HUV 5420 DXR Homologated Diesel Vehicle for Europe Owner’s Manual [Refer to back cover for applicable build code range]
NOTICE This manual is valid for vehicles manufactured in the build code range provided on the back cover of this manual. If the vehicle build code is different from that shown on the back cover of this manual, please contact your nearest dealer or go to www.husqvarna.com to retrieve the proper owner’s manual for the vehicle. See also Model Identification in this manual.
FOREWORD Thank you for choosing Husqvarna, the name most widely recognized as the industry leader in vehicle efficiency and long-lasting value. You have chosen the finest utility vehicle on the market. Please protect your investment and ensure that your Husqvarna vehicle(s) provides years of reliable, superior performance by reading and following the maintenance instructions in this manual.
TABLE OF CONTENTS Safety Decal and Feature Identification .................................................................................................................. 4 Practice Safety ..................................................................................................................................................... 6 Safety Details .......................................................................................................................................................
Safety Decal and Feature Identification SAFETY DECAL AND FEATURE IDENTIFICATION The following pages contain safety decal and feature identification information. For detailed information on specific features, read the appropriate section in this manual.
Safety Decal and Feature Identification HUSQVARNA HUV 5420 DXR HOMOLOGATED DIESEL VEHICLE ! 5 WARNING 8 7 3 6 1 2 4 9 10 378 1 1011553 2 101609401 3 102224001 4 102459301 5 102459401 Decal, Trailer Hitch Tongue Weight Notice (on trailer/receiver hitch) Decal, Crush Area Warning (behind seat, near cargo bed) Decal, Rotating Parts Warning (on frame) Decal, Bed Latch Warning (on vehicle body, below bed latch) Decal, Young Driver Warning (on ROPS) Decal, Rotating Parts Warning (on vehicle
Practice Safety PRACTICE SAFETY 399 Figure 1 Practice Safety Safety signs like you see above may at first seem shocking, but their impact is mild compared with the reality of severe personal injury. Your safety and satisfaction are of the utmost importance to us. That is why before operating the vehicle, we urge you to review the information in this manual.
Safety Details SAFETY DETAILS WARNING • 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. • The homologated diesel vehicle is equipped to operate at a top speed of 25 mph (40 km/h) and is intended for use as a low-speed vehicle.
General Warnings CAUTION • A CAUTION without the safety alert symbol indicates a potentially hazardous situation that could result in property damage. GENERAL WARNINGS The following safety statements must be heeded whenever the vehicle is being operated, repaired, or serviced. See Safety Decal and Feature Identification on page 4. Other specific safety statements appear throughout this manual and on the vehicle. DANGER • Battery – Explosive gases! Do not smoke.
General Warnings WARNING drop cargo bed; lower gently and keep entire body clear. Failure to heed this warning could result in severe personal injury or death. • Only trained technicians should service or repair the vehicle. Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair. The appropriate instructions must be used when performing maintenance, service, or accessory installation.
General Warnings 2 (+) PO S NEG 1 (–) 1. Remove negative battery cable. 2. Remove positive battery cable. Connect battery cables in reverse order. 189 188 Figure 2 Battery Cable Removal Figure 3 All-Wheel Drive Warning RECYCLING LEAD-ACID BATTERIES WARNING • Lead-acid batteries contain lead (Pb), other metals, acids and other compounds. If improperly handled, they can contaminate both water and soil, causing environmental damage and personal injury.
General Information GENERAL INFORMATION This homologated vehicle is designed for operation on public roads. Its construction also allows operation on rough terrain with inclines not exceeding 20%. This manual includes operating procedures, maintenance, and regular servicing information for the Husqvarna HUV 5420 DXR vehicles that have been homologated for Europe. MODEL IDENTIFICATION The vehicle identification number (Figure 5) is located on the center cross bar underneath the bed at the rear of the car.
Controls and Indicators CONTROLS AND INDICATORS See General Warnings on page 8. WARNING • Before allowing anyone to drive the vehicle, make sure the driver is familiar with all controls and operating procedures. • Do not tamper with the high idle speed setting on the diesel vehicle. Doing so will void the warranty, as well as damage the engine and other components, and could result in property damage, personal injury, or death due to unsafe speeds.
Controls and Indicators WARNING • Moving parts! Keep clear of the engine compartment while the engine is running. CAUTION • Do not shift the Forward/Reverse handle while the accelerator pedal is pressed. Shift the handle only when the vehicle is at a complete stop and the engine is at idle. Failure to heed this caution could result in damage to the transmission. NOTE: The key can be removed only when the key switch is in the OFF position.
Controls and Indicators BRAKE LIGHTS The brake lights illuminate when the brake pedal is pressed. When the park brake is engaged, the brake lights will turn off. See following NOTE. NOTE: When the key switch is in the OFF position, the brake lights are disabled. PARK BRAKE The park brake pedal (3) is located to the left of the brake pedal (Figure 7). To engage the park brake, first apply pressure to the brake pedal, then firmly press the park brake pedal until it latches into place.
Controls and Indicators 12-VOLT ACCESSORY OUTLET The 12-volt accessory outlet (11) is located to the right of the key switch (Figure 7). It provides a constant 12VDC with the key switch in the ON or OFF position. See following NOTE. NOTE: Extended use of this accessory outlet can cause the battery to become heavily discharged. LOW OIL WARNING LIGHT The low oil warning light (9) is located on the instrument panel just to the left of the steering column (Figure 7).
Controls and Indicators 227 Figure 9 Turn Signal and Horn Controls ELECTRIC BED LIFT The electric bed lift switch (13) is located on the instrument panel to the left of the key switch (Figure 7). To lift the bed, pull up and hold the toggle switch in the upper position. Release switch to stop lifting operation. To close the bed, press down and hold switch in the lower position. The bed lift will make a loud clicking sound to signal the bed is in the rest position.
Roll-Over Protective Structure and Seat Belts ROLL-OVER PROTECTIVE STRUCTURE AND SEAT BELTS This Husqvarna HUV 5420 DXR vehicle is equipped with a Roll-Over Protective Structure (ROPS) and seat belts for each occupant. See following WARNING. WARNING • The ROPS must be properly installed before operating the vehicle. Husqvarna strongly urges that the vehicle’s occupants be properly restrained at all times with the seat belts provided. Pregnant woman: Consult your doctor for specific recommendations.
Roll-Over Protective Structure and Seat Belts WARNING • Do not operate the vehicle if the ROPS is damaged. If the ROPS is damaged, replace the structure. Do not attempt repair. • The driver and passenger must be restrained at all times with the seat belts provided to help prevent injury in the event of sudden braking, collision, or roll-over. • In the event of a roll-over, do not attempt to jump or otherwise exit the vehicle. Remain seated with seat belt fastened and with arms and legs inside the vehicle.
Roll-Over Protective Structure and Seat Belts NOTE: Use care to avoid excessively decreasing seat tension. Excessive adjustment will cause the adjustment bolt to disengage from its bracket, and the adjustment handle will not function properly. If the adjustment bolt becomes disengaged from its bracket, it must be hand-threaded back into the bracket.
Pre-Operation and Daily Safety Checklist PRE-OPERATION AND DAILY SAFETY CHECKLIST Each Husqvarna vehicle has been thoroughly inspected and adjusted at the factory; however, upon receiving your new vehicle(s), you should become familiar with the controls, indicators, and operation. Carefully inspect each vehicle to ensure that it is in proper working condition before accepting delivery. Use the following list as a guide to inspect the vehicle.
Driving Instructions • Park brake: When latched, the park brake should lock the wheels and hold the vehicle stationary on an incline of 20% or less. • Reverse buzzer: The reverse buzzer should sound as a warning when the Forward/Reverse handle is in the REVERSE position. • Steering: The vehicle should be easy to steer and should not have any play in the steering wheel. Be sure the steering wheel adjustment lever is securely locked into position.
Driving Instructions WARNING • To help prevent overturning the vehicle, drive slowly straight up and down slopes. Avoid driving the vehicle on slopes exceeding 20% incline. • Avoid stopping a loaded vehicle on a hill. If a loaded vehicle must be stopped on a hill, avoid sudden starts or rolling backwards and stopping suddenly. Failure to heed this warning could result in overturning the vehicle.
Driving Instructions WARNING • Operator must control vehicle speed when going downhill. • Never shift the vehicle out of the FORWARD position while going downhill. If you do, you will not be able to shift into the REVERSE position or back into the FORWARD position until stopped. • Press the brake pedal as necessary and press the accelerator pedal partially when descending a hill.
Loading and Unloading Cargo CAUTION • When stopped on a hill, use the brake pedal to hold your position. Do not use the accelerator pedal to hold position. PARKING AND LEAVING THE VEHICLE 1. 2. After stopping the vehicle, firmly set the park brake. Make sure it is fully engaged. This will prevent the vehicle from rolling. Turn the key switch to the OFF position, remove the key, and place the Forward/Reverse handle in the NEUTRAL position.
Vehicle Load Capacities Gross Trailer Weight Gross trailer weight is the combination of the trailer weight and the trailer load weight. Maximum Payload Capacity The maximum payload capacity is the maximum amount of load that the vehicle can haul in the cargo bed and/or tow in a trailer. The combined weight of bed load and gross trailer weight cannot exceed the vehicle’s stated maximum payload capacity.
Towing with the Vehicle TOWING WITH THE VEHICLE WARNING • Do not tow a vehicle or trailer on public streets or highways. • Normal vehicle operating speed should be reduced when towing. • Extreme caution should be used when towing. • Do not allow riders in the vehicle or trailer being towed. • Avoid sudden starts, sudden stops, and tight turns when towing. • Avoid stopping on a hill when towing. If you must stop on a hill, avoid sudden starts, or rolling backwards and stopping suddenly.
Storage STORAGE See General Warnings on page 8. DANGER • Do not attempt to drain fuel when the engine is hot or while it is running. • Clean up any spilled fuel before operating the vehicle. • Store fuel in an approved fuel container only. Store in a well-ventilated area away from sparks, open flames, heaters, or heat sources. • Keep fuel out of the reach of children. • Do not siphon fuel from the vehicle.
Maintenance RETURNING THE STORED VEHICLE TO SERVICE 1. Make sure the key switch is in the OFF position and the Forward/Reverse handle is in the NEUTRAL position. Chock the wheels. 2. Restore the fuel system to operation (Figure 27). 2.1. Remove the plug from the fuel tank vent. 2.2. Connect the vent tube to the fuel tank vent. 3. Connect battery. See Connecting the Battery – Diesel Vehicles on page 9. Coat terminals with Battery Terminal Protector Spray (P/N 603 00 00-03). 4.
Periodic Service Schedule WARNING • If wires are removed or replaced make sure wiring and wire harness are properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury, or death. • Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic floor jack) with 1000 lb. (454 kg) minimum lifting capacity. Do not use lifting device to hold vehicle in raised position.
Periodic Service Schedule PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Pre-Operation and Daily Safety Checklist Performance Inspection See Pre-Operation and Daily Safety Checklist on page 20. See Performance Inspection on page 20. Check engine oil level; add if necessary. See Engine Oil Level Check on page 34. Engine Check engine coolant; add if necessary. See Daily service by owner or trained technician Engine Coolant Level Check on page 39. Fuel filters Drain water from fuel filter.
Periodic Service Schedule PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Check for leaks around gaskets, fill plugs, etc. Check the v-belt for proper tension or damage. Engine Adjust or replace if necessary. Change engine coolant. See Radiator and Cooling System Section in the maintenance and service manual. Annual service by trained technician only Radiator (or every 100 hours of operation, whichever comes first) Check clamps for tightness; check hose for cracks. Replace air filter element.
Periodic Lubrication Schedule PERIODIC LUBRICATION SCHEDULE PERIODIC LUBRICATION SCHEDULE REGULAR INTERVAL LUBRICATION POINTS SERVICE RECOMMENDED LUBRICANT First change 50 hours – additional change for both every 100 hours of operation Change engine oil and oil filter 1 Driveshaft 2 or annually, whichever comes 3 qt. (2.8 L) with filter. See Oil Viscosity on page 37. first.
Brake Fluid Reservoir BRAKE FLUID RESERVOIR 1 2 2 1 3 1. Full Level 2. Safe Level 3. Low Level 202 201 Figure 15 Brake Fluid and Coolant Access Figure 16 Brake Fluid Reservoir The brake fluid reservoir (1) is located under the hood (Figure 15). Raise the hood to check the brake fluid level. During the brake fluid level inspection, also inspect the following: • The presence of brake fluid on the exterior surface of the master cylinder indicates a leak.
Engine Oil ENGINE OIL LEVEL CHECK 1. Remove the oil level dipstick from the oil filler tube and wipe oil from the dipstick (Figure 17). See following CAUTION. CAUTION • Do not remove dipstick while engine is running. 2. 3. Check oil level by fully inserting the dipstick into the tube and immediately removing it. If the oil level is at or below the low level mark on the dipstick gauge, add oil to the engine until the level is between low and full levels (safe level). See following CAUTION.
Engine Oil 5. From the underside of the vehicle, use a socket or wrench to remove the drain plug (1). Turn the plug counterclockwise and drain the engine oil into the pan. See following WARNING. WARNING • Do not attempt to change engine oil when the engine is hot or even warm. Hot engine oil can cause skin burns. • Wear safety glasses or approved eye protection when servicing the vehicle. Wear rubber gloves when handling oil drain plug, oil filter, and oil drain pan. 6.
Engine Oil 26 27 Figure 19 Remove Engine Oil Filter 4. 5. Figure 20 Coat Rubber Seal Use a clean, lint-free rag to wipe the oil filter port flange surface clean where the oil filter gasket seats. To help seal the new oil filter to the oil port flange, apply a light coat of white lithium NLGI Number 2 grease (Dow Corning® BR2-Plus or equivalent) or new engine oil to the rubber seal around the outside surface of the filter before attaching it to the oil filter port (Figure 20).
Engine Oil Engine Oil Filling 1. Add engine oil; use a funnel or pour spout to direct the oil into the opening (Figure 21). With filter change, the engine requires 3 qt. (2.8 L) of oil. Refer to oil viscosity guidelines for selection of oil grade (Figure 22). See following CAUTION. CAUTION • Do not exceed recommended oil capacity. Doing so will decrease engine performance or result in damage to the engine. 2. 3. Connect battery. See Connecting the Battery – Diesel Vehicles on page 9.
Gearcase Lubrication GEARCASE LUBRICATION NOTE: Dispose of used oil according to the environmental laws and regulations for your area. LUBRICATION LEVEL CHECK FOR FRONT DIFFERENTIAL, TRANSMISSION, AND REAR DIFFERENTIAL Each gearcase component is equipped with two oil port plugs (1 and 2) (Figure 23, Figure 24, and Figure 25). When the vehicle is on a level surface, use the level indicator hole (upper plug) (1) as a lubricant level indicator.
Engine Coolant Check the level of lubricant at the level indicator plug (1). Apply Loctite 567 to the threads of the level indicator plug and tighten to 21 ft-lb (28 N·m). Rear differential: Clean and install the drain plug (2) and washer before filling the rear differential with new lubricant (Figure 25). Tighten the drain plug to 96 in-lb (10.8 N·m). Use a funnel to fill the differential through the lubricant level indicator hole (1). See Periodic Lubrication Schedule on page 32.
Air Intake System AIR INTAKE SYSTEM CAUTION • Do not drill into the driver-side frame. Failure to heed this caution could damage the engine by allowing excessive contamination to enter the air intake system. AIR FILTER REPLACEMENT The air filter should be inspected periodically and replaced when necessary. Filter changes should not exceed the recommended interval. See Periodic Service Schedule on page 29. More frequent service may be required in extremely dirty operating environments.
Fueling Instructions FUELING INSTRUCTIONS See General Warnings on page 8. DANGER • Turn the key switch to the OFF position before fueling. • Do not pour fuel into the fuel tank when the engine is hot or while it is running. • To avoid electric arc caused by static electricity, the fuel storage/pumping device must be grounded. If the pump is not grounded, the vehicle must be grounded to the pump before and during the fueling operation.
Fueling Instructions Biodiesel can damage painted surfaces. Be sure to remove all spilled fuel immediately to help prevent damage to painted surfaces. If biodiesel will be used in the Kubota D722 engine, be sure that it meets the following requirements: • The fuel blend should contain no more than 5% biodiesel by volume. • The petroleum portion of the fuel blend must meet ASTM standard D975 and the biodiesel portion of the fuel blend must meet ASTM standard D6751.
Battery 1 221 Figure 28 Fuel Filter BATTERY See General Warnings on page 8. DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries. • Battery – Poison! Contains acid! Causes severe burns. Avoid contact with skin, eyes, or clothing. Antidotes: – External: Flush with water. Call a physician immediately.
Battery WARNING • When jumping from a booster battery make final (negative) connection at engine frame. • Do not jump start or charge a frozen or damaged battery. Unplug charger before connecting or disconnecting cables to the battery. Never lean over battery while boosting, testing, or charging. The battery in a Husqvarna vehicle is a 12-volt, low-maintenance battery that requires infrequent checks (Figure 29). Electrolyte level should be checked semiannually. 2 1 3 POS NEG 1. Level Indicator 2.
Using A Booster Battery (Jump Starting) WARNING • If battery wire terminals are damaged or corroded, replace or clean them as necessary. Failure to do so may cause them to overheat during operation and could result in a fire, property damage, or personal injury. Be sure the battery hold-down clamp is properly tightened. Tighten to 108 in-lb (12.2 N·m). A loose clamp may allow the battery to become damaged from vibration or jarring. If battery appears weak, have it charged by a trained technician.
Cleaning the Vehicle 4 2 POS NEG 3 G E N P O S 1 223 Figure 31 Jump Starting CLEANING THE VEHICLE Each vehicle is equipped with hand-washable front and rear bodies. The vehicle has a powder-coated steel cargo bed (or optional aluminum flat bed). Use commercial automotive cleaning solutions with a sponge or soft cloth for normal cleaning. A garden hose at normal residential water pressure is adequate.
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 WARNING and CAUTION. WARNING • Custom cab assemblies, canopy tops, weatherproof enclosures, and windshields will not protect occupants from flying objects.
Vehicle Specifications VEHICLE SPECIFICATIONS SPECIFICATIONS DIESEL VEHICLES POWER SOURCE Engine: 4-cycle OHV, 719 cc 15Kw (20.0 maximum HP) @3600 RPM (per SAE J • 1940/1349) Three-cylinder, liquid-cooled, with pressure lubrication system Fuel system: Mechanical injection, fuel water separator, fuel filters, and electric fuel pump • Governor: internal to engine, mechanical, centrifugal ball • Ignition: Compression • Transmission: Forward and reverse with neutral (4.98:1 forward, 7.
Vehicle Specifications SPECIFICATIONS DIESEL VEHICLES Standard option: High capacity option: 706 lb. (320 kg) 961 lb. (436 kg) 1106 lb. (544 kg) 1361 lb. (657.6 kg) Maximum payload capacity (level surface only) Vehicle rated capacity (payload, driver, and passenger; level surface only) NOISE AND VIBRATION SPECIFICATIONS Drive-by noise level to operator per BS EN 1726-1:1999 82 dBA Drive-by noise level to environment 79.9 dBA Vibration at driver’s seat per BS EN 13059:2002 +A1:2008 1.
BC55284 Publication Part Number 103472543 Edition Code 0409D0609C This manual is valid for vehicles built during the 2009 model year. It is also valid for vehicles with build codes between 54699 and the one indicated at the top of this page.
