Husqvarna HUV 4421 4421-D/DX/DXL manual

HUV 4421 Owner ’ s Manual 4421-G/GX/GXL Gas and 4421-D/DX/DXL Diesel Utility V ehicles [Refer to back cover for applicable build code range][...]

[...]

NOTICE This manual is valid for vehicles manufactured in the build code range provided on the back cover of this manual. If the vehicle build code is different from that shown on the back cover of this manual, please contact your nearest dealer or go to www .husqvarna.com to retrieve the proper owner ’s manual for the vehicle. See also Model Iden[...]

FOREWORD Thank you for choosing Husqvarna, a world leader in outdoor products. Y ou have chosen the nest utility vehicle on the market. Please protect your investment and ensure that your Husqvarna vehicle provides years of reliable, superior performance by reading and following the maintenance instructions in this manual. Y our comfort and safe[...]

T ABLE OF CONTENTS Safety Decal and Feature Identication .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 5 Practice Safety .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..[...]

V ehicle Specications ... .. ... .. .. ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 56 W arranties.. .. .. ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .[...]

Safety Decal and Feature Identication SAFETY DECAL AND FEA TURE IDENTIFICA TION The following pages contain safety decal and feature identication information. For detailed information on specic features, read the appropriate section in this manual. HUV 4421 Owner’s Manual Page 5[...]

Safety Decal and Feature Identication ALL HUV 4421 TWO P ASSENGER MODELS 2412 1 10 7 9 4 6 5 2 3 8 1 101547601 Decal, Gasoline Fuel W arning (at fuel ll or on frame, near fuel tank) 6 102459101 Decal, Ground W arning (on vehicle frame, near battery) 2 102231601 Decal, Winch Safety W arning (on vehicle body , below seat) 7 102459201 Decal, Die[...]

Safety Decal and Feature Identication ALL HUV 4421 TWO P ASSENGER MODELS 364 7 10 5 8 3 1 4 9 11 6 2 1 101 1553 Decal, T railer Hitch T ongue W eight Notice (on trailer/receiver hitch) 7 102884401 Decal, Rollover W arning (on instrument panel) 2 101609401 Decal, Crush Area W arning (behind seat, near cargo bed) 8 102961201 Decal, ROPS W arning ([...]

Safety Decal and Feature Identication ALL HUV 4421 FOUR P ASSENGER MODELS 2413 1 7 5 2 4 8 6 3 9 10 1 101547601 Decal, Gasoline Fuel W arning (at fuel ll or on frame, near fuel tank) 6 102459101 Decal, Ground W arning (on vehicle frame, near battery) 2 102231601 Decal, Winch Safety W arning (on vehicle body , below seat) 7 102459201 Decal, Di[...]

Safety Decal and Feature Identication ALL HUV 4421 FOUR P ASSENGER MODELS 366 11 6 7 9 5 3 1 8 2 4 10 1 101 1553 Decal, T railer Hitch T ongue W eight Notice (on trailer/receiver hitch) 7 102884401 Decal, Rollover W arning (on instrument panel) 2 101609401 Decal, Crush Area W arning (behind seat, near cargo bed) 8 102889201 Decal, Falling Off W [...]

Practice Safety PRACTICE SAFETY 399 Figure 1 Practice Safety Safety signs like you see above may at rst seem shocking, but their impact is mild compared with the reality of severe personal injury . Y our safety and satisfaction are of the utmost importance to us. That is why before operating the vehicle, we urge you to review the information in [...]

Safety Details SAFETY DET AILS W ARNING • This owner ’ s manual should be read completely before attempting to drive or service the vehicle. Failure to follow the instructions in this manual could result in property damage, severe personal injury , or death. It is important to note that some vital statements throughout this manual and on the de[...]

General W arnings W ARNING • Follow the procedures exactly as stated in this manual, and heed all DANGER, W ARNING, and CAUTION statements in this manual as well as those on the vehicle. • Do not leave children unattended on vehicle. • Children requiring a child safety seat must not ride on the vehicle. Comply with state and local laws pertai[...]

General W arnings DISCONNECTING THE BA TTER Y – GASOLINE/DIESEL VEHICLES 1. Disable the vehicle. See Disabling the V ehicle on page 12. 2. Disconnect the battery cables, negative (–) cable rst, as shown (Figure 2) . 3. Gasoline V ehicles Only : Disconnect the spark plug wire(s) from the spark plug(s). NE G PO S 1 2 (–) (+) 1. Remove negati[...]

General Information 1403 Figure 4 Dispose of Lead-acid Batteries Properly GENERAL INFORMA TION This manual includes operating procedures, maintenance, and regular servicing information for all gasoline and diesel HUV 4421-G and HUV 4421-D vehicles. GXP and DXP models have been renamed GX and DX, respectively . All operating procedures, maintenance,[...]

Controls and Indicators P H 0901- 123456 B C54679 SERIAL NUMBER 4 1 2 3 1400 Figure 5 Serial Number Decal CONTROLS AND INDICA T ORS See General W arnings on page 1 1. W ARNING • Before allowing anyone to drive the vehicle, make sure the driver is familiar with all controls and operating procedures. • Do not tamper with the high idle speed setti[...]

Controls and Indicators 9 6 1 1 1 3 2 B A C 7 8 1 3 4 5 12 1 5 14 192 Figure 6 Instrument Panel – Gasoline V ehicles 9 6 1 1 1 3 2 B A C 7 10 8 1 3 4 5 12 1 5 193 Figure 7 Instrument Panel – Diesel V ehicles Page 16 HUV 4421 Owner’s Manual[...]

Controls and Indicators KEY SWITCH – GASOLINE VEHICLES The key switch (7) is mounted on the instrument panel to the right of the steering column (Figure 6) . It has three positions: OFF , ON, and ST AR T . T o start the vehicle, place the Forward/Reverse handle in the NEUTRAL position and turn the key to the ST ART position, and hold it there unt[...]

Controls and Indicators BRAKE PEDAL The brake pedal (2) is located to the immediate left of the accelerator pedal (Figure 6 and Figure 7) . T o slow or stop the vehicle, press the brake pedal. P ARK BRAKE The park brake pedal (3) is located to the left of the brake pedal (Figure 6 and Figure 7) . T o engage the park brake, rst apply pressure to [...]

Controls and Indicators 12-VOL T ACCESSOR Y OUTLET The 12-volt accessory outlet (1 1) is located to the right of the key switch (Figure 6 and Figure 7) . It provides a constant 12VDC with the key switch in the ON or OFF position. See following NOTE. NOTE: Extended use of this accessory outlet can cause the battery to become heavily discharged. LOW [...]

Roll-Over Protective Structure and Seat Belts normal safe operating temperature, the warning light will illuminate. If the warning light lights up, stop the vehicle and allow it to idle for approximately ve minutes before stopping the engine. Contact the dealer/distributor or a trained technician. See following W ARNING. W ARNING • Allow the e[...]

Seat Latch and Adjustment W ARNING • Do not operate the vehicle with the ROPS removed. Doing so could result in property damage, personal injury , or death. • Do not remove or modify any component of the ROPS structure. Doing so will result in voiding the ROPS certication and could weaken the ROPS, resulting in serious injury or death. • D[...]

Pre-Operation and Daily Safety Checklist W ARNING • Do not adjust the driver-side seat while the vehicle is in motion. T o adjust the passenger-side seat 1. Remove the seat from the vehicle. 2. Remove the four bolts and washers from the bottom of the seat mounting plate. 3. Align the mounting plate holes with holes in the seat to achieve the desi[...]

Driving Instructions PERFORMANCE INSPECTION After you have familiarized yourself with the vehicle controls and have read and understood the driving instructions, take the vehicle for a test drive. Use the following list, in addition to the Pre-Operation and Daily Safety Checklist , as a guide to inspect the vehicle daily for proper operation. Any p[...]

Driving Instructions W ARNING • Stop the vehicle before shifting the Forward/Reverse handle. Engine must be at idle before shifting the Forward/Reverse handle. Failure to do so may result in injury to inattentive passengers and (or) damage to the vehicle. • T o help avoid being struck, do not stand in front of or behind the vehicle. • Do not [...]

Driving Instructions 7. Press and hold the brake pedal. 8. T o start the vehicle 8.1. Gasoline vehicles: T urn the key to the ST AR T position and hold it there until the engine starts. Activate the choke as necessary . If the engine does not start after 10-15 seconds, release the key and repeat the procedure. Once the engine starts, release the ke[...]

Bed Latch and Prop Rod W ARNING • Reduced steering control can occur if the front differential becomes locked. T o help prevent this condition, avoid extremely hard braking in reverse. STOPPING THE VEHICLE T o stop the vehicle, release the accelerator pedal and press the brake pedal until the vehicle comes to a complete stop. See following W ARNI[...]

Loading and Unloading Cargo W ARNING persons are clear of cargo bed area. Keep hands clear of all crush areas. Do not drop cargo bed; lower gently and keep entire body clear . Failure to heed this warning could result in severe personal injury or death. NOTE: HUV 4421 gas and diesel vehicles are equipped with an automatically engaging prop rod (Fig[...]

V ehicle Load Capacities W ARNING • Unload cargo bed before raising vehicle with a lift, hoist, or jack. • A void stopping on a hill when loaded. If you must stop on a hill, avoid sudden starts, or rolling backwards and stopping suddenly . Failure to heed this warning may cause vehicle to overturn, possibly resulting in severe personal injury .[...]

T owing with the V ehicle B D A C B D A C 197 Figure 12 V ehicle Load Capacity – T wo-Passenger V ehicles 198 Figure 13 V ehicle Load Capacity – Four-Passenger V ehicles TOWING WITH THE VEHICLE W ARNING • Do not tow a vehicle or trailer on public streets or highways. • Normal vehicle operating speed should be reduced when towing. • Extrem[...]

Storage W ARNING • A void stopping on a hill when towing. If you must stop on a hill, avoid sudden starts, or rolling backwards and stopping suddenly . Failure to heed this warning could cause the vehicle to overturn, possibly resulting in severe personal injury . • Reduce normal driving speed when transporting a vehicle on a trailer . • For [...]

Storage 1 2 3 1. Fuel Shut-off V alve 2. Closed (OFF) 3. Open (ON) NOTE: When selecting valve position, ensure that it is fully opened or fully closed. 449 Figure 14 Fuel Shut-off V alve PREP ARING THE VEHICLE FOR EXTENDED ST ORAGE 1. Unload the vehicle so that the tires are supporting only the weight of the vehicle. 2. Store the vehicle in a cool,[...]

Maintenance 8. Disconnect battery and spark plug (Gas only) wires. See Disconnecting the Battery – Gasoline/Diesel V ehicle on page 13 . 9. The battery should be clean and free of corrosion. Wash the battery top and terminals with a solution of baking soda and water (1 cup (237 mL) baking soda per 1 gallon (3.8 L) of water). Rinse the solution of[...]

Periodic Service Schedule W ARNING • If any problems are found during scheduled inspection or service, do not operate vehicle until repairs are made. Failure to make necessary repairs could result in re, property damage, severe personal injury , or death. • Do not wear loose clothing or jewelry such as rings, watches, chains, etc., when serv[...]

Periodic Service Schedule PERIODIC SER VICE SCHEDULE REGULAR INTERV AL SERVICE Pre-Operation and Daily Safety Checklist See Pre-Operation and Daily Safety Checklist on page 22. Daily service by owner Performance Inspection See Performance Inspection on page 23. Check engine oil level; add if necessary . See Engine Oil Level Check on page 39. Engine[...]

Periodic Service Schedule PERIODIC SER VICE SCHEDULE REGULAR INTERV AL SERVICE appropriate maintenance and service manual. Check for leaks around gaskets, ll plugs, etc. Kawasaki gasoline engines: Adjust valve clearance. See Kawasaki FH680D Service Manual. Gasoline vehicles: Inspect, clean, and gap spark plug; replace if necessary . See authoriz[...]

Periodic Lubrication Schedule PERIODIC LUBRICA TION SCHEDULE PERIODIC LUBRICA TION SCHEDULE REGULAR INTERV AL SERVICE LUBRICA TION POINTS RECOMMENDED LUBRICANT Gasoline vehicle: Kawasaki engine- First change 10 hours Diesel vehicle: First change 50 hours Additional change for all engines every 100 hours of operation or annually , whichever comes ?[...]

Periodic Lubrication Schedule 5 6 3 1 4 2 2 3 199 Figure 15 Lubrication Points – Gasoline V ehicles 5 6 3 1 4 2 2 3 200 Figure 16 Lubrication Points – Diesel V ehicles HUV 4421 Owner’s Manual Page 37[...]

Brake Fluid Reservoir BRAKE FLUID RESERVOIR 1 2 1 2 3 1. Full Level 2. Safe Level 3. Low Level 201 Figure 17 Brake Fluid and Coolant Access (diesel vehicle shown) 202 Figure 18 Brake Fluid Reservoir The brake uid reservoir (1) is located under the hood (Figure 17) . Raise the hood to check the brake uid level. During the brake uid level in[...]

Engine Oil ENGINE OIL Even though the low oil warning light on the instrument panel should illuminate if the oil level becomes low , the engine oil level should be checked daily . The vehicle should be on a level surface when the oil is checked. Do not overll the engine with oil. OIL PRESSURE – GASOLINE ENGINE Kawasaki engine: The Kawasaki gas[...]

Engine Oil 3 2 1 1. Full Level 2. Safe Level 3. Low Level 3 2 1 1. Full Level 2. Safe Level 3. Low Level 205 Figure 19 Engine Oil Level Check – Kawasaki Gasoline V ehicles 204 Figure 20 Engine Oil Level Check – Diesel V ehicles ENGINE OIL AND FIL TER CHANGE The engine oil and oil lter should be changed at the following intervals: • Kawasak[...]

Engine Oil 7. Use a socket or wrench to replace the oil drain plug (1) (Figure 21 or Figure 22) . T urn the plug clockwise and tighten to 61 in-lb (6.9 N·m) for Kawasaki gas vehicles with plastic drain plugs, 14.5 ft-lb (20 N·m) for Kawasaki gas vehicles with metal drain plugs, or 31 ft-lb (42 Nm) for diesel vehicles. 1 1 2 207 Figure 21 Engine O[...]

Engine Oil NOTE: An oil drip guard (1) can be used to prevent excess oil from dripping onto the engine base plate (Figure 24) . Use an empty quart (one liter) container and cut the bottom off at an angle, then slide the open area of the container up and under the oil lter (2) before removal. Position the port of the plastic container so oil will[...]

Engine Oil 203 Figure 26 Add Engine Oil – Gasoline V ehicles 212 Figure 27 Add Engine Oil – Diesel V ehicles Engine Oil Filling 1. Add engine oil (Figure 26 or Figure 27) . With lter change, the engine requires the following amounts: – Kawasaki gasoline engines: 1 qt. and 19 oz. (1.5 L) of oil per change. – Kubota diesel engines: 3 qt. ([...]

Gearcase Lubrication NOTE: Use engine oil with API classication SJ for gasoline engines and CF for diesel engines. Using multi-grade oils (5W-20, 10W-30, and 10W-40) may increase oil consumption. If multi-grade oil is used, check the oil level more frequently . SAE 5 W-30 SAE 10W-30/ SAE 10W-40 SAE 30 SAE 40 SAE 10W-30/SAE 10W-40 SAE 20 SAE 30 S[...]

Gearcase Lubrication 1 2 1 2 215 Figure 30 Front Differential Lubrication Level 216 Figure 31 T ransmission Lubrication Level T ransmission: Clean and install the drain plug (2) before lling the transmission with new lubricant (Figure 31) . T ighten the drain plug to 96 in-lb (1 1 N·m). Remove the ll plug from the top of the transmission cas[...]

Engine Coolant – Diesel V ehicles 1 2 217 Figure 32 Rear Differential Lubrication Level ENGINE COOLANT – DIESEL VEHICLES ENGINE COOLANT LEVEL CHECK The coolant reserve tank (2) is located under the hood on the passenger side (Figure 17) . Raise the hood to check the coolant level before every operation. 1. Check the coolant level of the reserve[...]

Air Intake System AIR INT AKE SYSTEM CAUTION • Do not drill into the driver-side frame. Failure to heed this caution could damage the engine by allowing excessive contamination to enter the air intake system. AIR FIL TER REPLACEMENT The air lter should be inspected periodically and replaced when necessary . Filter changes should not exceed the[...]

Fueling Instructions FUELING INSTRUCTIONS See General W arnings on page 1 1. DANGER • T urn the key switch to the OFF position before fueling. • Do not pour fuel into the fuel tank when the engine is hot or while it is running. • T o avoid electric arc caused by static electricity , the fuel storage/pumping device must be grounded. If the pum[...]

Fueling Instructions Biodiesel is an excellent medium for microbial growth and contamination. Microbial contamination can cause corrosion of the fuel system and prematurely plugged fuel lters. See following NOTE. NOTE: Use of biodiesel may result in premature failure of fuel system components. Kubota has documented problems such as plugged fuel [...]

Battery W ARNING • Clean up spilled fuel. Keep sparks and ames away from the vehicle and service area. Failure to heed this warning could result in an explosion or re, resulting in severe personal injury or death. 5. Close the valve by rotating it counterclockwise until the valve is rmly sealed. 6. T o resupply the lter with fuel, tur[...]

Battery DANGER – Eyes: Flush with water for 15 minutes. Call a physician immediately . • T ools, wires, and metal objects can cause sparks when shorted across a battery . W ARNING • Wear safety glasses or approved eye protection when servicing the vehicle. • Follow all instructions carefully when working with batteries. • When jumping fro[...]

Using A Booster Battery (Jump Starting) W ARNING • Wear safety glasses or approved eye protection when servicing the vehicle. W ear a full face shield and rubber gloves when working on or near batteries. 5. Carefully check the electrolyte level and add distilled water if necessary . Do not ll the battery cells above the designated ll line. [...]

Cleaning the V ehicle CAUTION • The alternator can be damaged if the following actions occur: – Engine is operated with battery cables disconnected. – Booster cables are connected wrong. P OS NEG PO S NEG 4 2 3 1 223 Figure 39 Jump Starting CLEANING THE VEHICLE Each vehicle is equipped with hand-washable front and rear bodies. The vehicle has[...]

Accessories ACCESSORIES There is a complete line of accessory equipment available from our dealers/distributors. Care should be taken that these accessories are properly installed by trained technicians and that they are used in the manner for which they were designed. See following W ARNING and CAUTION. W ARNING • Custom cab assemblies, canopy t[...]

Subsequent Owner Registration W ARNING • T o avoid the risk of rollover when operating a vehicle equipped with mud tires on a paved surface: reduce speed, use extreme caution, and drive slowly in turns. • The diameter of all tires on the vehicle must be equal; otherwise the all-wheel drive system will not operate as intended and could result in[...]

V ehicle Specications VEHICLE SPECIFICA TIONS SPECIFICA TIONS HUV 4421-G; HUV 4421- GXP HUV 4421-D; HUV 4421- DXP HUV 4421-GXL HUV 4421- DXL POWER SOURCE GASOLINE DIESEL GASOLINE DIESEL Engine: (Kawasaki) 4-cycle OHV , 675 cc, 23.0 maximum HP @3600 RPM (per SAE J 1940/1349), twin-cylinder , air-cooled, with pressure lubrication system • • En[...]

V ehicle Specications SPECIFICA TIONS HUV 4421-G; HUV 4421- GXP HUV 4421-D; HUV 4421- DXP HUV 4421-GXL HUV 4421- DXL Overall width: without mirror with mirror 58.5 in. (148.5 cm) 63.6 in. (161.5 cm) *Overall height (with ROPS): with mud tires with all-terrain tires 82.3 in. (209 cm) 80.3 in. (203.8 cm) Wheelbase 81.5 in. (207 cm) 1 14 in. (289.5[...]

V ehicle Specications SPECIFICA TIONS HUV 4421-G; HUV 4421- GXP HUV 4421-D; HUV 4421- DXP HUV 4421-GXL HUV 4421- DXL Rear differential: Mobil 424, Exxon Hydraul 560, or Esso Hydraul 56 lubricant 20 oz. (600 mL) T ransmission: Mobil 424, Exxon Hydraul 560, or Esso Hydraul 56 lubricant 20 oz. (600 mL) Engine coolant: mixture of 55% propylene glyco[...]

Warranties W ARRANTIES HUSQV ARNA® LIMITED TWO YEAR W ARRANTY FOR TRANSPORT A TION AND UTILITY VEHICLES 1. W ARRANTY : Husqvarna, Inc., ("Husqvarna") hereby warrants to the Original Retail Purchaser that its new Transportation and Utility V ehicles purchased from Husqvarna or an authorized dealer shall be free from defects in material an[...]

Warranties 5. HOW TO MAKE A W ARRANTY CLAIM: T o make a warranty claim under this limited warranty , you must present the vehicle or defective component to an authorized Husqvarna dealer . 6. DISCLAIMER: THIS LIMITED W ARRANTY IS EXCLUSIVE. HUSQV ARNA MAKES NO OTHER W ARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ANY IMPLIED W ARRANTIES OF MERCHANT AB[...]

Warranties - As the vehicle engine owner , you are responsible for the performance of the required maintenance listed in your owner ’ s manual. HUSQV ARNA recommends that you retain all receipts covering maintenance on your vehicle engine, but HUSQV ARNA cannot deny warranty solely for the lack of receipts or for your failure to ensure the perfor[...]

Warranties repair or replacement of the part. That notwithstanding, any adjustment of a component that has a factory installed, and properly operating, adjustment limiting device is still eligible for warranty coverage. The following emission warranty parts list are covered: SYSTEMS COVERED P ARTS DESCRIPTION Fuel Metering Carburetor assembly , fue[...]

[...]

[...]

[...]

Publication Part Number 103472526 Edition Code 0708D1010C 103472526 This manual is valid f or vehicles built during the 2009 model year . It is also valid for vehicles with build c odes between 54699 and the one indicated at the top of this page .[...]