Download HS 500/700 - Hisun Motors Corp, USA
Transcript
TM GRAB SOME SUN Published by Chongqing Huansong Industries (Group) Co., Ltd and Hisun Motors Corp USA. Chongqing Huansong Industries (Group) Co., Ltd and Hisun Motors Corp USA holds the copy right. No publishing and reprinting without permission. READ THIS MANUAL CAREFULLY For questions regarding this UTV, please contact HISUN at: (972)446-0760 hisunmotors.com Rev. 07231501 No one under the age of 16 should operate this vehicle. Provincial / Municipal governments have different regulations pertaining to owning and operating an off-road vehicle; learn the regulations in your area. HS 500/700 OWNER’S MANUAL Introduction HS 500/700 INTRODUCTION Congratulations on your purchase of the HS 700 UTV. This Owner’s / Operator’s manual will provide you information regarding safe operation, operational instructions, maintenance and care. Fully understanding and following all of the instructions in this manual will provide the knowledge needed to have safe operation and longevity of the UTV. For questions regarding this UTV, please call (972) 446-0760. IMPORTANT SAFETY MESSAGES ●READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR UTV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS. ●PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE UTV. ●NEVER OPERATE THE UTV WITHOUT PROPER TRAINING OR INSTRUCTION. ●THIS UTV SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE. 1-1 Introduction HS 500/700 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the machine operator, bystander or a person inspecting or repairing the machine. A CAUTION indicates special precautions that must be taken to avoid damage to the machine. NOTE: A NOTE provides key information to make procedures easier clearer. 1-2 Introduction HS 500/700 IMPORTANT NOTICE This UTV is designed and manufactured for OFF - ROAD use only. It is illegal and unsafe to operate this UTV on any public street, road or highway. This UTV complies with all applicable OFF - ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture. Please check your local riding laws and regulations before operating this UTV. When the temperature is below -4°F (-20°C), park the UTV in a place where the temperature is higher than -4°F (-20°C). Operate the UTV after the UTV has warmed up. Please see page 7-3 on the warming up process. Follow the proper parking procedures when the temperature is higher than 100°F (38°C): turn off the engine; make sure the radiator fan is on for 3 minutes before turning off the power switch. Starting the UTV for the first time will take longer because the fuel will need reach the fuel injectors. To start the UTV the first time, hold the ignition key on at 5-second intervals. Allow the starter to rest 15 seconds between each start attempt. 1-3 Introduction HS 500/700 Table of Contents Subject Introduction Important Warnings Notice Table of Contents Safe Operation Operation Children Safety Instructions Driving on a slope Driving in Harsh Conditions Driving at High speed Instructions for Carrier Parking Transportation Maintenance Warning and Caution Labels Servicing of Vehicle Specifications Traveling Speeds Vehicle Limitations Part Locations Pre-Operation Check Starting the engine Stopping the engine Operating the vehicle Lights Checking the brake pedal Selecting a gear Stopping Fuel gauge Coolant Temperature Gauge Speedometer Winch Mount Plate Transporting the vehicle Maintenance Intervals Periodic Service Front Hood cover Operator’s seat Raise the Cargo bed Jack Positions Checking and refueling Checking the Oil level Checking the coolant level Cleaning the radiator screen Checking the Brake Fluid level Checking the brake pedal Page I-1 I-2 I-3 I-4 1-1 1-2 1-2 1-3 1-3 1-3 1-3 1-4 1-4 1-4 1-5 2-1 3-1 3-2 4-1 5-1 6-1 7-1 7-2 8-1 8-2 8-3 8-3 8-4 8-5 8-5 8-6 9-1 9-1 10-1 11-1 11-1 11-1 11-1 11-2 11-3 11-3 11-3 11-4 11-4 Subject Checking the parking brake Checking the tire Inflation 50 Hour Check Checking the engine start system Testing the gear shift lever safety switch Wheel Lug nut torque Cleaning the air filter Checking the Battery Directions for storage Adjusting the Toe-In Cleaning the Muffler 200 Hour Changing Engine oil Changing engine oil filter Checking the brake pedal Precautions at overheating 300 hour 400 hour Flushing cooling system Light Bulbs Replacing Mini blade fuses Storage Removing the vehicle from storage Engine Troubleshooting Trouble Codes Battery Troubleshooting Vehicle Troubleshooting Options Electric Power Steering System EPS Trouble Codes Universal Symbols 11-5 1-4 Page 11-5 11-6 11-6 11-7 11-7 11-7 11-8 11-9 11-10 11-10 11-11 11-11 11-11 11-12 11-13 11-14 11-14 11-15 11-16 11-18 11-18 12-1 12-1 13-1 13-2 13-3 13-4 14-1 15-1 15-4 16-1 Introduction HS 500/700 1-5 SAFE OPERATION SAFE OPERATION All operators, including experienced UTV drivers or parts on the vehicle and could cause a severe passengers, should carefully read and fully injury to occur. understand this Users Manual, and operate strictly 5. You should always wear protective equipment, as the manual states in order to achieve the best such as helmet, boots, eye protection, ear performance and avoid accidents. Others who will protection, and gloves etc. use your UTV should be trained on how to operate 6. Only a qualified driver with driving license the UTV and be required to read this manual should operate this UTV. Never operate after before operation. drinking alcohol, using drugs or controlled substances, or while fatigued. 1. Safety Instructions: 7. Always perform the pre-operation checks as following: 1. Understand this UTV by reading this manual 1. Check seat belt for wear or damage, if and understanding all the components of the necessary, replace it. vehicle. Only start and operate the vehicle 2. 3. 2. Check brakes, throttle, brake pedal and other after you have finished reading this manual. mechanical parts for proper operation. If you Pay close attention to the warning and caution discover any irregularities, replace related labels on the UTV. parts as necessary. Periodically check the Understand completely and learn to use the fittings and fasteners. safety devices (roll-over protective structure, 3. Check engine oil level and engine coolant seat belts), and never change the original level. safety devices. If safety devices are damaged, 4. Check that the UTV is equipped to handle the consult your local dealer for replacement. surroundings. Always use seat belts. 5. Check and keep vehicle clean. Sludge, grease and debris can cause a fire and severe injury. 6. Passenger quantity and loading: 1) Only the driver and one passenger inside cab. It is suggested that children under age of 5 not be allowed as a passenger. 2) Single-row vehicle’s loading limit is 660lbs (300KG). Reduce the loading weight according to road conditions. Never exceed the weight limits for operation. ① Roll-over protective structure; ② Seat belts; 4. 8) Never allow unauthorized persons to repair Do not wear loose articles of clothing during this operation, as these can be drawn into moving performance and cause injury. 1-1 UTV. This may affect vehicle SAFE OPERATION 2. Operation dams, excessive mud, or the vehicle can get stuck because of the vehicles weight. 1. 2. Start the engine only in an open ventilated 11. Always 5. to your and is emitted from the engine and can cause intersections or other obstacles. death in areas with poor ventilation . 12. Always use signals in advance of turns. Never start the vehicle or operate the gear 13. Do not allow entrance or exit of the vehicle while it is moving. Never start the engine until the select lever is 14. Keep the floorboard free of debris that can placed in “N” position and the brake is in the obstruct the ability to use the brake pedal. 15. Position your hands on the steering wheel. The driver and passenger shall always wear Always keep your hands and feet inside their seatbelt while the vehicle is being passenger area of the vehicle. Never try to operated. stand while operating the vehicle. Operators of the UTV should not wear 16. Do not tow passengers, or attempt to jump the earphones. 6. attention surroundings, and check for streets, trail brake position. 4. close area. Carbon monoxide is colorless, odorless selector unless seated in the driver’s seat. 3. pay vehicle. Use the proper trailer hitch to haul cargo, 3. Children safety instructions otherwise, serious injury or death can happen. Always watch children when they are around the vehicle. Children like to imitate adults and this could lead to an accident. Do not leave children alone beside the vehicle. Keep children from the operating area of the vehicle. Turn off the engine and remove the key when children are in the operating area. ① Trailer Hitch Never carry children in the cargo area. This is very 7. Do not accelerate quickly when starting the dangerous to children. Children under age of 5 engine, especially driving on rough terrain as should not be allowed in this vehicle. this can cause injury or death. Press the Never allow children to touch or climb on the accelerator pedal slowly. vehicle, even if they are under adult supervision. 8. Drive at slow speeds before braking. Always check for people or obstacles behind the 9. When the differential is unlocked (DIFF.LOCK vehicle before shifting the vehicle into reverse. is off) the front/rear wheels can turn at Avoid a collision with an obstacle or person. different speeds to assist in the stability of the Park the vehicle in a firm, flat area. If parking on a vehicle. slope, you should use the parking brake then 10. Never drive over terrain such as a ditch, a hole, 1-2 remove the key. SAFE OPERATION 4. Driving on a slope roads or hidden obstacles. 5. Avoid operate in the unknown depth of waters. (water depth can not exceed axle) Be cautious when riding on a slope, as this is the main reason for loss of control, and overturn, 6. Driving at high speed leading to severe injury or even death. 1. Drive in a straight line on a slope at a 1. low-speed. 2. 3. 4. 5. Reduce weight when riding on a slope or wheels. Be cautious when driving over a ditch, rough terrain. stone roads or hidden obstacles. 2. Avoid the sudden application of the brakes performances between two and four-wheel careful when vehicle turns on a slope. drive. Slow down when turning. Turning at If you start to lose momentum or need to park high speeds, may result in overturn or even when climbing, use the hand lever brakes to death. come to a stop. Release the brake and begin 3. Turn on your headlights at high speeds. to coast down the hill. 4. Drive only when the vehicle speed can be controlled. If do not believe you can operate the UTV 5. Do not use DIFF.LOCK when driving at high slope any further. speeds. This may cause loss of control of the Riding in mud, a ditch, and on slopes will vehicle. 6. increase the risk of an overturn. Be more 7. Pay attention to the difference of braking when you go uphill or downhill. Be more safely in reverse do not attempt to ascend the 6. Check the condition of the front and rear When driving at high speeds, sudden turning cautious when operating in 4WD, vehicle of the steering wheel will reduce vehicle traction will increase and it is easy to misjudge stability. Never sharply turn the steering wheel for vehicle’s ability to climb a grade. at high speeds. Drive gradually and slowly when climbing. 7. Instructions for carrier Avoid suddenly changes of vehicle speed or direction. 5. Driving in harsh conditions 1. Never carry a passenger in the cargo area. 2. Evenly distribute the cargo to maintain proper stability. Avoid overloading the carrier. Cargo 1. should be securely attached. Vehicle can be operated during the day or 3. under good light conditions. 2. 3. road conditions or on steep inclines. Under all conditions, both operator and passengers should wear helmet 4. and Do not put your hands or your body under the protective equipment. carrier when the carrier is up. Avoid driving The Driver should slow down according to before securing and locking the cargo bed. road conditions, terrain, visibility conditions. 4. Reduce loaded weight when driving on poor Be cautious when driving over a ditch, stone 1-3 SAFE OPERATION 8. Parking hydrogen and oxygen during charging and this could accelerate the risk of explosion. 1. To release the parking brake, depress the 4. brake pedal. Read and follow the instructions before replacing the battery. 5. During maintenance, first aid kits and fire extinguishers should be placed at your fingertips. 6. During maintenance, you should disconnect the battery cables. ① Parking brake. 9. Transportation 1. Avoid dragging the vehicle behind another vehicle. Use a trailer or truck to transport the ① Battery vehicle. 2. When loading or unloading, pay attention to 7. your surroundings and others in the area. Do not open the radiator cap before coolant has cooled down. When the coolant is cold, open slowly and let the coolant pressure 9. Maintenance reduce, and then open radiator cap. Check for the coolant level in the coolant reservoir. If Stop the vehicle and park it on level ground. Pull necessary, add coolant. the parking brake and remove all cargo. Place the 8. shift lever in the “N” position, stop the engine and equipment, only by professionals. remove the key. 1. 9. When working next to the engine, exhaust, or 10. Elevate the vehicle and place a suitable stand Wait for the engine to stop running and cool under the frame when removing the wheels. down before checking the coolant level. Be sure to re-tighten the wheel nuts to the Otherwise, you could be burned by hot fluid or specified torque. steam. 3. Keep the specified tire pressure to ensure driving safety. radiator, work only after it has cooled down. 2. Tires should be mounted on rims with special No smoking when adding electrolyte or refueling. The fuel tank and battery should be kept away from sparks. The battery produces 1-4 SAFE OPERATION 11. Warning and caution labels ⑴ ⑵ ⑶ ⑷ ⑸ 1-5 SAFE OPERATION ⑹ ⑺ ⑻ ⑼ ⑽ 1-6 SAFE OPERATION ⑾ ⑿ ⒀ ⒁ ⒂ 1-7 Servicing of the Vehicle SERVICING OF VEHICLE Your dealer is interested in your new vehicle and has the desire to help you get the most value from it. After reading this manual thoroughly, you will find you can do some of the regular maintenance by yourself. However, when in need of parts or major service, be sure to see your dealer. For service, contact the dealership from which you purchased your vehicle or your local dealer. When in need of parts, be prepared to give your dealer both the vehicle and engine serial numbers. Locate the serial numbers now and record them in the space provided. Type Vehicle Engine Product Identification Number Date of Purchase Name of Dealer ① Vehicle serial number. ① Engine serial number Serial No. SPECIFICATIONS SPECIFICATIONS SPECIFICATION TABLE Model Make Type Engine 1 cylinder, 4-cycle, gasoline, SOHC, liquid cool Displacement L(cu.in.) 0.8(48.8) Horsepower Kw(HP) 22(29.64) Rated revolution Low idling revolution Fuel Capacity rpm 5000 rpm 1350 to 1500 L(U.S.gas) 28(8.9) Transmission CVT Wheels, Drive system 4, Rear 2WD or 4WD Differential lock Electric control: switch Gear selection H-Lo range forward, Neutral, Reverse Front/Rear Wet disk brake Parking brake Axis brake, parking brake Brakes Steering Electronic power Front Double A arm (gas+oil shock) Rear Double A arm (gas+oil shock) Suspension Dimensions Length mm(in.) 2980 (138.2) Wide mm (in.) 1550(57.87) Height mm (in.) 1950(76.77) Front tread centers mm (in.) 1300 (45.866) Rear tread centers mm (in.) 1285 (46.5) Wheelbase mm (in.) 1950(103.54) Ground Clearance front axle 310(13) mm (in.) rear axle Turning diameter 310(13) m (ft) 8.6(34.769) Max. rolling weight (Towing Capacity) kg (lbs.) 957(2110) Payload capacity kg (lbs.) 159(300) Weight kg (lbs.) 638(1407) 3-1 SPECIFICATIONS Model Cargo bed Worksite/Camo Width mm (in.) 1170(51.38) Length mm (in.) 900(32.88) Depth mm (in.) 280(11.4) m3 (cu.ft.) 0.29(11.35) mm (in.) 810(34.25) kg (lbs.) 159(300) Volume Bed height (unloaded) Cargo bed capacity (1 row/2 row) Sound level, operator ear Tire Worksite/Red db (A) 86.5 Front 26×9-12 6PR 26×9-12 6PR Rear 26×11-12 6PR 26×11-12 6PR Red Camo Body color NOTE: The values in “Ground clearance” and “Weight” are those of the machine equipped with the tires in the table above. The company reserves the right to change the specifications without notice. TRAVELING SPEEDS Range gear shift lever km/h (mph) Low 13(8) High 60(37) Reverse 16(10) 3-2 VEHICLE LIMITATIONS VEHICLE LIMITATIONS The Vehicle has been thoroughly tested for proper performance with implements sold or approved by. Use with implements which are not sold or approved and which exceed the maximum specifications listed below, or which are otherwise unfit for use, vehicle may result in malfunction or failures of the vehicle damage to other property and injury to the operator or others, [Any malfunctions or failures of the vehicle resulting from use with improper implements are not covered by the warranty] Max. Cargo loading weigh Rear trailer hitch (a)1 ROW SEATING MODE Cargo Bed Capacity=159Kg(300 lb) Max. rolling weight Cargo Load Capacity=179kg(395 lb) 957 kg (2110 lbs.) Max. tongue weight 50 kg (110 lbs.) 1. Above mentioned specifications are based on level ground condition. 4-1 INSTRUMENT PANEL AND CONTROLS INSTRUMENT PANEL AND CONTROLS LOCATION OF PARTS 5-1 INSTRUMENT PANEL AND CONTROLS ILLUSTRATED CONTENTS 5-2 INSTRUMENT PANEL AND CONTROLS 5-3 PRE-OPERATION CHECK PRE-OPERATION CHECK DAILY CHECK To better prevent troubles, it is important to know condition of the vehicle well. Check it before starting. CAUTION: To avoid personal injury: Be sure to check and service the vehicle on a level surface with the engine shut off and the parking brake “ON” and implement lowered to the ground if equipped. Check items - Visually inspect the exterior of the vehicle -Check engine oil level -Check transmission oil level -Check brake fluid level -Check coolant level -Clean radiator screen (When used in a dusty place) -Check brake and pedal -Check parking brake -Check indicators, gauges and meters -Check lights -Check seat belts and roll-over protective structures. -Check front and rear joint boots. -Check tire inflation pressure. -Refuel (See "DAILY CHECK" in "PERIODIC SERVICE" section.) -Care of danger, warning and caution labels (See "DANGER, WARNING AND CAUTION LABELS"in"SAFE OPERATION"section.) 6-1 OPERATING THE ENGINE OPERATING THE ENGINE NOTE: CAUTION: The parking brake warning lamp (P) comes on To avoid personal injury: while parking brake is applied and goes off when it Read "SAFE OPERATION" in front of this is released. manual. Read the danger, warning and caution labels located on the vehicle. To avoid the danger of exhaust fume poisoning, do not operate the engine in closed buildings without proper ventilation. Start engine only from operator’s seat. Never start engine while standing on ground. ① Parking brake warning lamp Make it a rule to set gear shift lever to 2. Set gear shift lever to the “NEUTRAL” position. “NEUTRAL” position before starting the engine. IMPORTANT: Do not use starting fluid or ether. To protect the battery and the starter, make sure that the starter is not continuously turned for more than 10 seconds. STARTING THE ENGINE 1. Make sure the parking brake is set. ① Range gear shift lever. (L) Low Range (H) High Range (L) Low Range (N) “Neutral” position (R) “REVERSE” 3. Push the speed control pedal down about 1/2 way. ① Parking brake 7-1 OPERATING THE VEHICLE start except when the gear shift lever is placed in the “NEUTRAL” position. ■ Cold Starting When the ambient temperature is below -15℃( 5℉), the engine is very cold. If the engine fails to start after 10 seconds, turn off the key for 30 seconds and start again. ① Accelerator pedal STOPPING THE ENGINE ②=>③ INCREASE 1. After slowing the engine to idle, turn the key to ③=>② DECREASE “OFF”. 2. Remove the key. 4. Push the accelerator pedal down about 1/2 way. WARMING UP CAUTION: To avoid personal injury: Be sure to set the parking brake during warm-up. Be sure to set the shift lever to the “NEUTRAL” position during warm-up. Allow the engine to warm up for 5 minutes without applying any load. This is to allow oil to 1. Insert the key into the key switch and turn it reach every engine part. If a load is applied to “START”. OFF ON the engine without warm-up engine damage (Engines stop) may occur. (Engine run or headlight on) START ■ Warm-Up Transmission Oil in the Low (Engine start) IMPORTANT : Temperature Range Relying on the engine warning lights is never IMPORTANT: enough. Never fail to conduct daily checks carefully by referring to Pre Operation Check “ in it is sufficiently warmed up. “PERIODIC SERVICE” section. 5. Turn the key to “START” position and release when the engine starts. IMPORTANT: Do not operate the vehicle under full load until Because of safety devices, the engine will not 7-2 OPERATING THE VEHICLE OPERATING THE VEHICLE OPERATING NEW VEHICLE ■ Changing Lubricating Oil for New Vehicles How a new vehicle is handled and maintained The lubricating oil is especially important for a determines the life of vehicle. new vehicle. Various parts are not “broken-in” A new vehicle just off the factory production line and are not accustomed to each other. Small has been tested, however the various parts are not pieces of metal grit may develop during the mated to each other, so the operator should pay operation of the vehicle; and this may wear out more attention to the vehicle operation for the first or damage the parts. Therefore, take care to 50 hours. Drive at a slower speed and avoid change the lubricating oil a little earlier than excessive work or operation until the various parts would ordinarily be required. For further details become “broken-in”. How you break in the vehicle of change interval hours, see “MAINTENANCE” greatly affects the life of your vehicle. Therefore, to section. obtain the maximum performance and the longest STARTING life of the vehicle, it is very important to properly break-in your vehicle. For better handling of a new 1. Fasten the seat belt. vehicle, the following precautions should be observed. ■ Seat Belt ■ Do not operate the vehicle at full speed for WARNING the first 50 hours. To avoid personal injury: Do not start quickly nor apply the brakes Seat belts reduce injury. Always wear your suddenly. seat belts. The lap-style seat belts may not In winter, operate the vehicle after fully provide adequate protection for small warming up the engine. children. Pay special Do not run the engine at speeds faster than carrying a child passenger. attention when prescribed. On rough roads, slow down to suitable speeds. CAUTION: Do not operate the vehicle at fast speed. The To avoid personal injury: above precautions are not limited to new vehicles, but to all vehicles. It should be Always use the seat belts when operating and riding the vehicle. especially observed for new vehicles. Adjust the seat belts for proper fit and connect the buckle. This seat belt is an auto-locking retractable type. 8-1 ⑮ Plug cover NOTE: Turning the head light switch to the “ON” position causes the following lamps to light simultaneously. 1. Tail lights (lamps at the rear portions of the vehicle) 2. Lamp built in the coolant temperature gauge 3. Lamp built in the fuel gauge 4. Lamp built in the speedometer ① Seat belt 5. Front left and right position lights 2. Selecting light switch position. ■ Hazard Light Switch [if equipped] ■ Head Light Switch Press the top half of the hazard light switch, the Turn on the key switch and turn the head light hazard light flash along with the indicator on the switch to the “ON” position. instrument panel. Press the bottom half of the Turn the head light switch to the “OFF” position to hazard light switch to turn off the hazard light. turn off the head light. Note: The hazard light switch is operative when the key switch is in the “ON” or “OFF” position. Be careful that keeping the switch “ON” causes the battery to run out. ■ Turn Signal Light Switch [if equipped] To indicate a right turn, push on the lower half of ① Head light switch ② Head lights “OFF” the turn toggle switch. ③ To indicate a left turn, push on the upper half of the High beam lights "ON" ④ Low beam lights "ON" ⑤ 4WD button ⑥ 2WD button turn toggle switch. When the left or right signal is activated, the indicated turning light will flash and the other will ⑦ Front axle differential lock ⑧ Front axle differential unlock stay on. ⑨ Emergency light "ON" The indicator lamp at the instrument panel also ⑩ Emergency light "OFF" flashes indicating the direction of the turn. ⑪ Winch cable release ⑫ Winch cable pulled up NOTE: ⑬ Left turning lights ⑭ Right turning lights 8-2 The turn signal light switch only operates when the key switch is in the “ON” position. make sure the vehicle is correctly loaded to If the hazard light switch is pressed to the avoid skidding or loss of steering control. “ON” position while the turn signal is activated, Reduce the speed. the indicated turning light will flash and other The brake pedal is the left pedal on the foot board. will stay on. Depress the pedal to slow or stop the vehicle. Be sure to return switch to center position after turning. ① Brake pedal 4. Selecting the travel speed. ■ Gear Shift Lever CAUTION: To avoid personal injury: Avoid changing range gear shift lever when ascending or descending a slope. Before ascending or descending a slope, shift to the “L” range to control the vehicle speed. ① Head light ③ ② Front turn signal lamp; Rear turn signal lamp Operate in reverse at slow speeds to maintain control. 1. 3. Checking the brake pedal. The gear shift lever can only be shifted when the vehicle is completely stopped and the ■ Brake Pedal brake pedal is pressed. 2. CAUTION: damage, completely stop the vehicle using the To avoid personal injury: If the operator suddenly brake pedal before shifting gears. brakes, an 3. accident may occur due to loss of control Select proper gear and depending on the type of job. or shifting forward of heavy loads. To avoid transmission and shift linkage When driving on icy, wet or loose surface, 8-3 engine speed ① Range gear shift lever (L) LOW Range (H) HIGH Range (N) NEUTRAL” POSITION (R) “REVEREE” ① Parking brake ■ Accelerator Pedal The Accelerator pedal is used to increase the engine and vehicle speed. Push down on it for NOTE: higher speed. When gear shift lever is hard to engage, do not force the lever. Set the parking brake, slightly depress the accelerator pedal and release it to neutral position, then shift the lever. When the lever is hard to disengage, do not force the lever. Depress the brake pedal fully, then shift the lever. An accident may occur if the brakes are ① Accelerator pedal applied suddenly while towing heavy loads. The load can shift forward causing loss of STOPPING control. The braking characteristics are different ■ STOPPING between two and four wheel drive. Be 1. Release the Accelerator pedal aware of the differences and practice the 2. Step on the brake pedal. differences at slower speeds first. CHECK DURING DRIVING IMPORTANT: ■ Immediately Stop the Engine if: 5. Release the parking brake and start slowly. The engine suddenly slows down or accelerates. To release the parking brake, depress the brake pedal. Make sure that indicator in the Instrument Unusual noises are suddenly heard. Panel goes off. Exhaust fumes suddenly become very white. 8-4 pressure before removing cap completely. While driving, check the following items to see if all 1. parts are functioning normally. With the key switch “ON” the temperature gauge indicates the temperature of the coolant. White Zone for “cold” and Red zone for “hot”. 2. If the indicator reaches the Red zone, engine coolant is overheated. Check the vehicle by referring to “TROUBLESHOOTING” section. ① Coolant temperature gauge ② Fuel gauge ■ Fuel Gauge Park the vehicle on a flat place. When the key switch is “START”, the fuel gauge ① Coolant temperature gauge indicates the fuel level. The hour meter indicates in five digits the hours the Be careful not to empty the fuel tank. Otherwise air vehicle has been used; the last digit indicates 1/10 may enter the fuel system. of an hour. ① Fuel gauge ① Hour meter ■ Coolant Temperature Gauge CAUTION: To avoid personal injury: Do not remove radiator cap until coolant temperature is well below its boiling point. Then loosen cap slightly to relieve 8-5 The speedometer indicates the traveling speed. ① Speedometer 8-6 WINCH MOUNT PLATE WINCH MOUNT PLATE WINCH MOUNT PLATE Always read and follow the instructions in the winch owner’s manual before attempting to install or use a winch. ① Winch mount plate ■ Transporting Vehicle Pay attention to the following points when transporting the vehicle. 1. Use a suitable truck or trailer. Apply the parking brake and place chocks against the front and rear tires. 2. Tie the vehicle to the sides of the trailer or truck using suitable tie-downs. 9-1 MAINTENANCE MAINTENANCE AND ADJUSTMENT CAUTION: To avoid personal injury and vehicle damage: Be sure you have sufficient knowledge, experience, the proper replacement parts and tools before you attempt any vehicle maintenance task. If you don’t have the knowledge and equipment which are necessary to perform the maintenance task, consult your local dealer. Have your local dealer perform inspection items which are marked *4 in the chart below. SERVICE INTERVALS IMPORTANT: The jobs indicated by ◎ must be done after the first 50 hours of operation. *1 Air cleaner should be cleaned more often in dusty conditions than in normal conditions. *2 Every year or every 6 times of cleaning. *3 Replace only if necessary. *4 Consult your local dealer for this service. *5 When the battery is used for less than 100 hours per year, check the battery condition by reading the indicator annually. The items listed below (@marked) are registered as emission related critical parts by DEALER in the U.S.EPA non road emission regulation. As the engine owner, you are responsible for the performance of the required maintenance on the engine according to the below instruction. Please see Warranty Statement in detail. Indication of No. 50 1 Engine oil Change ◎ 2 Engine oil filter Replace ◎ 3 4 After Items Transmission fluid Engine start system 100 150 200 250 300 350 400 450 500 550 600 650 700 ○ ○ ○ ○ ○ ○ Every 200 hrs Every 200 hrs Every ○ Change 400 hrs Check ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 5 Greasing Apply ○ ○ 6 Muffler Clean ◎ ○ ○ ○ 10-1 ○ 700 hrs ○ ○ ○ Every 50 hrs Every 50 hrs Every 100 hrs MAINTENANCE 7 8 Spark arrester Wheel bolt torque Clean Check ◎ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 9 Battery condition Check ○ ○ ○ ○ ○ ○ ○ 10 Ton-in Adjust ○ ○ ○ ○ ○ ○ ○ Indication of No. 11 Fuel filter element ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Fuel line Air cleaner element ○ Adjust ◎ Check ◎ Check ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 19 20 21 pipe Tire wear Front axle case oil Change 500 hrs ○ years Every 1 years Every 200 hrs Every 200 hrs Every 200 hrs Every 200 hrs years ◎ ○ ○ ○ Check Check Every Every 1 Replace Check 100 hrs years Intake air line Brake hose & Every Every 2 Replace Check 18 700 hrs 100 hrs Parking brake and clamp 100 hrs Every 15 Radiator hose ○ Replace ◎ 17 Every Every 1 Clean Check switch 100 hrs 100 hrs Brake pedal Brake light Every Every 14 16 100 hrs 100 hrs Replace 13 Every Every ○ Replace Check 12 100 150 200 250 300 350 400 450 500 550 600 650 700 ○ Check 100 hrs After Items 50 Every Every 200 hrs Every 4years ◎ ○ ○ ○ Every 300 hrs Every 400 hrs MAINTENANCE 22 23 Knuckle case oil Change Engine valve clearance Adjust 24 Fuel injection Check 25 Injection Check 26 Brake fluid Change 27 28 Remote hydraulic hose Rear brake cylinder seal ○ Replace Replace 29 Front brake seal Replace 30 Cooling system Flush 31 Coolant Change 32 Fuel system Bleed 33 Fuse Replace 34 Light bulb Replace Every 400 hrs Every 800 hrs Every 1500 hrs Every 3900 hrs Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Service as required NOTE: ◆Engine Oil:(15W/40SL) Oil used in the engine should have an American Petroleum Institute (API) service classification and Proper SAE Engine Oil according to the ambient temperatures as shown above. ◆Brake fluid: Always use DOT3 GENUINE BRAKE FLUID from a sealed container. MAINTENANCE MAINTENANCE PERIODIC SERVICE PERIODIC SERVICE ■ Operator’s Seat CAUTION: To open the seat, raise the seat to the forward To avoid personal injury: position. How TO OPEN THE FRONT HOOD COVER AND SEAT CAUTION To avoid personal injury from contact with moving parts: Never open operator’s seat while the engine is running. ■ Front hood cover ① To open the hood, turn the latch in the direction shown in the picture below and lift the hood off. To close, tilt cover back to closed position and fasten Operator’s seat HOW TO RAISE THE CARGO BED the latches. CAUTION To avoid personal injury: ● When servicing under raised cargo bed, make sure safety support is properly mounted. ● Do not touch muffler or exhaust pipes while they are hot; Otherwise, severe burns could result. ■ Raising and Lowering the Cargo Bed ◆To raise the cargo bed 1. Apply the parking brake with the engine off. 2. Pull up the cargo bed release lever. 3. When the cargo bed has been raised, mount the safety support. ◆To lower the cargo bed Press down the cargo bed hard untill it is locked. 11-1 PERIODIC SERVICE ① Cargo bed release Lever ② UP ③ DOWN ② Front frame tube ① Jack ■ Rear End Jack up the rear side after placing a wooden block under the right and left pipe frames for securing the engine and then supporting it. Do not jack it up supporting the steel plate portion under the engine directly. ① Gas spring JACK-UP POINT WARNING ① Jack ② Rear frame tube To avoid personal injury, death or vehicle damage: Do not work under the vehicle unless it is DAILY CHECK secured For your own safety and maximum service life of by safe stands or blocking. suitable the vehicle, make a thorough daily inspection before operating the vehicle. ■ Front End CAUTION Jack up at the front frame tube only. To avoid personal injury: Be sure to park the vehicle on a flat surface with the engine off and the parking brake "ON". 11-2 PERIODIC SERVICE ■ Visual Inspection Look around and under the vehicle for such items as loose bolts, trash build-up, oil or coolant leaks, broken or worn parts. ■ Checking and Refueling CAUTION To avoid personal injury: Do not smoke while refueling. Be sure to stop the engine before refueling. 1. Turn the key switch to “ON”, check the amount 2. ① Oil Level ② Dipstick of fuel by fuel gauge IMPOTTANT Fill fuel tank when fuel gauge shows1/4 or less If oil level is low, do not run engine fuel in tank. ■ Checking Coolant Level CAUTION TO avoid personal injury Do not remove radiator cap while coolant is hot .when cool .slowly rotate to the first stop and allow sufficient time for excess pressure to escape removing the cap completely. 1. Park the vehicle on a flat surface with engine ① Fuel tank cap off, raise the cargo bed, mount the safety support. 2. Fuel tank capacity Check to see that the coolant level is between the “FULL” and” LOW” marks of recovery tank. 28L 3. IMPORTANT When the coolant level drops due to evaporation, add water only up to the full level. In If oil level is low, do not run engine. case of leakage add anti-freeze and water in the Checking engine oil level specified mixing ratio up to the full level.(see flush 1. Park the vehicle on a flat surface with engine cooling system and changing coolant in EVERY 2 off, raise the cargo bed, mount the safety YEARS in PERIODIC SERVICE section) support. 2. To check the oil level, draw out the dipstick, wipe it clean, replace it, and draw it out again, check to see if the level id too low, add new oil to the prescribed level at the oil inlet. 11-3 PERIODIC SERVICE ① Radiator screen ① Recovery tank ② FULL ③ LOW IMPORTANT IMPORTANT Radiator screen must be clean from debris to prevent engine from overheating If the radiator cap has to be removed, follow the cautions above and securely retighten the ■ Checking brake fluid level cap. Use clean fresh water and anti-freeze to fill the CAUTION recovery tank. TO avoid personal injury: If water should leak, consult your local HSUN Dealer. Never operate the vehicle if the brake fluid is below the minimum mark. ■ Cleaning radiator screen Use only DOT3 from a sealed container. Other types of Brake fluid may ruin CAUTION synthetic resin or rubber installed in brake TO avoid personal injury: system components and may cause brake failure. Be sure to stop the engine before removing the screen Avoid contamination of the brake fluid 1. Park the vehicle on a flat surface, thoroughly clean before removing the filler 2. Remove the radiator cover, cap. Do not open the brake fluid reservoir 3. Detach the screen and remove all foreign cap unless absolutely necessary. materials, Use extreme care when filling the reservoir. If brake fluid spills on power steering hose, wash off with water immediately, as brake fluid quickly ruins synthetic resin or rubber hoses. 1. Check to see that the brake fluid level is the LOWER mark. 2. If it is below the “LOWER” mark add brake fluid . 11-4 PERIODIC SERVICE ① OIL CUP ② LOWER ① Parking brake ■ Checking brake pedal ■ Checking gauges ,meter and Display lamps 1. CAUTION gauges, meter and Display lamps. TO avoid personal injury: Inspect the instrument panel for broken 2. Replace if broken. Stop the engine and chock the wheels before checking brake pedal. ■ Checking head light turn signal light etc 1.Inspect the brake pedals for free clearance and 1. Inspect lights for broken bulbs and lenses smooth operation. 2. Replace if broken Adjust if incorrect measurement is found. (see checking brake pedal in” EVERY 200 HOURS in ■ Checking seat belt and ROPS PERIODIC SERVICE section) 1. Always check condition of seat belt and ROPS attaching hardware before operating vehicle. 2. Replace if damaged. ■ Checking CV joint boot 1. Check to see if the joint boots are damaged. 2. If the boots are cut gashed or show signs of deterioration. consult your local dealer. ① Brake pedal ② FREE TRAVEL ③ PEDAL STROKE ■ Checking parking brake Use the parking brake to stop, depress the brake pedal to release the park. Make sure the parking brake warning lamp on the easy Display goes off when parking brake lever is down. 11-5 PERIODIC SERVICE lubricate grease fittings more often. ① joint boot ① Joint boot ② Drive shaft ② Drive shaft ① Parking brake ② Parking brake pivot(spray type grease) ■ Checking tire inflation pressure Though the tire pressure is factory-set to the prescribed level, it naturally drops slowly in the course of time, check it everyday and inflate as necessary. tire sizes inflation pressure Front: 26x9-12 70kPa (0.7kgf/cm2, 10psi) Rear: 26x11-12 70kPa (0.7kgf/cm2, 10psi) EVERY 50 HOURS ■ Greasing Apply a small amount of multi-purpose grease to the following points every 50 hours. If you operated the vehicle in extremely wet and muddy conditions 11-6 PERIODIC SERVICE ① Range gear shift lever ① Range gear shift lever pivot (spray type grease ) ■ Checking engine start system CAUTION TO avoid personal injury Do not allow anyone near the vehicle while testing. If the vehicle does not pass the test, do not operate the vehicle. ① Accelerator pedal ◆ Preparation before testing 1. Place all control levers in the “NEUTRAL” ■ Checking wheel Lug Nut torque position. 2. Set the parking brake and stop the engine. CAUTION To aroid personal injury ◆ Test range gear shift lever safety switch 1. Sit on the operators seat. 2. Shift the range gear shift lever to: “L”, “H”, “N” Never operate vehicle with a loose Lug Nuts. Any time Lug Nuts are loosened they or REVERSE position. should be retightened to the specified 3. Turn the key to “START” position. torque. 4. The engine must not crank. 5. If it cranks consult your local dealer for this service. 11-7 Check all Lug Nuts frequently and keep them tight. PERIODIC SERVICE ① Torque wheel bolts to 75to 90 N.m ① Air filter frame ② Air filter element ③ Element retaining plate ■ Cleaning air cleaner primary element 1. Open the hood cover. 2. Open the air cleaner case cover. 3. 4. 5. Remove the air filter element. Remove the sponge material from its frame. Wash the sponge material gently but thoroughly in solvent. Squeeze the excess solvent out of the sponge material and let it dry. 6. 7. 8. Inspect the sponge material and replace it if damaged. Thoroughly apply foam air filter oil or other quality liquid foam air filter oil (not spray type) to the sponge material. 9. Pull the sponge material over its frame. 10. Install the air filter element. 11. Install the air filter case cover and be sure the crankcase breather hose is connected. ① Holder(×6) ② Air filter case cover IMPORTANT Do not run the engine with filter element removed. Be sure to refit the cover with the arrow (on the rear of cover) upright if the cover is improperly fitted evacuator valve will not function and dust will adhere to the element. ◆ Evacuator Valve Open the air cleaner cover once a week under ordinary conditions –or daily when used in a dusty place-to get rid of large particles of dust and dirt. Check fuel line and fuel filter. ① Air filter element 11-8 PERIODIC SERVICE CAUTION To avoid personal injury: Be sure to stop the engine and remove the key when attempting to make the following checks and changes. Never fail to check the fuel lines periodically the fuel lines are subject to wear and aging fuel may leak out onto the running engine causing a fire. The fuel line connections should be ① fuel pump ② fuel line ③ Exit pipe checked annually or every 100 service hours whichever comes first. 1. ■ Checking battery condition Park the vehicle on a flat surface and raise the cargo bed. 2. The fuel line is made of rubber and ages regardless of service period. 3. To avoid personal injury If the fuel line and clamps are found to be damaged or deteriorated replace them. 4. CAUTION Never remove the battery while the engine is running. Check the fuel filter, if it is clogged by debris or Keep electrolyte away from eyes, hands and clothes If you are spattered with it, contaminated with water replace it. wash it away completely with water immediately and get medical attention. IMPORTANT When the fuel line is disconnected for maintenance Wear eye protection and rubber gloves when working around the battery. or repair, cover both ends of the fuel line with a piece of clean cloth or paper to prevent dust and The factory –installed battery is non-refillable type dirt from entering. Care must be taken not to admit if the battery is weak charge the battery is weak dust and dirt into the fuel pump entrance. Even a charge the battery or replace it with new one small amount of dust or dirt will cause premature wear and malfunction of the fuel pump and injector components. ◆ Battery charging CAUTION To avoid personal injury When the battery is being activated, hydrogen and oxygen gases in the battery are extremely explosive. Keep open sparks and flames away from the battery at all times, battery. 11-9 especially when charging the PERIODIC SERVICE When disconnecting the cable from the battery start with the negative terminal first; ■ Adjusting toe-in when connecting the cables to the battery start with the positive terminal first. Proper toe-in 0 to12 mm (0 to 0.47 in) Always use a voltmeter to check a battery’s charge. 1. Park vehicle on flat place. 2. Turn steering wheel so front wheels are in the straight ahead position. 3. Lock the park brake and stop the engine. 4. Measure distance between front tires center to center of tire at hub height ①. Rotate the tires 180 degrees and measure at the rear of the front tires. 5. Front distance should be shorter than rear distance if not adjust tie rod length. ① Battery 1. To slow charge the battery, connect the battery positive terminal to the charger positive terminal and the negative to the negative. Then recharge in the standard fashion. 2. A boost charge is only for emergencies it will partially charge the battery as early as possible. 3. When exchanging an old battery for a new one use battery of equal specification shown in ① Wheel-to-wheel distance at front table 1. ② FRONT Battery type Volts 12V32Ah 12 ◆ Adjusting procedures 1. Loosen the lock nut and turn the tie rod to adjust the rod length until the proper toe-in ◆ Direction for storage 1. measurement is obtained. When storing the vehicle for a long period, 2. Retighten the lock nut. remove the battery from level vehicle, store in 2. a dry place out of direct sunlight. IMPORTANT The battery will self discharge while it is stored, recharge it once every three months in hot seasons and once every six months in cold seasons. 11-10 Keep the equal length of the left and right tie-rod. PERIODIC SERVICE ■ Cleaning Muffler Replace the entire muffler if it is damaged. Do not operate the vehicle with a damaged CAUTION muffler. To avoid personal injury: Before touching any part of an exhaust system, be absolutely sure that it has sufficient time to cool! Always wear safety goggles and face mask. The particulate matter contained in the muffler contains chemicals that are harmful to people, animals and marine life. If you are unable to do this work, have it ① Muffler done by your dealer. ④ Back cover Cleaning spark arrester of muffler. Maintenance & cleanout procedure: The screen type spark arrester should be removed, cleaned, and inspected after every 100 hours EVERY 200 HOURS ■ Changing Engine Oil of use. 1. CAUTION The spark arrester is located inside of the exhaust pipe, and fastened with six bolts. 2. To avoid personal injury: Loosen the bolts and remove the spark arrester. 3. 1. Park the vehicle on flat surface and raise the cargo bed. 2. If any breaks in the screen or welds are To drain the used oil, remove the drain plug at the bottom of the engine and completely drain discovered, the assembly must be replaced. 5. Allow engine to cool down sufficiently, oil can be hot and can burn. wire brush. Soak in solvent and again clean with wire brush if necessary. Be sure to stop the engine before replacing oil. Shake loosened particles out of the screen assembly and lightly clean the screen with 4. ② Spark arrester the oil into an oil pan. Return the spark arrester to the muffler body and refasten the bolts. 3. After draining, reinstall the drain plug. 4. Fill with the new oil up to the upper notch on the dipstick. IMPORTANT: (See “LUBRICANTS, FUEL AND COOLANT” Visually check the muffler for cracks or holes in “MAINTENANCE” section.) in the body, weldment or pipes at regular intervals. USDA approval requires clearance between [Filter exchanged] 1.8L (1.89U.S. qts.) Oil capacity spark arrester sleeve and exhaust pipe to be no larger than 0.023”(0.584 mm). 11-11 [Filter non-exchanged] 1.6L (1.68U.S. qts.) PERIODIC SERVICE ① Oil Level ② Dipstick ■ Replacing Engine Oil Filter ① Bolt; ② Cover ③ “O” seal ring; ④ Engine oil filter IMPORANT: CAUTION To prevent serious damage to the engine, use only a genuine filter. To avoid personal injury: Be sure to stop the engine before changing ■ Replacing Transmission Oil the oil filter cartridge. 1. Allow engine to cool down sufficiently, oil CAUTION can be hot and can burn. To avoid personal injury: Park the vehicle on a flat surface, remove the seat and open the adjustment hatch cover. oil. 2. Remove the oil filter. 3. Put a film of clean engine oil on the rubber seal of the new filter. 4. 5. Be sure to stop the engine before changing Allow engine to cool down sufficiently, oil can be hot and can burn. 1. Tighten the filter quickly until it contacts the Park the vehicle on a flat surface, raise the cargo bed, and mount the safety support. mounting surface. 2. Put a film of clean transmission oil; Tighten filter by hand an additional 1/2 turn 3. Quickly tighten the filter until it contacts the only. mounting surface, tighten it an additional 1 After the new filter has been replaced, the turn only. engine oil normally decreases a little. Make 4. After running the engine for a few minutes, sure that the engine oil does not leak through stop the engine and check the oil level again. the seal and check the oil level on the dipstick. Add oil to the prescribed level. Then replenish the engine oil up to the prescribed level. Oil capacity 11-12 [Filter exchanged] 1L (1.05U.S. qts.) PERIODIC SERVICE 3. If brake pedal stroke is outside of the specifications, contact your local dealer for adjusting the brake. ① Oil Level ② Dipstick ① Brake pedal ② “FREE TRAVEL” ■ Checking Brake Pedal ■ Checking Brake Hose and Pipe 1. CAUTION Stop the engine and chock the wheels before checking brake pedal. If movement is outside of the specifications contact your local dealer for adjusting the ◆Checking the brake pedal free travel Proper brake pedal 7 to 14mm free travel (0.3 to in.)On the pedal Check to see that brake hoses and lines are not swollen, hardened or cracked. 2. Check the brake hoses and fittings for oil leaks. 3. If there is any abnormality, consult your local dealer for this service. brake. ■ Checking Brake Light Switch 1. Park the vehicle on a flat surface and raise the cargo bed. 1. Release the parking brake. 2. Slightly depress the brake pedal and measure 2. Turn the key switch to the “ON” position. 3. Step on the brake pedal to check if the brake light comes on. 4. free travel at the top of the pedal stroke. 3. ③ “PEDAL STROKE” If it does not, check the bulb or brake light switch. If brake pedal free travel is outside of the specifications, contact your local dealer for ■ Checking the Radiator Hoses and Clamps adjusting the brake. Park the vehicle on a flat surface and raise the cargo bed. Check to see if radiator hoses are ◆ Checking the brake pedal stroke properly fixed every 200 hours of operation or six Pedal stroke Less than 120mm (4.7in.) months, whichever comes first. On the pedal 1. 1. Release the parking brake. 2. Step on the pedal and measure the pedal If hose clamps are loose or water leaks, tighten bands securely. 2. stroke. Replace hoses and tighten hose clamps securely, if radiator hoses are swollen, 11-13 PERIODIC SERVICE hardened or cracked. Replace hoses and engine again. hose clamps every 2 years or earlier, if checked and found that hoses are swollen, ■ Checking Intake Air Line hardened or cracked. 1. Check to see if the hoses and hose clamps are tight and not damaged. 2. If hoses and clamps are found to be worn or damaged, replace or repair them at once. ① Hose ② Hose joint EVERY 300 HOURS ■ Checking the Tires ① Radiator hose 1. Check to see if the tires are damaged. 2. If the tires are cracked, bulged, or cut, or they ② Clamp bands are worn out, replace or repair them at once. ◆Precaution at Overheating Take the following actions in the event the coolant ◆Tire Tread Depth temperature is close to or more than the boiling Always replace the tires when the tread depth is point, which is called “Overheating”. worn to minimum allowable. 1. Stop the vehicle operation in a safe place and keep the engine unloaded idling. 2. Don’t stop the engine suddenly, but stop it after about 5 minutes of unloaded idling. 3. Keep yourself well away from the vehicle for at least 10 minutes or while the steam is blowing out. 4. Check to see if there is no danger such as burning, get rid of the causes of overheating by following the “TROUBLESHOOTING” section of the manual, and then start the ① 3mm(0.12in) 11-14 PERIODIC SERVICE EVERY 400 HOURS 2. ■ Changing Transmission Fluid To drain the used oil, remove the drain the oil completely into the oil pan. 3. CAUTION Fill with the new oil up to the upper notch on the dipstick. To avoid personal injury: (See “LUBRICANTS, FUEL AND COOLANT” in “MAINTENANCE” section.) Park the vehicle on a flat surface, raise the cargo bed, mount the safety support. 4. can be hot and can burn. 1. Oil capacity for Park the vehicle on a flat surface, raise the front axle cargo bed, mount the safety support. 2. After filling, reinstall the filling plug. Allow engine to cool down sufficiently, oil 0.6L(0.6U.S.gals.) case To drain the used oil, remove the drain plug at Oil capacity for the bottom of the transmission case and drain rear axle case ? the oil completely into the oil pan. 3. After draining, reinstall the drain plug. 4. After running the engine for a few minutes, stop the engine and check the oil level again; add oil to prescribed level. ① Drain plug IMPORTANT: Do not operate the vehicle immediately after changing the transmission fluid. Run the engine at medium speed for a few minutes to prevent damage to the transmission. Front axle case drain plug Rear axle case drain plug EVERY 500 HOURS ■ Replacing Fuel Filter ■ Changing Front and Rear Axle Case Oil 1. ① ② Consult your local dealer for this service. Park the vehicle on a firm, flat and level surface. EVERY 600 HOURS 11-15 PERIODIC SERVICE ■ Adjusting Engine Valve Clearance anti-freeze until the coolant level is just below Consult your local dealer for this service. the radiator cap. Install the radiator cap securely. EVERY 1500 HOURS 7. ■ Checking Injection and Fuel Pump Fill with fresh water up to the “FULL” mark on the recovery tank. Consult your local dealer for this service. 8. Start and operate the engine for few minutes. EVERY 1 YEAR 9. Stop the engine and let cool. ■ Replacing Air Cleaner Primary Element and 10. Check coolant level of recovery tank and Secondary Element coolant if necessary. (See “Cleaning Air Cleaner Primary Element” in “every 100 HOURS” in “PERIODIC SERVICE” Coolant capacity 4.0L (4.2U.S.qts.) section.) EVERY 2 YEARS ■ Changing Brake Fluid Consult your local Dealer for this service. (See “Checking Brake Fluid Level” in “DAILY CHECK” in “PERIODIC SERVICE” section. ■ Flushing Cooling System and Changing Coolant ① Recovery tank CAUTION ③ “ LOW” To avoid personal injury: Do not remove the radiator cap while coolant is hot. When cool, slowly rotate cap to the first stop and allow sufficient time for excess pressure to escape before IMPORTANT: Do not start engine without coolant. Use clean, fresh water and anti-freeze to fill the radiator and recovery tank. removing the cap completely. 1. Stop the engine and let cool down. 2. To drain the coolant, open the radiator drain plug and remove radiator cap. The radiator Securely tighten radiator cap. If the cap is loose or improperly fitted, water may leak out and the engine could overheat. coolant. After all coolant is drained, close the drain ■ Anti-Freeze plug. 4. When the anti-freeze is mixed with water, the antifreeze mixing ratio must be less than 50%. cap must be removed to completely drain the 3. ②“ FULL” Fill with clean water and cooling system cleaner. CAUTION To avoid personal injury: 5. Follow directions of the cleaner instruction. 6. After flushing, fill with clean water and 11-16 When using antifreeze, put on some PERIODIC SERVICE protection such as rubber gloves. (Antifreeze IMPORTANT: contains poison.) If you should drink antifreeze, throw up at When the antifreeze is mixed with water, the antifreeze mixing ratio must be less than 50%. once and seek medical attention. skin or clothing, wash it off immediately. Freezing point VOL% When antifreeze comes in contact with the Anti-freeze ℃ 40 50 Do not mix different types of Antifreeze. The mixture can produce chemical reaction Boiling point ° ° F ℃ -24 -12 106 222 -37 -34 108 226 F causing harmful substances. Antifreeze is extremely flammable and *At 1.013×105Pa (760mmHg) pressure (atmospheric). explosive under certain conditions. Keep fire and children away from antifreeze. A higher boiling point is obtained by using a radiator When draining fluids from the engine, place pressure cap which permits the development of some container underneath the engine body. pressure within the cooling system. Do not pour waste onto the grounds, down a drain, or into any water source. 5. Adding the LLC Also, observe the relevant environmental 1) Add only water if the mixture reduces in amount by evaporation. protection regulations when disposing of 2) antifreeze. If there is a mixture leak, add the LLC of the If it freezes, coolant can damage the cylinders and same manufacturer and type in the same radiator. If the ambient temperature falls below mixture percentage. 0℃(32°F) or before a long-term storage, let out * Never add any long-life coolant of different cooling water completely, or mix fresh water with manufacturer. (Different brands may have long-life coolant and fill the radiator and recovery different tank with the mixture.· engine may fail to perform as specified.) 1. 2. Long-life coolant (hereafter LLC) comes in 6. additive components, and the When the LLC is mixed, do not employ any several types. Use ethylene glycol (EG) type radiator cleaning agent. The LLC contains for this engine. anticorrosive agent. If mixed with the cleaning Before employing LLC-mixed cooling water, fill agent, the radiator with fresh water and empty it affecting the engine parts. 7. again. sludge may build up, adversely The vehicle’s genuine long-life coolant has a Repeat this procedure 2 or 3 times to clean up service life of 2 years. Be sure to change the the inside. coolant every 2 years. 3. Mixing the LLC NOTE: 4. The procedure for the mixing of water and The above data represent industry standards antifreeze differs according to the make of the that require a minimum glycol content in the antifreeze and the ambient temperature. Refer concentrated antifreeze. to SEA J1034 standard, more specifically also When the coolant level drops due to evaporation, add water only to keep the to SAE J814c. 11-17 PERIODIC SERVICE antifreeze mixing ratio less than 50%. In case 3) Pull out the mini blade fuse. of leakage, add antifreeze and water in the 4) Insert a new mini blade fuse into the slow-blow specified mixing ratio before filling into the radiator. fuse box. 5) Close the mini blade fuse box cover. 6) Connect the negative battery cable. ■ Replacing Radiator Hose (Water pipes) Replace the hoses and clamps. (See “Checking Radiator Hose and Clamp” in “EVERY 200 HOURS” in “PERIODIC SERVICE” section.) ■ Replacing Fuel Hose Consult your local Hisun Dealer for this service. ■ Replacing Brake Master Cylinder (Inner ① Mini Blade fuse box cover parts) Consult your local dealer for this service. ■ Replacing Light Bulb ■ Replacing Front Brake Seal Head lights Take the bulb out of the light body and replace Consult your local dealer for this service. it with a new one. ■ Replacing Rear Brake Cylinder Seal Other lights Detach the lens and replace the bulb Consult your local dealer for this service. Light Capacity ■ Replacing Intake Air Line Head lights 2x55W Consult your local dealer for this service. Tail light LED 0.5W Brake light LED 1W Instrument panel light 1W EVERY 4 YEARS ■ Replacing Brake Hose Consult your local Dealer for this service. ■ Replacing Mini Blade Fuses The mini blade fuses are intended to protect the electrical wiring. If any of them have blown out, be sure to pinpoint the cause. ◆Replacing procedure 1) Disconnect the negative cable of the battery. 2) Open the mini blade fuse box cover. 11-18 STORAGE STORAGE 7. STORAGE Remove the battery from the vehicle. Store the battery following the battery storage procedures. CAUTION 8. Keep the vehicle in a dry place where the To avoid personal injury: vehicle is sheltered from the elements. Cover the vehicle. Do not clean the vehicle when the engine is running. 9. Keep the vehicle indoors in a dry area that is To avoid the danger of exhaust fume protected from sunlight and excessive heat. If poisoning, do not operate the engine in a the vehicle must be stored outdoors, cover it closed building without proper ventilation. with a waterproof tarpaulin. When storing, remove the key from the key Put boards under the tires to keep dampness switch to avoid unauthorized persons from away from tire. operating the vehicle and getting injured. Keep the tries out of direct sunlight and extreme heat. VEHICLE STORAGE If you intend to store your vehicle for an extended IMPORTANT: period of time, follow the procedures outlined When washing the vehicle, be sure to stop the below. engine. These procedures will insure that the vehicle is Allow sufficient time for the engine to cool ready to operate with minimum preparation when it before washing. is removed from storage. Do not wash with a pressure washer. 1. Cover the vehicle after the muffler and the Check the bolts and nuts for looseness, and tighten if necessary. 2. engine have cooled down. Apply grease to vehicle areas where bare metal will rust also to pivot areas. 3. Unload from cargo bed. REMOVING THE VEHICLE FROM STORAGE 4. Inflate the tire to a pressure a little higher than 1. usual. 5. if they are low. Change the engine oil and run the engine to 2. circulate oil throughout the engine block and 6. Check the tire air pressure and inflate the tires Before installing the battery, Be sure it is fully charged. internal moving parts for about 5 minutes. 3. Check to see if the fan works. With all implements lowered to the ground, 4. Check all fluid levels (engine oil, transmission coat any exposed rods with grease (if oil, engine coolant, transmission coolant and equipped). any attached implements). 5. Start the engine. Observe all gauges. If all gauges are functioning properly and reading 12-1 STORAGE normal, move the vehicle outside. Once outside, park the vehicle and let the engine idle for at least five minutes. Shut the engine off and do a visual inspection looking for evidence of oil or water leaks. 6). With the engine fully warmed up. Release the parking brake and test the brakes for proper adjustment as you move forward. Adjust the brake as necessary. 12-2 TROUBLESHOOTING TROUBLESHOOTING ENGINE TROUBLESHOOTING If something is wrong with the engine, refer to the table below for the cause and its corrective countermeasure. Trouble Cause In winter, oil viscosity increases, and Engine revolution is slow. Battery becomes weak and the engine does not turn over quick enough. Clean or replace the air cleaner. Clean or replace the spark plug. Replace the ignition coil. Insufficient fuel. The injector is clogged. Crankshaft position sensor is Spoiled. The air cleaner is clogged. Spark plug is dirty or spoiled. Ignition coil is spoiled. Check with the diagnostic instrument (Motor Scan KF90121 ). Engine overloaded Countermeasure Check the fuel tank and fuel filter。 Check the electric fuel pump. Check the injector. Check the ECU with Motor Scan KF90121. Replace filter electric fuel pump injector and ECU If necessary. Check to see if the fuel tank cover is tight. Use oils of different viscosities, depending on ambient temperatures. Clean battery cables and terminals. Charge the battery. In cold weather (-15℃), always remove the battery from the vehicle, charge and store it indoors. install it on the vehicle only when the vehicle is going to be used。 Check the fuel system. Clean or replace the injector. Replace crankshaft position sensor. Low coolant level. The motor driven fan does not turn. Dirty radiator core or grille screens. Coolant flow route corroded. Shift to lower gear or reduce load. Fill cooling system to the correct level; Check radiator and hoses for loose connections or leaks. Check to see if the fuse is not blown. Check the electric system. Remove all trash. Flush cooling system. No fuel flow ·Water is in the fuel system Engine is difficult to start or Will not start. Engine power insufficient is Engine stops suddenly Engine overheats If you have any questions, consult your local dealer. 13-1 TROUBLESHOOTING Check malf code meaning by reading the below table. Mt05 ECU Malf Code Table:23 Malf code in MT05 Description P0107 MAP Circuit Low Voltage or Open P0108 MAP Circuit High Voltage P0112 IAT Circuit Low Voltage P0113 IAT Circuit High Voltage or Open P0117 Coolant/Oil Temperature Sensor Circuit Low Voltage P0118 Coolant/Oil Temperature Sensor Circuit High Voltage or Open P0122 TPS Circuit Low Voltage or Open P0123 TPS Circuit High Voltage P0131 O2A Circuit Low Voltage P0132 O2A Circuit High Voltage P0031 O2A Heater Circuit High Voltage P0032 O2A Heater Circuit Low Voltage P0201 Injector 1 Circuit Malfunction P0202 Injector 2 Circuit Malfunction P0230 FPR Coil Circuit Low Voltage or Open P0232 FPR Coil Circuit High Voltage P0336 CKP Sensor Noisy Signal P0337 CKP Sensor No Signal P0351 Cylinder 1 Ignition Coil Malfunction P0352 Cylinder 2 Ignition Coil Malfunction P0505 Idle Speed Control Error P0562 System Voltage Low P0563 System Voltage High P0650 MIL Circuit Malfunction P1693 Tachometer Circuit Low Voltage P1694 Tachometer Circuit High Voltage If you have any questions, consult your local dealer. 13-2 TROUBLESHOOTING BATTERY TROUBLESHOOTING Trouble Cause Battery Preventive measure overused until lights are dim. Countermeasure Battery has Charge the battery sufficiently. not Charge the battery properly. been recharged. Starter does not function Poor terminal and connection From beginning starter does not function, and Battery life expired Insufficient Battery was used with an insufficient top amount plates, look * Refillable type battery only of Battery was used with too Apply grease and treat with anti-corrosive. with a battery much Battery life expired. Charge the battery corroded and heat up. Poor terminal connection properly Regularly check the Charge battery properly Replace battery. Terminals are severely Keep the terminal Clean the terminal clean and tight. and Apply tighten securely. grease treat anti-corrosives. Battery electrolyte level * Refillable type battery only There is a crack or pin holes in the drops rapidly. Replace battery. Consult your local electrolytic cells. Charging system trouble. dealer. If you have any questions, consult your local dealer. The factory installed battery is non-refillable type. 13-3 be electrolyte level. Insufficiently must before initial use Add distilled water charge Battery serviced battery. without recharging. Recharging is impossible. Charge and electrolyte. whitish. clean and tight. Insufficiently When viewed from the of Replace Keep the terminal new battery charging tighten securely. lights soon become dim Clean the terminal and with TROUBLESHOOTING MACHINE TROUBLESHOOTING Trouble Cause High idling speed of engine High rotary speed for clutch connection. Not good adjustment gearshift stay wire. Non agility for Gearshift Transmission noise Replace the gears Replace the gears Replace the gears Loosen the lay-up rod Contact the distributor. for Gear abrasion Big matching clearance for the inner and outside gears of transmission shaft Big clearance of transmission gears. Not good connection of gear end face Parking brake Not full Uncoupling for disc brake Less vehicle power No good brake or noise Countermeasure Replace throttle cable; Replace throttle petal Replace he throttle Replace he junior clutch spring; Replace the primary clutch. Put the gearshift rod into the position of “N”. Put the gearshift arm of engine into ”N”. Adjust the stay wire and the bolt. Lock tightly. Replace the gears CVT transmission sliding Less brake oil Air inside the braking system. Brake discs abrasion Assembling bolt of disc plate loose Assembling bolt for disc brake clippers loose If you have any questions, consult your local dealer. 13-4 Removing the grease for the clutch. Replace CVT transmission belt Replace the clutch. Check the braking oil level Contact the distributor. Contact the distributor. Lock tightly Lock tightly 13-1 OPTIONS OPTIONS Consult your local dealer for further details. 1. Head rest; 2. Plastic Canopy; 3. Rear Trailer Hitch & Pin(2〞); 4. Windshield; 5. Steel Cab; 6. Motor Scan KF90121; 7. EPS 14-1 ELECTRIC POWER STEERING SYSTEM ELECTRIC POWER STEERING SYSTEM INTRODUCTION barriers on steering wheel can be greatly Our UTV is equipped with Electric Power Steering decreased. System (EPS). To keep reliability of EPS during 5) No pollution to environment. For the traditional operation, please correctly use EPS system hydraulic power steering system, the hydraulic according to the following descriptions and keep circuit has hydraulic hose and fittings inside so daily inspection and maintenance. oil leaks may occur, and hydraulic hose is not This chapter also provides important information to recycled, so this is produce pollution to safely use EPS system. If you encounter any environment. However, EPS system has not problem during operation or maintenance, please pollution to environment. feel free to consult your local dealer. 6) When engine does not start, EPS system can also work as battery, and once sufficient power ADVANTAGES OF EPS SYSTEM: generate, steering power can be workable. 1) High efficiency. Traditional hydraulic power and hydraulic, and it is of low efficiency, usually IMPORTANT INFORMATION FOR SAFETY: only 60%-70%. However, EPS system is UTV you buy is equipped with EPS system, please connected by mechanical and electric motor read this chapter carefully before operating UTV, and it is much high efficiency with up to 90%. and only you are familiar with and master enough steering system is connected by mechanical 2) Less energy consumption. In practical driving of EPS system about using methods and process of UTV, time in steering condition is precautions information can you start to drive your only 5% among the total travelling time. As to UTV. hydraulic power steering system, as long as Make inspection and maintenance on EPS system the engine is running, the hydraulic pump is on regular, and ensure the security and reliability always when you use your UTV. in working condition, and fuel consumption will increase 4%-6%. However, EPS system starts the motor, only when it Please carefully read this chapter before needs steering, to generate power without operation or driving to acknowledge increasing fuel consumption. completely about correct way to operate and 3) The power characteristics of EPS system can drive the UTV with EPS system, and also be controlled by software, so that UTV can be characteristics, functions and limits of UTV. satisfied with power steering characteristics at Doing inspection and maintenance on EPS various speeds. system on regular, correct operation and 4) Feeling comfortable on road. Inside of EPS driving skills will ensure the security and system, we use rigid connection, so under reliability of UTV. auxiliary of start motor, the impact of road 15-1 ELECTRIC POWER STEERING SYSTEM To make sure your EPS system will be useful ■ Construction of EPS for a long time and no problem, please follow 1. Structure chart of EPS the method for maintenance in this chapter. This chapter also includes detailed disassembly and maintenance information. User wants to repair by themselves must have qualified mechanical skills, electronic maintenance skills and the special tools mentioned in the manual. ① Steering wheel INTRODUCTION OF EPS SYSTEM ② Reducer ■ What is EPS system ③ Motor The EPS system (Electric Power Steering System) ④ Steering transmission shaft is a complete set of parts, including a special ECU ⑤ Universal joint only for EPS system (hereinafter referred to as ⑥ Tie rod joint ECU), many sensors and actuators, by signal such ⑦ Tie rod as monitoring UTV speed, the operating force of ⑧ Steering knuckle the steering wheel, as well as temperature of ECU ⑨ Steering gear and motor to provide an accurate power torque of 2. Steering Torque Sensor: the motor and aligning torque. As a result, it will Install sensor on the reducer. have easy steering function and soft effect of steering wheel aligning. ■ Typical parts of EPS system In general, EPS system has the following parts: Steering torque sensor Motor to generate power torque EPS system control unit (ECU) 。 Speed sensor。 Temperature sensor ① Sensor Battery voltage sensor No change after the sensor fixed. Mechanical reduction transmission Sensor assembly position is certained and can not mechanism(Reducer) make any change, if found sensor postion was Gear/rack type steering gear changed caused by bolt looseness,please tighten the Steering rod joint bolt and initialize the ECU at once(See Page12-12) Ball stud of steering knuckle 3. ECU: Steering shaft and universal joint ECU is sophisticated electronic equipment, and 15-2 ELECTRIC POWER STEERING SYSTEM controls all the power performance of EPS, so do On the shell of ECU unit, there are sets of electric not repair ECU by yourself. plugs by cables and function as follows: If any problem happens on ECU, please contact • P1:positive pole (○ + pole) for EPS motor your local dealer to repair it. • P2:negative pole (○ - pole) for EPS motor • P3:connect with cable of UTV and transfer single that ECU required • P4:connect with steering torque sensor, supply power to steering torque sensor and accept single of torque • P5:connect with motor ① Upper housing ② ECU unit ③ Seal ring ④ Lower housing Installation position of ECU and reducer 4. Reducer: Install reducer on the frame of UTV. Install motor and steering torque sensor on reducer. Outside view of reducer ① ECU ② Reducer The installation location of the ECU will be greatly effected by temperature changes and external humidity. Housing has a membrane made of Goretex material for pressure balance between inside the shell and the surrounding environment, but also to prevent the parts from moisture intrusion. 5. Gear/rack type steering gear Do not remove the membrane or replace by other UTV use gear/rack type steering gear to perform parts. steering function. Steering gear was fixed on 15-3 ELECTRIC POWER STEERING SYSTEM frame. monitors working condition of EPS system. Fault can be displayed by fault indicator light and Installation position of steering as follows: fault indicator of EPS system, so the driver can acknowledge fault of EPS in time and take some measures to keep himself/herself safe. When fault occurs on EPS system, fault indicator light will be lit up. At the same time, fault indicator of EPS system will display the fault code for maintenance. 6. Electronic connectivity diagram of EPS system: ① Fault indicator light of EPS system ② Fault indicator of EPS system Fault code diagram No. Fault code 1 F00001 2 F00002 ② ECU split cable 3 F00006 ③ Battery 4 F00005 5 F00003 6 F00011 7 F00010 ECU non-working ① ECU (with waterproof metal box) ④ Meter ⑤ Steering torque sensor ⑥ Motor ⑦ Speed sensor ⑧ Main switch Fault style 1#fault of steering torque sensor 2#fault of steering torque sensor ECU overheating low voltage battery alarm Dynamic motor without power alarm Fault of speed sensor Fault indicator light of EPS system lit lit lit lit lit lit lit ⑨ Fuse 7. Meter: OPERATION AND USE OF EPS SYSTEM Meter is an important part of UTV. ■ EPS system operation Meter works together with EPS system and 15-4 ELECTRIC POWER STEERING SYSTEM Operate as the following steps: ④ Negative Wire Of Cable Assembling your new UTV. ⑤ Negative Wire Of EPS System Ensure main switch is off. ⑥ Nut ⑦ Screw main switch CAUTION If connection terminals do not fixed, power of ECU may be constantly on-off during UTV driving, and finally cause ECU damaged. Open main switch of UTV, and EPS system will automatically enter into working state. ① Main switch Check the meter. If fault indicator light of EPS ② OFF system does not be lit, ECU can be for regular ③ ON use. ④ START If fault indicator light of EPS system is lit, that means EPS system find out some fault during ECU self-checking process, then you should CAUTION consult your local dealer for maintenance in time. If main switch is not off, ECU can be destroyed by battery power in on-off condition during the Meter following connection with cables. Use screw/nut to connect the connecting terminals of cables firmly to ○ + and ○ of battery. ① Fault indicator light of EPS system ② Fault indicator of EPS system ① Battery ② Positive Wire Of Cable ③ Positive Wire Of EPS System DANGER 15-5 ELECTRIC POWER STEERING SYSTEM Drive UTV with faulty EPS system may cause torque, power torque of the EPS system will be accident, severe injury or even death. relatively small. This can be achieved outstanding Never operate UTV with faulty EPS system. auto-centering effect, that means when UTV is in straight-line, steering system will be not sensitive ■ Function of EPS system (the steering wheel does not move from side to side). EPS system requires enough power to supply correct power torque. Supply steering power according to speed Fault alarm and protection function UTV’s steering power can change as different In order to ensure EPS system can supply a various speeds and steering angle. long-term, reliable working, a variety of detection EPS systems can supply different power torque and alarm functions are set in the ECU software depending on the speed and steering angle. program. Once fault has been checked on EPS system, UTV can accurate shutdown the EPS system. Shut off the EPS system, UTV will be able to continue to complete the steering function through the mechanical structure of the steering system. However, at this time the driver will feel the turning resistance increases, you can continue your driving of UTV only throw a greater force to operate ① T1 : steering resistant torque which is checked by the steering system. steering power sensor ② T2:power torque on steering gear which is supplied by DANGER EPS system When meter indicated malfunction of EPS system ③ Power Torque In Static Condition or when the driver found EPS system operation ④ Power Torque At Middle Speed abnormally, please do some steps as below: ⑤ Power Torque At The Highest Speed Stop vehicles immediately, close the main switch, open the front panel’s repair cover, and Stationary, the maximum power torque can make pull up the outlet which power supply for EPS UTV U-turn or stop into place as much as possible system (See page12-3) to ease the steering operation. With increased speed, reduce power torque can Driving UTV to dealer by lower velocity and repair EPS system. make UTV at high speed, to make ii easier to maintain driving direction. EPS SYSTEM’S INSPECTION, MAINTENANCE, REPAIR: As shown, power auxiliary effect depends not only EPS system had already inspected by strict quality on speed, but also steering torque exerted by the restriction before delivery, so it has high reliability. driver. If the driver is to impose a smaller steering 15-6 ELECTRIC POWER STEERING SYSTEM But if there is no inspection or maintenance as When ECU detected its own fault and can not stated time period during in use of EPS, it may be work normally, it will indicate EUC stop cause EPS system work abnormally or spare parts working code to dash board. Meanwhile, EPS in EPS system are damaged abnormally. system fault indicator light is lighten. When EPS system work wrong or get malfunction, ■ To drive UTV at every time, need to do daily the malfunction warning and fault code can be indicated on meter. inspection of EPS system Before drive UTV at every time, need to do daily ■ Malfunction assortment: inspection as following steps. During long time continuous fast steering, especially when ambient temperature is very 1. each part’s interval. high, it may cause ECU radiator of high Check steering system’s mechanical part of temperature, and at this time ECU can get through detection temperature sensor’s signal Move steering wheel and Check whether is loosen to issue ECU over-heating failure warning’s or with squeak through axis direction and fault code to meter. Meanwhile, EPS system horizontal direction. If defection found, repair or fault indicator light is lighten. replace it. Check steering wheel is loosened or not. When ECU detected 1# steering torque sensor or 2# steering torque sensor had fault, then it will indicate 1# steering torque sensor Steering wheel’s range of free clearance is: 0-15mm(0-0.59in.) fault or 2# steering torque sensor fault code to If the free clearance is over range, check spare dash board. parts as below, any defection found, replace it. Any Meanwhile, EPS system fault indicator light is defection found, replace it. lighten. When ECU detected the storage batter’s voltage is lower than 9VDC through sensor, it Steering tie rod ball head is whether to wear down。 will indicate the fault code of storage battery Swizzle ball of knuckle wear out or not voltage low to dash board. Meanwhile, EPS Gear rack on steering wheel wear out or not system fault indicator light will be lighten. Spline on steering drive shaft is loosen or not When ECU detected motor is out of work Between input and output shaft’s reducer through sensor, it will indicate fault code of whether had idle running. dynamic motor without power warning to dash board. Meanwhile, EPS system fault indicator The steering system checking in steering process: light is lighten. When ECU detected the speed sensor had Turn the steering wheel from left to right and right fault, it will indicate vehicle speed sensor fault to left .it required smoothly and no blocking code to dash board. Meanwhile, EPS system allowed. fault indicator light is lighten. 15-7 ELECTRIC POWER STEERING SYSTEM 2. Check steering power in static condition block, no recoil force which opposite of Let UTV stop on the level road, steering wheel is operation force. placed in a straight forward position. Check tire inflation pressure whether meet During return process, the return force is equal to the velocity at both left and right directions. specified requirements (see tire instructions or If any problem occurs, it must driven to dealer and UTV user manual). repair it immediately. If necessary, refill it. Check front wheel’s front beam, wheel offset positioning whether is correct (see UTV user manual). If necessary, adjust it. Open the main switch. Turn the steering wheel left and right successively, turning force on both sides should be equal. Turn the steering wheel to rotate back and forth; turning shall be smoothly, no block, no recoil forces which opposite of operation force. If any problem found, it must driven to dealer and repair it immediately. 3. Steering force’s checking during running conditions: During running process, the feeling of steering force to the left and right must be consistent. During steering, turning shall be smoothly, no ■ Solutions for common fault: 1. Open the main switch, no auxiliary power of left and right steering. S/N 1 2 FAULT PHENOMENON Meter warning fault code:F00010 Meter warning fault code: F00001&F00002 FAULT POINT Special fuses of ECU is blown in fuses box (see figure 1), Or ECU is damaged SOLUTION Replace fuses. To dealers for repair Sensor is damaged or sensor’s connector with bad contact or ECU is damaged 15-8 To dealers for repair ELECTRIC POWER STEERING SYSTEM 3 Meter warning fault code: F00005 Charge Low voltage in storage battery storage battery, replace it if necessary. Motor is damaged or driving 4 Meter warning fault code: circuit in motor is damaged or Replace fuses, to dealer F00003 power motor special fuses are for repair blown. 5 No electrical power connected No meter alarm, UTV can 6 electrify Main fuses melted. ECU initialization Replace fuses choose pin connector with poor contact (sees Reinsert well, replace attached figure 2), or in the wire connector or repair cables. cable is disconnect 7 No meter alarm ECU is damaged To dealers for repair. Figure 1:Fuses box Figure 2:ECU initialization connector’s position ① ① ECU dedicated fuse ECU initialization connector 2. Open the main switch, only steering left or right is power-assisted. S/N 1 2 Fault phenomenon No meter alarm Meter warning fault code: F00001 or F00002 Fault point Solution ECU damaged Sensor damaged, To dealers for repair. sensor’s connector with bad contact or ECU damaged 15-9 To dealer for repair. ELECTRIC POWER STEERING SYSTEM 3. All have auxiliary power to turn left or right, when turned the steering wheel is not smooth, locked, backswing and other feelings. S/N Fault phenomenon Steering 1 system mechanical parts has the big gap 2 Fault point Solution Steering system mechanical parts become loose or damaged. Mechanical parts without ECU damaged, or the gap software program has error. Retighten loose bolts. Replace damaged spare parts. ECU To dealers for repair. 4. When running, all have power-assisted to turn left or right, when return ability is slowly or during return processing out of nimbleness. S/N Fault phenomenon Fault point Meter warning fault cod: The speed sensor damaged, or Replace F00011 from meter to ECU transmit speed Check and repair cables. signal ‘s guide wire broken circuits Replace or ECU connectors is loose assembly. Positional parameter of steering Adjust wheel (front wheel) error. positional parameter. EPS system’s speed reducer To dealers for repair. 1 No meter alarm 2 3 No meter alarm Solution speed sensor. connector front wheel’s damaged 5. All have power-assisted to turn left or right,but steering become more heavy. S/N Fault phenomenon Fault point ECU 1 Meter warning fault code: F00006 radiator overheat, Solution ECU reduce the power of the motor‘s Remove dirt or another output torque automatically, or covering on shell of ECU. ECU‘s inside temperature alarm To dealers for repair. sensor damaged. 15-10 ELECTRIC POWER STEERING SYSTEM No meter alarm, steering 2 becomes more difficult if no power. 3 Mechanical system’s spare parts are damaged. ECU No meter alarm steering damaged, or the Adjust、repair damaged spare parts. ECU software program has error. To dealers for repair. 6. All have power-assisted to turn left or right,the power of steering to left and right is different. S/N 1 Fault phenomenon Two No meter alarm No 2 Fault point meter alarm. channels’ Solution parameters of sensor changed Replace sensor or go to dealers for repair. No power-assisted the power Mechanical of spare parts are damaged. steering to left and steering system’s Adjust 、 repair damaged spare parts. right is different 3 No meter alarm 4 No meter alarm ECU damaged, or the ECU software program has error. To dealers for repair. The initialization parameter of ECU Restart has error. ECU initialization for 7. Open main switch, steering to the same direction automatically. S/N 1 2 Fault phenomenon Fault point Solution No meter alarm Sensor is loosen To dealers for repair. No meter alarm , The initialization parameter of ECU Restart Sensor no loosening. has error. ECU initialization for and flap the wheels for several times. ■ Maintenance and repair’s supplemental description: Open the main switch and wait for 5 seconds. Reinsert pin connector to finish the ECU parameter initialization process. 1. Restart initialization to ECU parameter: Then, open the main switch; check whether the Park UTV on the flat ground and keep the front fault is removed. If it is not removed, follow the wheels to be forward always. previous steps of initialization process. Because Pull-out initialization selects connector. (See the different mechanical clearance of UTV, it may Page 12-9 ) require 3-5 times to be repeated in order to get the Push UTV back and forth for several times, correct initialization parameters. 15-11 ELECTRIC POWER STEERING SYSTEM If a customer complaint" vehicle deviation", it system will be no power steering, and through the should take into account the fault causes not only instrument to show the corresponding fault code includes the EPS system fault, also includes a and remind driver to take care. chassis mechanical failure, customers may use" Deviation" to describe a specific situation. So four 3. The software function forms’ limit position wheel alignment need to be adjusted at first time, Although the mechanical structure of the EPS then ECU replacement and repair needed. system has mechanical limit position, it is still possible for EPS system to realize the function of 2. The Fault of closing function decreasing steering power before reaching the The main objective to research and develop EPS mechanical limit position in form of slope curve. system is needed to ensure that the vehicle is still Although the customer will feel the steering controlled by driver when malfunction happened. resistance increases, when turned to the limited Therefore we will not allow any directions position process will become obviously more (clockwise or counterclockwise) suddenly appear smoothly. bigger undesirable steering torque. In addition, it can also reduce the steering system’s Therefore, the EPS system has many monitoring mechanical and electrical components’ load, which function, used to identify the sensor, actuator and helps in obtaining reliable function and long service the involvement of the EPS system function life. whether is malfunctioning. All cannot continue to reliable accurate control motor malfunction will ■ EPS system Periodic maintenance lead to the interruption of motor control ECU, then For primary use after 50 hours, adjust EPS system closed function of EPS system. part of parameters according to the steering Close the EPS system’s bad results will also cause system’s clearance variation and chassis changes. the driver can not obtain power steering. Please go to the dealer for alignment. But close measure is mainly used for preventing For every 100 hours using time, according to the error control motor. steering system and the chassis changes, adjust When fault occurs, power steering disappear is a EPS system relevant parameters. predetermined EPS system response characteristic. Although the driver may feel the characteristics of some accidents, but increases CAUTION the control force, can ensure the vehicle steering Before adjust ECU for every time, please check the performance is not affected. Neither the EPS clearance of mechanical part and adjust four steering system nor hydraulic power steering wheels fixed position of UTV. system, when fault occurs, power steering will disappear. When a fault occurs, the two systems EPS SYSTEM PARAMETER TABLE reaction will be similar. This fault occurs, EPS ■ EPS system basic technical parameters system fault indicator light inside of meter will be lighten. If above circumstances happened, EPS ■ EPS system working conditions 1. Working environment temperature: 15-12 ELECTRIC POWER STEERING SYSTEM -40℃~+85℃ 2. Working voltage:(9~16V) DC 3. The seal type:IP65 4. Input shaft rotation angle:large than ±1.25rmp 5. Wheel rotation speed: 10round/min~15round/min ■ Motor assy basic parameters Type: DC permanent magnet control motor Rated working time: 3 min/per time Rated power:170W(nominal value) Rated operational voltage: 12V DC Rated motor revolving speed: (1050r±300r) /min Rated operational current:30A±3A Rated output torque :1.6N·m±0.16N·m 15-13 15-1 UNIVERSAL SYMBOLS As a guide to the operation of your vehicle, various universal symbols have been utilized on the instruments and controls. The symbols are shown below with an indication of their meaning. Safety Alert Symbol Lift Cylinder-Retract Fuel Lift Cylinder-Extend Engine coolant-Temperature Lift Cylinder-Float Parking Brake Hazard Warning Lights Battery Charging Condition Master Lighting Switch Engine Oil-Pressure Audible Warning Device Turn Signal/Hazard Fault indicator light of EPS system Differential Lock 2WD/ 4WD Position light bulb CONTENTS SAFETY OPERATION ………………………………………………………………… 1-1 SERVICING OF VEHICLE …………………………………………………………………… 2-1 SPECIFICATIONS ……………………………………………………………………………… 3-1 SPECIFICATION TABLE …………………………………………………………………… 3-1 TRAVELING SPEEDS ……………………………………………………………………… 3-2 VEHICLE LIMITATIONS ……………………………………………………………………… 4-1 INSTRUMENT PANEL AND CONTROLS …………………………………………………… 5-1 LOCATION OF PARTS ……………………………………………………………………… 5-1 ILLUSTRATED CONTENTS ………………………………………………………………… 5-2 PRE-OPERATION CHECK …………………………………………………………………… 6-1 DAILY CHECK ………………………………………………………………………………… 6-1 OPERATING THE ENGINE ……………………………………………………………………7-1 STARTING THE ENGINE ……………………………………………………………………7-1 Co ld Sta rt in g ………………………………… …………………… ………………7 -2 STOPPING THE ENGINE ………………………………………………………………………7-2 WARMING UP …………………………………………………………………………………7-2 Warm-Up Transmission Oil in the Low Temperature Range ………………………… 7-2 OPERATING THE VEHICLE ………………………………………………………………… 8-1 OPERATING NEW VEHICLE ……………………………………………………………… 8-1 Do not operate the Vehicle at Full Speed for the First 50 Hours ……………………… 8-1 Changing Lubricating Oil for New Vehicles ……………………………………………… 8-1 STARTING ……………………………………………………………………………………… 8-1 Seat Belt …………………………………………………………………………………… 8-1 Head Light Switch…………………………………………………………………………… 8-2 Hazard Light Switch ……………………………………………………………………… 8-2 Turn Signal Light Switch ………………………………………………………………… 8-2 Brake Pedal ………………………………………………………………………………… 8-3 Range Gear Shift Lever …………………………………………………………………… 8-3 4WD Lever ………………………………………………………………………………… 8-4 Speed Control Pedal ……………………………………………………………………… 8-4 STOPPING ……………………………………………………………………………………… 8-5 STOPPING …………………………………………………………………………………… 8-5 CHECK DURING DRIVING …………………………………………………………………… 8-5 Immediately Stop the Engine if:…………………………………………………………… 8-5 Fuel Gauge ………………………………………………………………………………… 8-5 Coolant Temperature Gauge ……………………………………………………………… 8-5 WINCH MOUNT PLATE ……………………………………………………………………… 9-1 WINCH MOUNT PLATE……………………………………………………………………… 9-1 Transporting Vehicle ……………………………………………………………………… 9-1 MAINTENANCE ……………………………………………………………………………… 10-1 SERVICE INTERVALS ……………………………………………………………………… 10-1 PERIODIC SERVICE ………………………………………………………………………… 11-1 HOW TO OPEN THE FRONT HOOD AND SEAT …………………………………… 11-1 Front hood cover………………………………………………………………………… 11-1 Operator’s Seat …………………………………………………………………………… 11-1 HOW TO RAISE THE CARGO BED ……………………………………………………… 11-1 Raising and Lowering the Cargo Bed ………………………………………………… 11-1 JACK-UP POINT …………………………………………………………………………… 11-2 Front End ………………………………………………………………………………… 11-2 Rear End ………………………………………………………………………………… 11-2 DAILY CHECK ……………………………………………………………………………… 11-2 Walk Around Inspection ………………………………………………………………… 11-3 Checking and Refueling ………………………………………………………………… 11-3 Checking Coolant Level ………………………………………………………………… 11-3 Cleaning radiator screen ………………………………………………………………… 11-4 Checking brake fluid level ……………………………………………………………… 11-4 Checking brake pedal ………………………………………………………………………11-5 Checking parking brake ……………………………………………………………………11-5 Checking gauges meter and easy checker™ lamps ………………………………… 11-5 Checking head light turn signal light etc ……………………………………………… 11-5 Checking seat belt and ROPS …………………………………………………………… 11-5 Checking joint boot ……………………………………………………………………… 11-5 Checking tire inflation pressure ………………………………………………………… 11-6 EVERY 50 HOURS ………………………………………………………………………… 11-6 Greasing ………………………………………………………………………………… 11-6 Checking engine start system ………………………………………………………… 11-7 Checking wheel bolt torque …………………………………………………………… 11-7 Cleaning air cleaner primary element ………………………………………………… 11-8 Checking battery condition …………………………………………………………… 11-9 Adjusting toe-in ………………………………………………………………………… 11-10 Cleaning Muffler ………………………………………………………………………… 11-11 EVERY 200 HOURS ……………………………………………………………………… 11-11 Changing Engine Oil …………………………………………………………………… 11-11 Replacing Engine Oil Filter …………………………………………………………… 11-12 Replacing Transmission Oil …………………………………………………………… 11-12 Checking Brake Pedal ………………………………………………………………… 11-13 Checking Brake Hose and Pipe ……………………………………………………… 11-13 Checking Brake Light Switch …………………………………………………………… 11-13 Checking Radiator Hose and Clamp ………………………………………………… 11-13 Checking Intake Air Line ……………………………………………………………… 11-14 EVERY 300 HOURS ……………………………………………………………………… 11-14 Checking Tire …………………………………………………………………………… 11-14 EVERY 400 HOURS ……………………………………………………………………… 11-15 Changing Transmission Fluid ………………………………………………………… 11-15 Changing Front and Rear Axle Case Oil ……………………………………………… 11-15 EVERY 500 HOURS ……………………………………………………………………… 11-15 Replacing Fuel Filter …………………………………………………………………… 11-15 EVERY 600 HOURS ……………………………………………………………………… 11-15 Adjusting Engine Valve Clearance …………………………………………………… 11-16 EVERY 1500 HOURS …………………………………………………………………… 11-16 Checking Injection and Fuel Pump …………………………………………………… 11-16 EVERY 1 YEAR …………………………………………………………………………… 11-16 Replacing Air Cleaner Primary Element and Secondary Element ………………… 11-16 EVERY 2 YEARS ………………………………………………………………………… 11-16 Changing Brake Fluid …………………………………………………………………… 11-16 Flushing Cooling System and Changing Coolant …………………………………… 11-16 Anti-Freeze ……………………………………………………………………………… 11-16 Replacing Radiator Hose (Water pipes) ……………………………………………… 11-18 Replacing Fuel Hose …………………………………………………………………… 11-18 Replacing Brake Master Cylinder (Inner parts) ……………………………………… 11-18 Replacing Front Brake Seal …………………………………………………………… 11-18 Replacing Rear Brake Cylinder Seal ………………………………………………… 11-18 Replacing Intake Air Line ……………………………………………………………… 11-18 EVERY 4 YEARS ………………………………………………………………………… 11-18 Replacing Brake Hose ………………………………………………………………… 11-18 Replacing Slow-Blow Fuses …………………………………………………………… 11-18 STORAGE ……………………………………………………………………………………… 12-1 STORAGE …………………………………………………………………………………… 12-1 VEHICLE STORAGE ……………………………………………………………………… 12-1 REMOVING THE VEHICLE FROM STORAGE ………………………………………… 12-1 TROUBLESHOOTING ……………………………………………………………………… 13-1 ENGINE TROUBLESHOOTING ………………………………………………………… 13-1 Check malf code meaning by reading the below table ……………………………… 13-2 BATTERY TROUBLESHOOTING ………………………………………………………… 13-3 MACHINE TROUBLESHOOTING ………………………………………………………… 13-4 OPTIONS ……………………………………………………………………………………… 14-1 Hisun Motors Corp., U.S.A. Emission Control System Warranty Statement YOUR WARRANTY RIGHTS AND OBLIGATIONS The U.S. Environmental Protection Agency and Hisun Motors Corp., U.S.A. (hereinafter “HISUN”) are pleased to explain the emission control system warranty on your Off-Road vehicle. New off-road motor vehicles must be designed, built and equipped to meet U.S. EPA Federal and California anti-smog standards. HISUN must warrant the emission control system on your vehicle for 5,000 km, or at least 30 months, whichever comes first, provided that there has been no abuse, neglect or improper maintenance of your vehicle. This off-road vehicle was designed to meet the emission standards for 10,000 km, or five years, whichever comes first. Your emission control system warranty covers components whose failure would increase an engine’s emissions of any regulated pollutant Where a warrantable condition exists, HISUN will repair your vehicle at no cost to you, including diagnosis, parts and labor. If an emission-related part on your vehicle is defective, the part will be repaired or replaced by HISUN. This is your EMISSION CONTROL SYSTEM WARRANTY. NOTICE! Use of this vehicle in any type of competitive event completely and absolutely voids this and all other warranties offered by HISUN. OWNER’S WARRANTY RESPONSIBILITIES As the vehicle owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. HISUN recommends that you retain all receipts covering maintenance on your vehicle, but HISUN cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. You are responsible for presenting your vehicle to the HISUN dealer as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. As the vehicle owner, you should be aware that HISUN may deny your warranty coverage if your vehicle or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications. If you use your vehicle in any type of competitive event, this warranty is immediately and completely void. If you have any questions regarding your warranty rights and responsibilities, you should contact Hisun Motors Corp., U.S.A., 1434 Patton Place, Ste. 106, Carrollton, TX 75007 (Phone: 972-446-0760 or Toll Free: 877-838-6188), or the U.S. Environmental Protection Agency at 2000 Traverwood Drive, Ann Arbor, MI 48105. Hisun Motors Corp., U.S.A. Limited Warranty on Emission Control System YOUR WARRANTY RIGHTS AND OBLIGATIONS Hisun Motors Corp., U.S.A. warrants that each new off-road vehicle: A. is designed, built and equipped so as to conform at the time of initial retail purchase with all applicable regulations of the United States Environmental Protection Agency, and B. is free from defects in material and workmanship which cause such vehicle to fail to conform to applicable regulations of the United States Environmental Protection Agency for the periods specified above. I. Coverage. Warranty defects shall be remedied during customary business hours at any authorized HISUN dealer located within the United States of America in compliance with the Clean Air Act and applicable regulations of the United States Environmental Protection Agency. Any part or parts replaced under this warranty shall become the property of HISUN. II. Limitations A. Repair or replacement as a result of (1) accident, (2) misuse, (3) repairs improperly performed or replacements improperly installed, unless performed by a HISUN authorized dealer, (4) use of improper replacement parts or accessories not conforming to specifications set forth by HISUN, which adversely affect performance and/or (5) Use in competitive racing or related events. B. Inspections, replacement of parts and other services and adjustments required for required maintenance. Any vehicle equipped with an odometer or hour meter on which the odometer mileage or hour meter reading has been changed so that actual mileage cannot be readily determined. C. III. This Emission Control System Warranty shall not cover any of the following: Limited Liability A. The liability of HISUN under this Emission Control System Warranty is limited solely to the remedying of defects in material or workmanship by an authorized HISUN dealer at its place of business during customary business hours. This warranty does not cover inconvenience or loss of use of the vehicle or transportation of the vehicle to or from the HISUN dealer. HISUN shall not be liable for any other expenses, loss or damage, whether direct, indidental, consequential or exemplary arising in connection with the sale or use of or inability to use the vehicle for any purpose. Some states do not allow the exclusion or limitation of any incidental or consequential damages, so the above limitations may not apply to you. Hisun Motors Corp., U.S.A. Limited Warranty on Emission Control System B. No express emission control system warranty is given by HISUN except as specifically set forth herein. Any emission control system warranty implied by law, including any warranty of merchantability or fitness for a particular purpose, is limited to the express emission control system warranty terms stated in this warranty. The foregoing statements of warranty are exclusive and in lieu of all other remedies. Some states do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply to you. C. No dealer is authorized to modify this Limited Emission Control System Warranty issued by HISUN. IV. LEGAL RIGHTS. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. V. This warranty is in addition to the limited vehicle warranty. VI. ADDITIONAL INFORMATION. Any replacement part that is equivalent in performance and durability may be used in the performance of any maintenance or repairs by the owner. However, HISUN is not liable for these parts. The owner is responsible for the performance of all required maintenance. Such maintenance may be performed at a service establishment or by any individual. The warranty period begins when the vehicle is placed into service. If you have any questions regarding your warranty rights and responsibilities, you should contact Hisun Motors Corp., U.S.A., or the U.S. Environmental Protection Agency at 2000 Traverwood Drive, Ann Arbor, MI 48105. Hisun Motors Corp., U.S.A. 1434 Patton Place, Ste. 106 Carrollton, TX 75007 Phone: 972-446-0760 Fax: 972-446-0765 Toll-Free: 877-838-6188 OWNER’S MANUAL WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. TM HISUN MOTORS 310 East University Dr McKinney, Texas 75069 PH (972) 446-0760 TF (877) 838-6188 hisunmotors.com