Snapper UVGT1621BV, 7085903, 7085668, 7085632, UVG1621BV User Manual

...

Safety Instructions & Operator’s Manual For

†

™

TURF CRUISER

™

TRAIL CRUISER

UTILITY VEHICLES

SERIES 1

UV1621BV (7085668)

UVG1621BV (7085632)

UVGT1621BV (7085903)

Thank you for buying a Turf Cruiser™/Trail Cruiser™ Utility Vehicle! Before operating your machine, read this manual carefully and pay particular attention to the “IMPORTANT SAFETY INSTRUCTIONS” on Pages 2 thru 6. Remember that all power equipment can be dangerous if used improperly. Also keep in mind that SAFETY requires careful use in accordance with the operating instructions and common sense!

NOTE: Specifications are correct at time of printing and are subject to change without notice.

* Actual sustained equipment horsepower will likely be lower due to operating limitations and environmental factors.

† Turf Cruiser™ & Trail Cruiser™ utility vehicles are manufactured by Snapper Products Inc., McDonough, GA 30253.

MANUAL No. 7026153 (Rev. 2, 11/11/04)

UVGT1621BV shown

NOTE: Not all utility vehicle models come with accessories shown above.

TP 100-5107-2-GC-N

IMPORTANT SAFETY INSTRUCTIONS

WARNING

This machine is a multi-purpose utility vehicle intended for off-road use only. It is not a toy and it is not a recreation vehicle. Careless, reckless operation can cause accidents resulting in damage and injury. Failure to comply with the following SAFETY instructions could result in serious injury or death to the operator or others. The owner of the machine must understand these instructions and only allow persons that understand these instructions to operate the machine. The operator must be an adult or teenager with mature judgment, 16 years old or older, and must possess a valid driver’s license. Each operator must evaluate his or her ability to operate the machine safely and is responsible for the safe operation of the machine and the safety of a passenger. Safe operation of the machine limits the number of occupants to one operator and only one passenger. Both the operator and the passenger must be seated in the seats provided with the seat belt buckle securely latched and the seat belt adjusted to a snug fit. The person operating the machine must be of sound mind and body and must not be under the influence of any substance, which might impair vision, dexterity or judgment. If you have any questions pertaining to your machine, which your dealer cannot answer to your satisfaction, call or write the Customer Service Department at SNAPPER, McDonough, Georgia 30253. Phone: 800-935-2967.

PROTECTION FOR CHILDREN

Tragic accidents can occur if the operator is not alert to the presence and safety of children. Children are often attracted to the machine and the work activity. Never assume that children will remain where you last saw them.

1. KEEP children out of the work area, away from the machine and under the watchful care of a responsible adult.

2. DO NOT allow children or others to ride in the cargo bed, on attachments or towed equipment. The one Passenger must be seated in the passenger seat with the seat belt buckle securely latched and the seat belt adjusted to a snug fit.

3. DO NOT allow pre-teenage children to operate the machine. All operators must be properly trained in the safe operation of the machine, be 16 years old or older, and possess a valid driver’s license.

4. ALLOW only adults or responsible teenagers, 16 years old or older, with mature judgment under close adult supervision to operate machine.

5. BEFORE BACKING, stop machine completely. LOOK and SEE behind and down for children, pets and hazards, before and while backing.

6. USE EXTRA CARE and reduce speed when approaching blind corners, shrubs, trees, or other objects that may obscure vision.

7. SEAT BELTS are provided for the comfort and safety of the operator and a passenger and must be worn at all times. Lap-style seat belts may not provide adequate protection for small children. Carrying infants or toddlers is not recommended. USE EXTRA CARE when carrying a child passenger.

PROTECTION AGAINST TIPOVERS

The machine is equipped with an Operator Protective Structure. The structure when used properly can offer additional security to the operator and a passenger in the event of a tip-over accident. The lap-style seat belts must be worn at all times for proper protection. Slopes, improper loads and towing are major factors related to lossof-control and tip-over accidents. All slopes require extra CAUTION. Loads, attachments and towing affect stability, handling and braking. Reduce speed, avoid sharp turns and sudden changes in speed. Allow extra distance for stopping machine.

1. DO NOT operate the machine on slopes exceeding 15 degrees (27% grade). Loss of control, sliding and/or tipover may occur.

2. Exercise EXTREME CAUTION on slopes above 10 degrees (18% grade).

3. DO NOT operate machine back and forth across face of slopes. Operate up and down. Practice on slopes with cargo bed empty, and no attachments or trailer hitched to machine.

4. Avoid uphill starts. If machine stops going uphill or tires lose traction, apply brake, back slowly and straight down the slope. Do not turn machine.

5. STAY ALERT for holes and other hidden hazards. Tall grass can hide obstacles. Keep away from ditches, washouts, culverts, fences and protruding objects.

6. Keep a safe distance (at least 3 feet) away from edge of ditches and other drop offs. The machine could turn over if an edge caves in.

7. Always begin forward motion slowly and with caution.

IMPORTANT SAFETY INSTRUCTIONS

PROTECTION AGAINST TIPOVERS

(Continued)

8. DO NOT operate machine on slopes exceeding 10 degrees (18% grade) when towing. Cargo bed must be loaded when towing.

9. DO NOT put your foot on the ground to try and stabilize the machine.

10. DO NOT operate machine under any condition where traction, steering or stability is doubtful.

11. DO NOT remove or modify the Operator Protective Structure. Operator and passenger must be properly seated and must wear seat belts, snuggly fastened, at all times.

12. DO NOT shift to neutral and allow machine to coast down slope. When descending a slope apply brake to maintain safe speed and drive straight. Avoid turning when descending a slope.

13. The use of a helmet, face shield or safety glasses and substantial clothing is recommended.

CARRYING LOADS

Carrying loads affects the handling, stability and braking of the machine. Improper loads, excessive speed, sharp turns, rough ground, loose or slippery surfaces and slopes can cause loss of control, sliding and/or tip-over accidents resulting in damage, serious injury or death. Extra caution is required whenever the machine is used to carry loads.

1. DO NOT exceed rated load capacity of the machine. Reduce load and speed when operating machine on slopes.

2. DO NOT carry off-center loads. All loads must be centered in the cargo bed and secured to prevent shifting.

3. DO NOT stack loads higher than the sides of the cargo bed. Keep all loads as low as possible to minimize effect on stability.

4. Loads affect stability, handling and braking. Reduce speed, avoid sharp turns, and allow extra distance for braking.

5. DO NOT attempt to dump loads from cargo bed. Empty load before raising bed. Raising a loaded cargo bed can affect stability, resulting in tip-over.

6. DO NOT drive machine with the cargo bed in a raised position.

7. DO NOT raise cargo bed when on a slope.

8. Tire pressure is extremely important to the handling, stability and braking of the machine. Tire inflation pressure must be maintained as specified on the machine and in this manual.

CARRYING LOADS

9. Always release accelerator and apply brake when descending slopes to maintain safe speed.

10. DO NOT replace tires with different size or construction. Tire size and construction are critical to the proper handling and stability of the machine. Use only tires approved by manufacturer.

(Continued)

TOWING

Towing, as with carrying loads, affects the handling, stability and braking of the machine. Towing loads requires extra caution. Reduce speeds when towing and avoid slopes whenever possible. Allow extra distance for braking.

1. DO NOT exceed rated towing capacity of machine. Reduce load on slopes.

2. DO NOT exceed rated tongue capacity of hitch.

3. DO NOT modify hitch. Towed loads must only be attached to the hitch point provided on the machine.

4. DO NOT attempt to tow where steering, traction or stability is doubtful.

5. Tow loads at a speed slow enough to maintain control. DO NOT exceed 10 MPH while towing.

6. Cargo bed must be loaded when towing to provide adequate traction and braking.

7. DO NOT tow a load that you cannot safely control.

8. DO NOT tow loads on rough ground, or loose, slippery surfaces.

9. DO NOT allow children or others to ride on a trailer or towed attachment.

10. DO NOT tow the machine behind any other machine or vehicle.

PREPARATION

Read, understand and follow instructions and warnings in this manual and on the machine, engine and attachments. Know the controls and the proper use of the machine before starting.

1. Only mature, responsible persons shall operate the machine and only after proper instruction. The operator must possess a valid driver’s license.

2. Handle fuel with care. Fuels are flammable and vapors explosive. Use only approved fuel container. DO NOT remove fuel cap or add fuel with the engine running. Add fuel outdoors only with engine stopped and cool. Clean spilled fuel from machine. DO NOT smoke while refueling the machine.

3. Practice operation of machine in a flat open area free from obstacles and hazards. Operate at reduced speed until familiar with the handling of the machine and operation of all controls.

IMPORTANT SAFETY INSTRUCTIONS

PREPARATION (Continued)

4. Be familiar with the area in which the machine will be operated. Inspect area for objects and hazards that could cause loss of control.

5. Keep people and pets clear of machine and work area.

6. Inspect shields, guards, switches, brakes and other safety devices frequently for proper operation and keep them in place.

7. Inspect headlights and repair as required before operating machine. Keep headlight lenses and rear reflectors clean to provide maximum visibility.

8. Make sure all safety signs are clearly legible. Replace if damaged.

9. Protect yourself; dress appropriately for the conditions and the work being performed. Protective equipment, such as helmet, safety glasses or face shield, substantial footwear, long pants, is recommended.

10. Know how to STOP the machine quickly and safely in preparation for emergencies.

11. Use extra care when loading or unloading machine into a truck or trailer.

12. Make sure accelerator, brake, steering, and shift lever function properly before operating machine.

13. Adjust tire inflation pressure to the specifications listed on the machine and in this manual.

14. Inspect condition of tires and replace worn or deteriorated tires before operating machine, using only tires of the same size, type and construction approved by SNAPPER.

15. Obey all local ordinances and laws governing the operation of off-road vehicles. Drive responsibly and respect private property.

SAFE HANDLING OF GASOLINE

To avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive

1. Extinguish all cigarettes, cigars, pipes and other sources of ignition.

2. Use only an approved fuel container.

3. DO NOT remove fuel cap or add fuel with the engine running. Allow the engine to cool before refueling.

4. DO NOT refuel the machine indoors.

5. DO NOT store the machine or fuel container inside where there is an open flame, spark or pilot light such as on a water heater or other appliances.

6. DO NOT fill fuel containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place the containers on the ground away from the vehicle before filling.

SAFE HANDLING OF GASOLINE (Continued)

7. Remove gas-powered equipment from the vehicle or trailer and refuel it on the ground. If this is not possible, then refuel equipment using a portable container, rather than a gasoline dispenser nozzle.

8. DO NOT start gas powered equipment in enclosed vehicles or trailers.

9. Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. DO NOT use a nozzle lockopen device

10. If fuel is spilled on clothing, change clothing immediately.

11. DO NOT overfill a fuel tank. Replace fuel cap and tighten securely.

OPERATION

It is extremely important that the operator of this machine understand that it is not a toy, an ATV or recreation vehicle. Engaging in horseplay, joy riding, racing, jumping, hill climbing and similar activities greatly increases the likelihood of accidents, which may result in damage, serious injury and death.

1. Operator must mount and dismount the machine from the left side. The passenger must mount and dismount the machine from the right side.

2. DO NOT attempt to start engine unless properly seated in the operator’s seat.

3. DO NOT leave the machine with the engine running. Stop engine, set park brake, shift to neutral and remove key before leaving the machine for any reason.

4. Operator must be properly seated with the seat belt buckle securely latched and the seat belt adjusted to a snug fit before operating machine.

5. Seating is restricted to only one operator and one passenger. The passenger must be properly seated in the passenger seat with the seat belt buckle securely latched and the seat belt adjusted to a snug fit before starting and operating the machine. DO NOT carry more than one passenger.

6. DO NOT shift transmission when machine is in motion. Machine must be fully stopped before shifting.

7. DO NOT operate machine on or near highways or public roadways. This machine is designed for off-road use only and is not licensed for use on public roads.

8. Keep hands and feet inside machine at all times.

9. DO NOT stand up in machine while machine is in motion.

IMPORTANT SAFETY INSTRUCTIONS

OPERATION (Continued)

10. DO NOT operate machine at speeds in excess of 10 MPH with the differential lock engaged.

11. DO NOT attempt to engage differential lock while machine or wheels are moving. Completely stop machine, before engaging differential lock.

12. DO NOT attempt to turn the machine with the differential lock engaged. To avoid loss of control, slow machine and disengage the differential lock before turning.

13. Reduce speed and use extra caution in unfamiliar areas.

14. Avoid low hanging or protruding objects that may strike the operator, passenger or Operator Protective Structure.

15. Slow machine before turning. Avoid sharp turns.

16. DO NOT park machine on slopes. Avoid uphill starts. DO NOT abruptly change speed or direction on slopes. Avoid turns when descending slopes. Slow down and use extra caution when turning on slopes.

17. Watch out for traffic when near or crossing roadways.

18. DO NOT operate engine in enclosed areas. Engine exhaust gases contain carbon monoxide, a deadly poison.

POWERLINKTM BY BRIGGS & STRATTON

(Not featured on all models) The POWERLINK produces electricity that could result in death, serious injury and/or property damage if proper precautions are not followed. A Briggs & Stratton Operating and Safety Instruction manual has been provided with utility vehicles equipped with the POWERLINK avoid serious injury or death, read, understand and follow all warnings and instructions in the manual, on the machine and engine before using the generator system.

ELECTRIC WINCH OPERATION

(Optional accessory on some models) Every winching operation has the potential for personal injury. The manufacturer of the winch has provided detailed operating and safety instructions that have been included with utility vehicles equipped with a winch. To avoid serious injury or death, read, understand and follow all warnings and instructions in the manual, on the machine and winch before performing a winching operation.

1. Read, understand and follow all warnings and instructions in the winch operator’s manual before performing a winching operation.

On-Board Generator System

On-Board Generator System. To

ELECTRIC WINCH OPERATION (Continued)

2. The wire rope must be free of tension and the wire rope drum fully stopped before engaging or disengaging the clutch.

3. DO NOT use a recovery strap or other types of stretchable straps in a winching operation.

4. Use the hook strap to hold the hook when spooling wire rope in or out.

5. Always wear heavy leather gloves and do not allow wire rope to slide through your hands.

6. DO NOT allow a helper to operate the winch while you are handling the wire rope or hook.

7. Always keep hands and clothing clear of the wire rope, spool and hook during operation and when spooling.

8. DO NOT leave remove control (optional accessory) plugged into winch while free spooling, rigging, or not in use.

9. DO NOT use the winch as a hoist.

10. DO NOT tow the vehicle using the winch’s wire rope.

MAINTENANCE

1. DO NOT store machine or fuel container inside where fumes may reach an open flame, spark, or pilot light such as in a water heater, furnace, clothes dryer or other gas appliance. Allow engine to cool before storing machine in an enclosure. Store fuel container out of reach of children in a well-ventilated, unoccupied building.

2. Keep engine free of grass, leaves, and excess grease and oil to reduce fire hazard and overheating.

3. When draining fuel tank, drain fuel into an approved container outdoors away from open flame.

4. Check brakes each time machine is used; adjust, repair or replace as needed.

5. Condition of tires and tire inflation pressure is critical to the proper handling and braking of the machine. Inspect tires and adjust pressure before operating the machine. DO NOT operate machine with worn or deteriorated tires. Use only tires approved by manufacturer.

6. Keep all bolts, nuts, and screws properly tightened.

7. Always provide adequate ventilation when running engine. Engine exhaust gases contain carbon monoxide, an odorless and deadly poison.

8. Disconnect negative (black) cable from battery before performing maintenance or service. Unexpected cranking of engine could cause injury.

9. DO NOT work under machine without safety blocks.

IMPORTANT SAFETY INSTRUCTIONS

MAINTENANCE (Continued)

10. When working on machine with cargo bed raised, make sure that prop rod support is securely latched.

11. Service engine and make adjustments only when engine is stopped. Remove spark plug wires and secure away from spark plugs.

12. DO NOT check for spark by grounding plug near sparkplug opening. The spark could ignite the gas exiting the engine.

13. DO NOT change engine governor speed settings or over speed engine.

14. DO NOT modify machine. Use only genuine replacement parts to assure that original standards and performance are maintained.

15. Have machine serviced by an authorized SNAPPER dealer at least once a year and have dealer install any new safety devices.

16. POWERLINK must be serviced by an authorized Service Dealer. DO NOT tamper with or modify the generator system in any way.

On-Board Generator System

TABLE OF CONTENTS

IMPORTANT SAFETY INSTRUCTIONS ...................................................................... 2-6

TABLE OF CONTENTS....................................................................................................7

SECTION 1 –

FAMILIARIZATION ................................................................................................. 8-9

CONTROL IDENTIFICATION & SAFETY SIGNS .............................................. 10-12

SECTION 2 - OPERATING INSTRUCTIONS ........................................................... 13-21

Pre-Start Check List......................................................................................................... 13-14

Controls – Function & Operation ................................................................................... 14-16

Starting & Stopping Engine ..................................................................................................17

Starting & Stopping Machine Motion...................................................................................17

Parking Machine.....................................................................................................................18

Using Differential Lock..........................................................................................................18

Driving the Machine......................................................................................................... 18-19

Carrying Loads.......................................................................................................................19

Towing............................................................................................................................... 19-20

Transporting Machine ...........................................................................................................20

Water Crossing.......................................................................................................................20

Operating POWERLINK™ Onboard Generator ............................................................. 20-21

SECTION 3 – MAINTENANCE ................................................................................. 22-25

Introduction ............................................................................................................................22

Service – After First 5 Hours........................................................................................... 22-24

Change Engine Oil..............................................................................................................22

Engine Air Cleaner........................................................................................................ 22-23

Check Transmission Fluid .................................................................................................23

Check Tire Pressure ...........................................................................................................23

Lubrication – Axle Couplings and Steering King Pins ...................................................23

Check Wheel Lug Nuts.......................................................................................................23

Check Brakes ......................................................................................................................23

Check Interlocks .................................................................................................................24

Service – Every 25 Operating Hours....................................................................................24

Check Battery......................................................................................................................24

Check Drive Belt .................................................................................................................24

Engine Service ....................................................................................................................24

Service – Every 50 Operating Hours.............................................................................. 24-25

Check Wear Pads on Driven Clutch..................................................................................24

Check Drive Clutch.............................................................................................................25

Change Engine Oil..............................................................................................................25

Service – Every 100 Operating Hours..................................................................................25

Change Engine Oil Filter ....................................................................................................25

Service – Every 200 Operating Hours (or Yearly)...............................................................25

Change Transmission Fluid...............................................................................................25

Replace Fuel Filter..............................................................................................................25

Storage – Out of Season .......................................................................................................25

SECTION 4 – ADJUSTMENTS & REPAIRS ............................................................ 26-29

Drive Belt Replacement.........................................................................................................26

Service Brake & Park Brake Adjustment....................................................................... 26-27

Battery Removal.....................................................................................................................27

Battery Installation.................................................................................................................28

Battery Charging....................................................................................................................28

Battery Storage ......................................................................................................................28

Battery Testing.......................................................................................................................28

Cargo Bed Latch Striker Adjustment...................................................................................28

Transmission Shift Rod Adjustment....................................................................................29

SECTION 5 – ELECTRICAL..................................................................................... 30-31

Wiring Schematic...................................................................................................................30

Wire Harness Detail ...............................................................................................................31

TROUBLESHOOTING ....................................................................................................32

MAINTENANCE SCHEDULE .........................................................................................33

WARRANTY & PRODUCT REGISTRATION FORM ............................................... 34-35

SECTION 1 – FAMILIARIZATION

STORAGE COMPARTMENT

BRUSH GUARD *

ELECTRIC WINCH *

* NOT ON ALL MODELS

1.1 INTRODUCTION

This manual has been prepared for the operators of Turf Cruiser™ & Trail Cruiser™ utility vehicles. Its purpose, aside from recommending standard operating procedures and routine service requirements, is to promote SAFETY through the use of accepted operating practices. Read, Understand and Follow the IMPORTANT SAFETY INSTRUCTIONS on Pages 2 thru 6 of this manual and All SAFETY messages on the utility vehicle and its accessories before operating.

HOOD RETAINING LATCH (2)

HEADLIGHTS

SEAT (2)

POWERLINK™ GENERATOR SYSTEM *

TAILGATE

TAILGATE LATCH (2)

RECEIVER HITCH

SEAT BELT (2)

OPERATOR PROTECTIVE STRUCTURE (OPS)

CARGO BED

CARGO BED LATCH LEVER

TOOL BOX

SEAT SIDE BAR (ONE EACH SIDE)

FUEL FILL

CARGO BED LIFT HANDLE (ONE EACH SIDE)

1.2 NOMENCLATURE

The nomenclature information above shows the essential parts of the vehicle. It is recommended that all operators of this equipment become thoroughly familiar with the controls, components, and operation of this machine before operating. Specific details involving the engine are found in the separate engine owner’s manual. Study these manuals before operating and keep both handy for future reference.

SECTION 1 – FAMILIARIZATION

STEERING WHEEL

HEADLIGHT SWITCH

ELECTRIC WINCH SWITCH (OPTIONAL)

DASHBOARD / PEDAL CLUSTER

IGNITION SWITCH

BRAKE PEDAL

FUSE PANEL

ACCELERATOR PEDAL

CONTROL CONSOLE

CHOKE KNOB

TRANSMISSION SHIFT LEVER

STORAGE TRAY

HOURMETER/TACHOMETER/ SERVICE MINDER COMBO

SPEEDOMETER/FUEL GAUGE COMBO

BEVERAGE HOLDERS

IMPORTANT NOTE: DUE TO SPACE LIMITATIONS, THE BRAKE AND ACCELERATOR PEDALS ARE OFFSET TO THE RIGHT OF THE OPERATOR’S SEAT. OPERATOR MUST EXERCISE EXTREME CAUTION WHEN FIRST OPERATING THE VEHICLE, UNTIL FAMILIAR WITH PEDAL OFFSET.

DIFFERENTIAL LOCK LEVER

BED LIFT SWITCH (OPTIONAL)

PARKING BRAKE KNOB

12V ACCESSORY PLUG

HAND GRIP

CONTROL IDENTIFICATION & SAFETY SIGNS

CHOKE

HEADLIGHTS

OFF

HEADLIGHT SWITCH

IGNITION SWITCH

DIFFERENTIAL LOCK

CARGO BED LIFT (OPTIONAL)

TRANSMISSION SHIFTER

PARK BRAKE

CONSOLE CONTROLS

SPEEDOMETER/FUEL GAUGE COMBO

DANGER –

OPERATOR PROTECTIVE STRUCTURE

CONTROL IDENTIFICATION & SAFETY SIGNS

WARNING – NO RIDERS

WARNING – OFF ROAD USE ONLY

WARNING – HITCH & TOWING

POWERLINK™ WARNINGS

● DO NOT OPERATE MACHINE WITH

CARGO BED RAISED.

● DO NOT RAISE CARGO BED WHEN

LOADED OR ON SLOPES.

WARNING - TO PREVENT FIRE

WARNING – HOT SURFACE

SPECIFICATIONS & MAINTENANCE

WARNING –CARGO BED & LOADS

● ALL LOADS MUST BE CENTERED

NO HIGHER THAN SIDES OF CARGO BED AND SECURED TO PREVENT SHIFTING.

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