Operator’s Manual 6x4 Utility Vehicle Model 642 IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY Warning: This unit is equipped with an internal combustion engine and should not be used on or near any unimproved forestcovered, brush-covered or grass-covered land unless the engine’s exhaust system is equipped with a spark arrester meeting applicable local or state laws (if any). If a spark arrester is used, it should be maintained in effective working order by the operator.
TABLE OF CONTENTS Content Important Safe Operation Practices Know Your Utility Vehicle Operating Your Utility Vehicle Servicing Your Utility Vehicle Service Chart Content Specifications Troubleshooting Commercial Warranty Residential Warranty Page 3 7 10 12 17 Page 18 19 23 24 FINDING MODEL NUMBER This Operator’s Manual is an important part of your new utility vehicle. It will help you assemble, prepare and maintain the unit for best performance. Please read and understand what it says.
SECTION 1: IMPORTANT SAFE OPERATION PRACTICES WARNING: This symbol points out important safety instructions which, if not followed, could endanger the personal safety and/or property of yourself and others. Read and follow all instructions in this manual before attempting to operate or service this vehicle. When you see this symbol - heed its warning.
Children 25. Do not start or operate vehicle in an inside area, unless it is adequately ventilated. Engine exhaust contains carbon monoxide fumes, which are very poisonous and can be deadly. 26. Do not change engine governor setting or over speed the engine. The governor is set at the factory for safe operating speed. 27. Assure safety interlock switch is adjusted correctly so engine cannot be started unless gearshift is in the neutral position. 28.
d. 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 lock-open device. e. Extinguish all cigarettes, cigars, pipes and other sources of ignition. f. Never fuel machine indoors. g. Never remove gas cap or add fuel while the engine is hot or running. Allow engine to cool at least two minutes before refueling. h. Never over fill fuel tank.
WARNING • This is an off-road utility vehicle. Do not operate on public highways. It handles and maneuvers differently than a normal passenger car. Sharp, high speed turns or abrupt maneuvers can cause vehicle to roll over or go out of control. • Handling and maneuvering characteristics of vehicle change depending upon cargo load. Heavy loads will affect steering, braking, stability and overall handling of vehicle. • Read and understand operator's manual before operating vehicle.
SECTION 2: KNOW YOUR UTILITY VEHICLE NOTE: Reference to right or left hand side of the utility vehicle is observed from the operating position. Figure 1 Brake Pedal Read this operator’s manual, safety labels, and operating instructions on the vehicle before operating. Compare the illustrations in this manual with your unit to familiarize yourself with the location of various controls and adjustments. Reference to the right or left hand side of unit is observed from the operating position.
• • 12V Power Outlet To engage the parking brake, push brake pedal down firmly, pull out on the parking brake latch, and release foot from brake pedal. Brake pedal will stay down and parking brake light on dash will come on to indicate parking brake is engaged. To release parking brake, push down on brake pedal and parking brake latch will release. The 12V power outlet is located on the right side of the dash panel.
Hour Meter Fuel Shut Off Valve The hour meter is located in the center of the warning light cluster. It reads the elapsed time engine has run. See Figure 6. The fuel shut off valve is located under the seat and it is strapped onto the fuel tank. It controls fuel to the engine. To turn fuel off, turn knob so indicator is down. To turn fuel on, turn knob to the up position. See Figure 9. NOTE: The hour meter initially displays the battery voltage when you first turn it on.
Tailgate The tailgate can be hinged at the top or the bottom depending on how you release the holding pins. If you pull out on the two top pins, the tailgate will swing down. If you pull out the two bottom pins, you can pivot the tailgate upwards. Cargo Box Figure 11 WARNING: Do not exceed 1,000 lb. in the cargo box. SECTION 3: OPERATING YOUR UTILITY VEHICLE • • • WARNING: This is an off-road utility vehicle and it should not be operated on public highways.
• WARNING: Do not stop or start suddenly when going uphill or downhill. Be especially cautious when changing direction on slopes. Apply brakes when going down slopes to maintain control of vehicle. • • Release brake pedal and apply pressure to the accelerator pedal. Release accelerator and apply brake pedal evenly and firmly to slow down or stop. Park the vehicle safely and turn key to the RUN position. Raise cargo box by pressing and holding top of electric lift switch.
Loading the Cargo Box Towing Loads WARNING: The utility vehicle may become unstable if the cargo box is loaded incorrectly. Avoid loose and shifting loads or uneven loading of material. • • • • • • • • WARNING: To help prevent personal injury due to loss of control or tipping, always tow a load slowly enough to maintain control. • • Verify cargo box is latched before loading. Securely anchor all loads in cargo box and do not load beyond maximum capacity. The maximum box capacity is 1000 lbs.
Battery Jumper Cables D WARNING: The battery produces a flammable and explosive gas. Do not smoke near battery. Wear eye protection and gloves when handling the battery. Do not allow direct metal contact across battery posts.The battery is sealed and is maintenance-free. Acid levels cannot be checked and fluid can not be added. B Figure 14 Charging disconnect the NEGATIVE (Black) wire from it’s terminal first, followed by the POSITIVE (Red) wire.
• • • Remove the appropriate electrical fuse and replace with proper amperage fuse. (See schematic under hood) Reattach socket and lower hood. Secure hood to dash. • • • Tire Pressure • • WARNING: Explosive separation of tire and rim parts is possible when they are serviced incorrectly. Do not stand in front or over tire assembly when inflating. IMPORTANT: Overtightening front wheel can result in bearing damage. The recommended operating tire pressure is approximately 5-7 psi for all tires.
Checking Transaxle Oil • IMPORTANT: Hot hydraulic oil will expand and show incorrect oil level. Check oil level when oil is cold and with engine is not running. • • • • IMPORTANT: Dirt and debris in oil may cause damage to transaxle. Clean area around opening before removing dipstick. Park vehicle on level surface and apply parking brake. Allow transmission sufficient time to cool before attempting any maintenance or repairs. Raise and secure cargo box, if manual lift.
Adjusting Brake Adjusting Throttle Pedal The wet brake system is an internal part of the transmission and it is adjusted externally without opening the transmission. There are two sets of brakes that may require adjustment. Each set consists of two rotating friction plates placed between three fixed steel plates operating in oil. Each set of brakes is operated by it’s respective lever arm. The brakes are properly adjusted at the factory.
Storage • • • • • • • • • • • Prepare fuel system for storage. If planning to store vehicle with fuel tank empty: Stop the vehicle on a level surface and apply parking brake. Allow vehicle to cool. Replace all worn, damaged, or missing parts and tighten loose hardware as needed. Wash the vehicle and clean inside the engine compartment and under the cargo box. Run engine for several minutes to dry belts, pulleys, and other moving parts. Clean and polish metal and plastic surfaces.
SECTION 6: SPECIFICATIONS Engine and Electrical Make HP Type Cylinders Valves Displacement Maximum Torque Ignition Lubrication Oil Filter RPM, idle (no load) RPM, fast (no load) Cooling System Air Cleaner Battery Alternator Headlights Wiring Kohler Command V-Twin OHV 20 HP 4-Cycle Gas 2 Overhead 38 cu. in. (624cc) 32.
SECTION 7: TROUBLESHOOTING Trouble Possible Cause(s) Trouble Possible Cause(s) Engine will not start Battery has low voltage. Loose or corroded battery connections. Fusible link is melted. Spark plug wire is loose or disconnected. Faulty spark plug or coil. Fuel shut-off valve turned off. No Fuel or improper fuel. Plugged fuel filter. Defective starter solenoid. Open-circuit in wiring. Engine is cold. Plugged fuel filter. Carburetor not adjusted properly or dirty. Engine oil viscosity too heavy.
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CUB CADET CORPORATION MANUFACTURER’S ONE YEAR LIMITED WARRANTY (COMMERCIAL USE) The limited warranty set forth below is given by CUB CADET LLC (“CUB CADET”) with respect to new merchandise purchased and used in the United States, its possessions and territories.
MANUFACTURER’S LIMITED WARRANTY FOR: (RESIDENTIAL USE) The limited warranty set forth below is given by Cub Cadet LLC with respect to new merchandise purchased and used in the United States, its possessions and territories. “Cub Cadet” warrants this product against defects in material and workmanship for a period of two (2) years commencing on the date of original purchase and will, at its option, repair or replace, free of charge, any part found to be defective in materials or workmanship.
