (if equipped with the or spark, do not store the vehi- ness, and tighten if necessary. dumping kit). cle with fuel in its fuel tank. 2. Apply grease to areas where bare 11. Check the coolant condition. If cool down the engine suffi- metal can rust. necessary, drain and flush it, and ciently before covering the ve- 3. Repair worn or damaged parts. then refill with anti-freeze and hicle with a protective cover. Replace parts as necessary. water. We recommends a 50/50 mix. 3. Remove the battery from the vehi- 4. Inflate the tires to a pressure a lit- cle in winter and store it indoors. tle higher than usual. 12. Set the shift lever to the neutral 4. Add anti-freeze to the vehicle in 5. Remove the battery from the ve- position. winter season in order to prevent hicle. Store the battery according 13. Attach a tag onto the vehicle to the radiator from freezing. to the applicable storage instruc- inform the storage condition of 5. Remove the ignition key and store tions. the vehicle. it separately.

UD120-OM-1600XD4-08.indd 2 2015-05-22 오전 8:56:51 STROAGE AND DISPOSAL 8-

Using vehicle after long-term storage

14. If the machine is being operat- 1. Check the tire inflation pressure 9. Stop the engine and check for oil ed with Bio-diesel, drain the bio- and inflate the tires if they are low. leakage. Repair the vehicle as diesel and fill the standard diesel 2. Install the battery to the vehi- necessary. to run the engine for more than cle. Check that the battery is fully CAUTION 30 minutes before the long term charged before installation. storage. (More than 90 days)  3. Check the tension of the fan belt. If the battery is not to be removed, disconnect its nega- IMPORTANT 4. Check all fluid levels, including the tive terminal at least. The wir-  When cleaning the vehicle, be engine oil, gearbox oil, front/rear ing can be gnawed by rodents, sure to stop the engine. Allow differential case oil, engine coolant leading to a fire. sufficient time for the engine and brake fluid. to cool before cleaning. 5. Remove grease from the exposed  Cover the vehicle after the cylinder rod. muffler and engine is cooled 6. Apply grease to the lubrication down. points, and grease fitting as need-  The battery should be re- ed. charged every 90 days while it 7. Check if the instrument cluster and is stored. all parts operate correctly while  Store the vehicle in a dry and running the engine for a few min- protected place. If the vehicle utes. should be kept outside, cover 8 8. Drive the vehicle outside and test it with a water-proof cover. the vehicle’s brake operation, shift operation, high-speed, low-speed and reverse driving, and parking brake operation for normal operation.

UD120-OM-1600XD4-08.indd 3 2015-05-22 오전 8:56:51 8- HAULER 4X4 DIESEL CREW Disposal

In order to protect the environment, use and dispose of the vehicle keep- ing the following in mind: 1. When changing the oil or coolant by yourself, be careful not to spill it and dispose used oil and coolant properly according to the applicable regulations. 2. Never leave or discard the expired vehicle, but contact your local Dealer to dispose it according to the regulations.

UD120-OM-1600XD4-08.indd 4 2015-05-22 오전 8:56:51 TROUBLESHOOTING

vehicle Troubleshooting...... 9-2 9

UD120-OM-1600XD4-09.indd 1 2015-05-22 오전 8:57:13 9- HAULER 4X4 DIESEL CREW

This troubleshooting chart summarizes simple service items for users who are familiar with mechanical systems. For more detailed service items, contact your local Dealer. vehicle Troubleshooting

Problem Check item Maintenance code

1. Start motor cannot run  Blown main fuse (slow-blow fuse: near start motor cable) AG or run at low speed  Loose battery cable AD

 Discharged battery (alternator malfunction) AD

 Key switch malfunction, Hard to start the engine

2. Engine is hard to start  Insufficient preheating (with start motor running)  Malfunctioning electrical parts related to preheat operation such, as preheat relay, controller

 Extra manual preheating is required in extremely cold weather

 Insufficient fuel

 Air in fuel line, loose fuel line clamp or pinched fuel line

 Water or foreign material in fuel

 Clogged fuel filter or fuel hose, blocked fuel filter valve L, M

 Gelled fuel in extremely cold temperature (fuel for winter not used) L, M

UD120-OM-1600XD4-09.indd 2 2015-05-22 오전 8:57:13 TROUBLESHOOTING 9-

Problem Check item Maintenance code

2. Engine is hard to start  Fuel with low cetane used (with start motor running)  No operation of solenoid valve

 Injection pump malfunctioning

 Too high viscosity of engine oil (improper type of oil)

 Incorrect injection of injection nozzle or carbon accumulated onto it N

 Improper valve clearance

3. Engine power is insufficient  Excessive engine oil (overfilling, water or hydraulic oil mixed with engi- (knocking, vibration, smoke) ne oil)

 Overheated engine

 Restricted fuel supply (clogged filter, water in fuel, loose fuel line, etc.) M,L 9

 Improper fuel, low cetane

 Clogged air cleaner H

 Improper injection timing

UD120-OM-1600XD4-09.indd 3 2015-05-22 오전 8:57:13 9- HAULER 4X4 DIESEL CREW

Problem Check item Maintenance code

3. Engine power is insufficient  Poor injection nozzle condition or carbon accumulated onto it (knocking, vibration, smoke)  Improper valve clearance

4. Engine is overheated  Clogged radiator grille and core O

 Insufficient or leaking coolant (loose hose connection) Q

 Broken cooling fan

 Defected temperature sensor

 Improper mixing ratio of antifreeze

 Defected radiator cap

 Improper bleeding after coolant change Q

 Faulty cooling fan motor or switch

 Aged or faulty water pump

 Air in coolant line Q

 Thermostat malfunction

UD120-OM-1600XD4-09.indd 4 2015-05-22 오전 8:57:13 TROUBLESHOOTING 9-

Problem Check item Maintenance code

4. Engine is overheated  Insufficient engine oil

5. Engine stops abruptly during  Insufficient fuel or clogged filter and hose H operation  Air in fuel line or contaminated fuel

 Seizure due to overheated engine

5. Engine stops abruptly during  Engine oil leakage Q operation  Coolant leakage Q

 Faulty solenoid

 Injection pump malfunctioning

6. Electrical device is malfunc-  Blown fuse AF, AG tioning (parts related to preheat,  Improperly connected wiring starting, illumination, horn, 9 etc.)  Faulty relay and controller (in engine compartment)

 Discharged battery

7. Battery is discharged  Key switch left in the "ON" position

UD120-OM-1600XD4-09.indd 5 2015-05-22 오전 8:57:13 9- HAULER 4X4 DIESEL CREW

Problem Check item Maintenance code

7. Battery is discharged  Electrical devices (headlamps, work lamps, turn signal lamps, etc) left "ON"

 Natural discharge due to no operation for a long period of time

 No charging due to faulty alternator, faulty alternator wiring connection

 Frequent repetition of engine start and stop (lack of time to charge)

 Excessive electricity use from external device (additionally attached device, such as implement)

 Prolonged cranking in severe condition

 Expired battery

8. Vehicle cannot be driven  Parking brake not released AA

 Shift lever not shifted. AJ

 Faulty CVT belt J, K

9. Poor shift operation (HI-LO,  Improperly adjusted shift cable AJ 4WD)  Improperly adjusted 4WD cable AJ

10. Vehicle cannot escape a pit  Faulty 4WD shift operation AJ or rough road

UD120-OM-1600XD4-09.indd 6 2015-05-22 오전 8:57:13 TROUBLESHOOTING 9-

Problem Check item Maintenance code

10. Vehicle cannot escape a pit  Differential lock system malfunction (improperly adjusted differential lock cable) AI or rough road

11. Power is insufficient to drive  Shift lever not in "L" position uphill  4WD not used

 Worn CVT belt J, K

12. Vehicle cannot reach its  Worn CVT belt J, K max. speed  Improperly adjusted accelerator pedal cable (engine cannot reach its full speed)

13. Braking force is insufficient  Wet brake

 Insufficient brake fluid X

 Air in brake line X

 Excessively worn brake pad Y, Z 9

14. Vehicle pulls to one side  Wet brake pads on one side when braking  Excessively worn brake pads one side Z

 Air in brake line X

UD120-OM-1600XD4-09.indd 7 2015-05-22 오전 8:57:13 9- HAULER 4X4 DIESEL CREW

Problem Check item Maintenance code

15. Parking brake is malfunc  Improperly adjusted parking brake cable AA tioning (vehicle rolls down on slope)  Worn parking brake pad AA

16. Steering wheel feels heavy  Insufficient inflation pressure of front tires

 Insufficient lubrication and contamination due to torn steering rack boots W

17. Steering wheel is not  Faulty steering knuckle W operated smoothly  Improperly adjusted toe-in

 Excessive steering wheel play

18. Hydraulic pressure is faulty  Lack of Hydraulic fluid in hydraulic tank (if equipped with dumping kit or auxiliary hydraulic kit)  Improper hydraulic oil used

 Faulty valve and pump

※ If you do not find the cause of trouble, consult your dealer for assistance.

UD120-OM-1600XD4-09.indd 8 2015-05-22 오전 8:57:14 INDEX

index...... 10-2 10

UD120-OM-1600XD4-10.indd 1 2015-05-22 오전 8:57:36 10- HAULER 4X4 DIESEL CREW

NUMERIC Cautions for decal maintenance...... 1-24 12V power outlet...... 4-12 Changing coolant (Q)...... 7-22 2WD/4WD shift lever...... 4-21 Changing engine oil and filter (F)...... 7-11 4WD operation...... 5-24 Check item...... 5-2 Checking air hose and clamp(I)...... 7-14 a Checking and changing front axle oil (T)...... 7-26 Accelerator pedal...... 4-23 Checking and changing gearbox oil (S)...... 7-24 Access for service...... 7-7 Checking and changing rear axle oil (U)...... 7-27 Adjusting belt tension (AL)...... 7-41 Checking and replacing fuse (AF)...... 7-37 Adjusting suspension (AB)...... 7-33 Checking brake fluid (X)...... 7-30 Aligning wheel and checking wheel nut (AH).....7-39 Checking brake pad (Z)...... 7-31 All terrain (recreatiONal)...... 4-30 Checking brake pedal free play (Y)...... 7-31 Applying grease (D)...... 7-9 Checking coolant in auxiliary coolant tank (P).....7-21 Checking CVT belt (J)...... 7-14 B Checking CVT driven pulley clutch buttons(K)...7-17 Battery (sealed) (AD)...... 7-35 Checking differential lock cable (AI)...... 7-39 Battery charging lamp...... 4-16 Checking drive shaft and CV boots (V)...... 7-28 Belts and rubber parts...... 6-3 Checking engine oil level (E)...... 7-10 BLEEDING FUEL LINE (M)...... 7-18 Checking fuel FILTER(L)...... 7-17 Brake pedal...... 4-21 Checking injection nozzle and fuel injection pump (N)...... 7-19 C Checking parking brake (AA)...... 7-32 Cargo bed...... 4-26 Checking shift and 4WD cables (AJ)...... 7-40 Cargo bed control lever (manual model)...... 4-26

UD120-OM-1600XD4-10.indd 2 2015-05-22 오전 8:57:36 INDEX 10-

Checking spark arrester of exhaust Driving on slippery surfaceS...... 5-14 pipe (if equipped) (R)...... 7-24 Driving on slope...... 5-15 Checking steering rack boots and ball joint (W).....7-29 Driving through water...... 5-17 Checking suspension shock absorber (AC)...... 7-34 dust valve (G)...... 7-13 Checking warning lamps after starting engine... 5-5 Cleaning radiator core (O)...... 7-20 e Combination switch...... 4-9 ELECTRIC COOLING FAN MOTOR...... 4-4 Controls...... 4-19 eLECTRIC PARTS ...... 6-3 Coolant temperature gauge...... 4-15 engine check warning lamp ...... 4-18 Coolant, brake fluid and electrical devices....4-29 Engine inspection...... 4-28 Cup holders and storage boxes...... 4-25 Engine oil pressure warning lamp...... 4-15 Engine serial number...... 2-2 D Essential replacement part...... 6-2 Daily check chart...... 7-3 Exterior dimensions...... 3-2 Daily inspection...... 5-2 Exterior view...... 4-3 Daily inspection...... 7-7 daily storage...... 8-2 f DeCALs...... 1-20 Filters...... 6-2 Differential lock lever (REAR WHEEL)...... 4-20 FRONT guard...... 4-25 DiffERENTIAL lock operation...... 5-25 Fuel gauge...... 4-14 Disposal...... 8-4 Fuel requirements...... 4-28 Driving backward...... 5-18 Fuel tank...... 4-27 Driving in forest...... 5-17 Driving on road...... 5-19 10

UD120-OM-1600XD4-10.indd 3 2015-05-22 오전 8:57:36 10- HAULER 4X4 DIESEL CREW

g k General precautions...... 1-2 Key switch...... 4-8 General specifications...... 3-3 Glow plug indicator...... 4-17 l Long-term storage...... 8-2 H Lower fUEL LEVEL WARNING INDICATOR ...... 4-18 Hazard lamp switch...... 4-11 LUBRICANTS...... 7-6 Head light high beam lamp...... 4-16 Headlamp...... 4-5 m Headlamp switch...... 4-10 Main fuse (slow-blow fuse) (AG) ...... 7-38 Hill inclined sideward...... 5-16 Maintenance check list...... 7-3 Hood...... 4-4 MAINTENANCE interval table...... 7-4 Horn switch...... 4-11 mounting location...... 1-19 HOW TO DRIVE...... 5-7 How to warm up engine...... 5-10 n nEUTRAL indicator ...... 4-18 i index...... 10-2 O Instrument panel...... 4-13 Oil and fluid...... 6-2 Opening inspection shield (A)...... 7-7 J Opening seat cushion (B)...... 7-8 Jump start...... 5-11 Operating principle of preheat system...... 5-6 OPERATING THE ENGINE...... 5-2

UD120-OM-1600XD4-10.indd 4 2015-05-22 오전 8:57:36 INDEX 10-

OPERATING THE VEHICLE...... 5-7 Safety precautions during servicing...... 1-14 OPTION List and FEATURES...... 3-5 Safety precautions when using the ROPS...... 1-18 Seat...... 4-23 p Seat belt...... 4-23 Parking...... 5-12 Shift lever...... 4-19 Parking brake indicator...... 4-17 Shifting...... 5-13 Parking brake lever...... 4-22 Spare switch panel...... 4-12 Precautions before operation...... 1-2 SPECIFICATION...... 3-2 Precautions during operation...... 1-4 SPECIFICATIONS...... 3-1 PRE-OPERATION...... 5-2 SPEEDOMETER / Hourmeter...... 4-14 Proper inflation pressure...... 4-31 Standard tire for worksite...... 4-30 Protecting plastic and painted surface(AO) ....7-42 Starting the engine...... 5-2 Stopping...... 5-12 R Stopping the engine...... 5-6 Raising cargo bed (C)...... 7-8 SUN Canopy...... 4-25 Rear hitch receiver...... 4-5 Suspension...... 4-5 Rear wheel mudguard...... 4-6 Switches...... 4-7 Reflex Reflector...... 4-6 Replacing air filter (H)...... 7-13 T Replacing headlamp bulb (AE)...... 7-37 Tailgate (back door)...... 5-26 ROPS ...... 4-24 Tire...... 4-29 tire tread patterns...... 4-30 S Towing trailer...... 5-22 Safety decal...... 1-19 Transporting...... 5-23 10

UD120-OM-1600XD4-10.indd 5 2015-05-22 오전 8:57:36 10- HAULER 4X4 DIESEL CREW

T When starting the engine...... 1-4 Transporting cargo...... 5-19 Turf...... 4-30 Turn Signal Lamp...... 4-17 Turn signal lamp switch...... 4-10 Turning...... 5-15

U Unloading (manual model)...... 5-21 Uphill and downhill...... 5-15 Using Biodiesel (AK)...... 7-41 Using vehicle after long-term storage...... 8-3

V Vehicle Identification Number...... 2-2 Vehicle serial number...... 2-2 vehicle sTORAGE...... 8-2 vehicle Troubleshooting...... 9-2

W Warming up...... 5-10 Washing (AM)...... 7-42 When driving the vehicle...... 1-6 When parking the vehicle...... 1-13

UD120-OM-1600XD4-10.indd 6 2015-05-22 오전 8:57:36 UTV-EZGO-Hauler 4X4 Diesel-00.in2 2 2015-05-26 오전 8:58:20 Read all this manual to become thoroughly familiar with this vehicle. Pay particular attention to all notes, cautions and warnings.