Transcript
Introduction HS 200UTV-2/HS 250UTV-2 INTRODUCTION Congratulations on your purchase of the HS 200UTV-2/HS 250UTV-2. This Owner’s / Operator’s manual will provide you information regarding safe operation, operational instructions, maintenance and care. Fully understanding this manual and following all of the instructions herein will provide the knowledge needed to have safe and enjoyable UTV operation. 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 12 YEARS OF AGE.
1-1
Introduction HS 200UTV-2/HS 250UTV-2 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 200UTV-2/HS 250UTV-2 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). Start 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 200UTV-2/HS 250UTV-2 Table of Contents Subject Introduction Warnings Cautions and Notes Important Notice Table of Contents Location Of Parts Illustrated Contents Safe Operation Safety Instructions 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 Specification table Traveling speeds Vehicle limitations Pre-Operation Operating the Engine Engine and other check lamps Stopping the engine Operating new vehicle Seat belt Head light switch Emergency light switch Turn Signal light switch Brake Pedal Gear shift lever Accelerator pedal Stopping Fuel Gauge Coolant temperature gauge Speedometer Winch Mount Plate Transporting vehicle Service intervals Periodic Service Hood Jack-up point Coolant Level radiator screen brake fluid level brake pedal parking brake
Page 1-1 1-2
Subject Greasing engine start Wheel bolt Evacuator valve Battery condition Battery charging Direction for storage Adjusting toe-in Adjusting procedures Cleaning Muffler Changing engine oil Replacing engine oil filter Checking brake pedal Every 300 Hours Changing brake fluid Anti-freeze Every 4 years Vehicle storage Removing the vehicle from storage Troubleshooting Engine Diagnostic Trouble Code table Battery Troubleshooting Machine Troubleshooting Options Emissions Warranty
1-3 1-4 1-5 1-6 2-1 2-2 2-2 2-2 2-2 2-3 2-3 2-3 2-3 2-3 2-4 3-1 4-1 5-1 5-2 5-3 6-1 7-1 7-2 7-3 8-1 8-1 8-2 8-2 8-2 8-3 8-4 8-5 8-5 8-5 8-5 8-6 9-1 9-1 9-1 10-1 10-1 10-2 10-3 10-4 10-4 10-5 10-5
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Page 10-6 10-7 10-7 10-8 10-9 10-9 10-10 10-10 10-10 10-11 10-11 10-12 10-13 10-14 10-15 10-16 10-17 10-18 10-19 11-1 11-1 11-2 11-3 11-4 12-1 13
Introduction HS 200UTV-2/HS 250UTV-2 LOCATION OF PARTS
①
Roll-over protective structure.
②
Front hood
③
Headlights
④
Turn signal lights
⑤
Front bumper
1-5
Introduction HS 200UTV-2/HS 250UTV-2
ILLUSTRATED CONTENTS
① Parking brake lever ② Steering wheel ③ Range gear shift lever ④ Accelerate pedal ⑤ Brake pedal ⑥ Fuel gauge ⑦ Headlights switch ⑧ High beam / Low beam ⑨ Emergency light switch ⑩ DC-socket 11 ○ Winch in /out 12 Turn signal lights ○
1-6
Introduction HS 200UTV-2/HS 250UTV-2
① Seat belts ② Seat
1-7
Introduction HS 200UTV-2/HS 250UTV-2 All operators, including experienced UTV drivers 5. Only a qualified driver should operate this or passengers, should carefully read and fully
UTV. Never operate after drinking, using
understand this Users Manual, and operate
drugs or controlled products, or while fatigued.
strictly as the manual states in order to achieve 6. Always perform the pre-operation checks as the best performance and avoid accidents. Others who will use you UTV should be trained how to operate the UTV and be required to read this manual before operation.
following: 1) Check seat belt for wear or damage, if necessary, replace it. 2) Check brakes, throttle, brake pedal and other mechanical parts for proper operation. If you
1. Safety Instructions:
discover any irregularities, replace related
1. Understand this UTV by reading this manual
parts as necessary. Periodically check the
and understanding all the components of the vehicle. Only start and operate the vehicle after finishing reading this manual.
fittings and fasteners. 3) Check engine oil level and engine coolant level.
2. Pay close attention to the warning and caution labels on the UTV.
4) Check that the UTV is equipped to handle the surroundings.
3. Understand completely and learn to use the
5) Check and keep vehicle clean. Sludge,
safety devices (roll-over protective structure,
grease and debris can cause a fire and
seat belts), and never change original safety
severe injury.
devices. If safety devices are damaged,
7. Passenger quantity and loading:
consult your local dealer for replacement.
1) Only the driver and one passenger inside cab.
Always use seat belts.
It is suggested that children under age of 5 not be allowed as a passenger. 2 ) S i ng l e - r o w ve h i c l e ’s l o a d i n g l i m i t i s 463lbs(210KG). Reduce the loading weight according to road conditions. Never exceed the weight limits for operation. 8. Never allow unauthorized persons to repair t h i s U T V. T h i s m a y a f f e c t v e h i c l e p e r f o r m a n c e a n d c a u s e i n j u r y. 9. This UTV is designed and manufactured for
4. Do not wear loosen articles of clothing during operation, as these can be drawn into moving parts on the vehicle and could cause a severe injury to occur. You should always wear protective equipment, 1-8
off-road use only, so never drive on paved roadways.
Introduction HS 200UTV-2/HS 250UTV-2 such as helmet, boots, eye protection, ear protection, and gloves etc.
1-9
Introduction HS 200UTV-2/HS 250UTV-2 2. Operation
3. Children safety instructions
1.
Always watch children when they are around the
Start the engine only in an open ventilated
area. Carbon monoxide is colorless, odorless vehicle. Children like to imitate adults and this
2.
and is emitted from the engine and can
could lead to an accident.
cause death in areas with poor ventilation.
Do not leave children alone beside the vehicle.
Never start the vehicle or operate the gear
Keep children from the operating area of the
selector unless seated in the driver’s seat. vehicle. 3.
4.
5. 6.
Never start the engine until the select lever is
Turn off the engine and remove the key when
placed in “N” position and the brake is in the
children are in the operating area. Never carry
brake position.
children in the cargo bed. This is very dangerous
The driver and passenger shall always wear
to children. Children under age of 5 are not be
their seatbelt while the vehicle is being
allowed in this vehicle.
operated.
Never allow children to touch or climb on the
Operators of the UTV should not wear
vehicle, even if they are under adult supervision.
earphones.
Always check for people or obstacles behind the
Do not accelerate quickly when starting the vehicle before shifting the vehicle into reverse. engine, especially driving on rough terrain as Avoid a collision with an obstacle or person. this can cause injury or death. Press the
Park the vehicle on a firm, flat area. If parking on
accelerator pedal slowly.
a slope, you should use hand lever parking
7.
Drive at slow speeds before braking.
brake, remove the key.
8.
Never drive over terrain such as a ditch, a hole, dams, excessive mud, or the vehicle
4. Driving on a slope
can get stuck because of the vehicles 9.
weight.
Be cautious when riding on a slope, as this is the
Always pay close attention to your
main reason for loss of control, and overturn,
surroundings, and check for streets, trail
leading to severe injury or even death.
intersections or other obstacles.
1.
Drive in a straight line on a slope at a low-
10. Always use signals in advance of turns.
speed.
11. Do not allow entrance or exit of the vehicle 2.
Reduce weight when ride on a slope or
while it is moving.
rough terrain.
12. Keep the floorboard free of debris that can 3.
Avoid the sudden application of the brakes
obstruct the ability to use the brake pedal.
when you go uphill or downhill. Be more
13. Position your hands on the steering wheel.
careful when vehicle turns on a slope.
Always keep your hands and feet inside
4. If you start to lose momentum or need to park
passenger area of the vehicle. Never try to
when climbing, use the hand lever brakes to
1-10
Introduction HS 200UTV-2/HS 250UTV-2 stand while operating the vehicle. 14. Do not tow passengers, or attempt to jump the vehicle.
1-11
come to a stop. Release the brake and begin to coast down the hill.
Introduction HS 200UTV-2/HS 250UTV-2 5.
6.
If do not believe you can operate the UTV 1.
Never carry a passenger in the cargo area.
safely in reverse do not attempt to ascend
Evenly distribute the cargo to maintain
2.
the slope any further.
proper stability. Avoid overloading the carrier.
Riding in mud, a ditch, and on slopes will
Cargo should be securely attached.
increase the risk of an overturn. Be more
3.
cautious when operating. Drive gradually and slowly when climbing. Avoid sudden
Reduce loaded weight when driving on poor road conditions or steep inclines.
4.
changes of vehicle speed or direction.
Do not put your hands you body under the cargo bed when it is raised. Once lowered, lock the cargo bed in place before operating
5. Driving in harsh conditions
the vehicle. Never driving before securing and locking the cargo bed.
1.
Vehicle can be operated during the day or
8. Parking
under good light conditions. 2.
Under all conditions, both operator and passengers should wear helmet and
3. 4. 5.
1.
Set the gear shift to the “N” position and pull
protective equipment.
the braking brake to the top position to park
The driver should slow down according to
the vehicle, before the driver exits the
road conditions, terrain, visibility conditions.
vehicle.
Be cautious when driving over a ditch, stone
2.
Avoid stopping the vehicle on a slope. If
roads or hidden obstacles.
stopping on a slope make sure the vehicle is
Avoid operating in any unknown depth of
stationary before exiting.
water.（water depth should not exceed axle height）
6. Driving at high speed 1.
Check for front/rear wheels conditions.
2.
Slow down when turning. Turning at high speed may result in overturn or even death.
3.
Turn on your headlights at high speeds.
4.
Drive only when the vehicle speed can be controlled.
5.
When driving at high speeds, sudden turning
9. Transportation
of the steering wheel will reduce vehicle 1.
stability. Never sharply turn the steering
Avoid dragging the vehicle behind another vehicle. Use a trailer or truck to transport the
wheel at high speeds. 1-12
Introduction HS 200UTV-2/HS 250UTV-2 2.
7. Instructions for carrier
1-13
vehicle. When loading or unloading, pay attention to your surroundings and others in the area.
Introduction HS 200UTV-2/HS 250UTV-2 10.Maintenance
7.
Do not open radiator cap before coolant has cooled down. When the coolant is cold, open
Stop the vehicle and park it on level ground. Pull
slowly and let the coolant pressure reduced,
the parking brake and remove all cargo. Place
and then open radiator cap. Check for the
shift lever in the “N” position, stop the engine and
coolant level in the coolant reservoir. If
remove the key.
necessary, add coolant.
1.
When working next to the engine, exhaust or 8.
Tires should be mounted on rims with special
radiator, work only after it has cooled down.
equipment, only by professionals.
Wait for the engine to stop running and cool 9.
Keeping specified tire pressure to ensure
down before checking the coolant level.
driving safety.
2.
Otherwise, you could be burned by hot fluid 10. Elevate the vehicle and place a suitable 3.
or steam.
stand under the frame when removing the
No smoking when adding electrolyte or
wheels. Be sure to re-tighten the wheel nuts
refueling. Fuel tank and battery should be
to the specified torque.
kept away from sparks. Battery produces hydrogen and oxygen during charging and this could accelerate the risk of explosion. 4.
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
Battery
Warning and caution labels 1-14
Introduction HS 200UTV-2/HS 250UTV-2 （1）
（2）
（3）
（4）
（5）
（6）
（7）
（8）
（9）
（10）
（11）
1-15
Introduction HS 200UTV-2/HS 250UTV-2
SERVICING OF VEHICLE
1-16
Introduction HS 200UTV-2/HS 250UTV-2 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
Serial No.
Vehicle Engine Product Identification Number Date of Purchase Name of Dealer
① Engine serial number
SPECIFICATION TABLE Engine
Make
Specification
1-17
Introduction HS 200UTV-2/HS 250UTV-2 1 cylinder, 4-cycle, gasoline, SOHC, liquid cooled
Type Displacement(s) Horsepower
cc
199CC/229CC
Kw(HP) rp m
Rated revolution Fuel Capacity
L(U.S.gas)
11.2kW or（15.02Hp @ 7500 Rpm）for 199cc 12 kW or（16.09Hp @ 7500 Rpm）for 229cc 7500 ≤13.5（3.6 + .01 Gal）
Transmission
CVT
Wheels, Drive system
4, Rear 2WD
Gear selection
L-H-N-R
Front/Rear
Wet disk brake
Parking brake
Rear wheel, hand lever
Brakes Steering
Mechanical power, Steering wheel Front
Independent, short-long arm type
Rear
Integral, rear driving axle type
Suspension
Dimensions
Length
mm(in.)
2450(96.47)
Wide
mm (in.)
1300(51.18)
Height
mm (in.)
1660(65.35)
Front tread centers
mm (in.)
973(38.3)
Rear tread centers
mm (in.)
975(38.38)
Wheelbase
mm (in.)
1780(70.08)
Ground Clearance
front axle
180(7.08) mm (in.)
rear axle
180(7.08)
Turning diameter
m (ft)
7(22.96)
Max. rolling weight
kg (lbs.)
N/A
Cargo load capacity
kg (lbs.)
50(110)
Weight
kg (lbs.)
298(657.5)
Model Cargo bed
Width
Specification mm (in.)
602(23.7)
1-18
Introduction HS 200UTV-2/HS 250UTV-2 Length
mm (in.)
846(33.3)
Depth
mm (in.)
208(8.2)
Volume Bed height (unloaded) Cargo bed capacity Sound level, operator ear Tire
3
m (cu.ft.)
0.1(1.6)
mm (in.)
720(28.3)
kg (lbs.)
50(110.3)
db (A)
85
Front
22×7-10 6PR
Rear
22×10-10 6PR
Body color
Red, Black, White, Blue, Yellow, Orange, Camo
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
40（25）
Reverse
16（10）
VEHICLE LIMITATIONS 1-19
Introduction HS 200UTV-2/HS 250UTV-2 The Vehicle has been thoroughly tested for proper performance with implements sold or approved by manufacturer. 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 vehicle malfunction or failures with a possibility of the vehicle damage, property damage 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 Cargo Bed Capacity=50kg(110 lb) Cargo Load Capacity=176kg(388 lb)
Max. rolling weight
*(operator+one passenger+opt+acc )weight
N/A
1. Above mentioned specifications are based on level ground condition.
1-20
Introduction HS 200UTV-2/HS 250UTV-2 The vehicle comes with the following key:
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 off, the parking
brake
“ON”
and
implements
[1] Master key
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. -Check backup beeper (if equipped). -Refuel (See
"PRE-OPERATION
CHECK"
in
"PERIODIC SERVICE" section.) -Check of danger, warning and caution labels (See "DANGER, WARNING AND CAUTION LABELS＂in＂SAFE OPERATION＂section.)
1-21
Introduction HS 200UTV-2/HS 250UTV-2 STARTING THE ENGINE CAUTION： 1. Make sure the parking brake is set.
To avoid personal injury：
Read "SAFE OPERATION" in front of this 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.
Make it a rule to set gear shift lever to ① Parking brake lever “NEUTRAL” position before starting
③ Release
the engine.
NOTE：
② Pull to “PARK”
IMPORTANT:
The parking brake warning lamp (P) comes on
Do not use starting fluid or ether.
while parking brake is applied and goes off
To protect the battery and the starter, when it is released. make
sure
that
the
starter
is
not
continuously turned for more than 5 seconds.
1-22
Introduction HS 200UTV-2/HS 250UTV-2 2. Set gear shift lever to the “NEUTRAL” position.
① Gear shift lever.
4. Insert the key into the key switch and turn
(L) Low Range
it to:
(H) High Range
OFF
(Stop the Engine)
(N) “Neutral” position
ON
(Engine runs or headlights on)
(R) “REVERSE”
START
3. Push the accelerator pedal down slowly.
◆ Engine and other Check Lamps:
(Start the Engine)
The parking brake warning lamp (1 parking brake) comes on while parking brake is applied and goes off when it is released.
① Speed control pedal ② INCREASE ③ “DECREASE
IMPORTANT :
Relying on the engine warning lights is never enough. Never fail to conduct daily checks carefully by referring to Pre Operation Check “ in “PERIODIC SERVICE” section.
1-23
Introduction HS 200UTV-2/HS 250UTV-2 5. Turn the key to the “START” position For 5 minutes after engine start-up, allow the and release when the engine starts. engine to warm up without applying any load. IMPORTANT:
This is to allow oil to reach every engine part. If
Because of safety devices, the engine will
load applied to the engine without warming-up,
not start except when the gear shift lever
troubles engine damage may occur.
is placed in the “NEUTRAL” position and ■ Warm-Up Transmission Oil in the Low
the brake is depressed.
Temperature Range ■ Cold Starting When the ambient temperature is below - IMPORTANT: 15℃( 5℉), the engine is very cold. If the
Do not operate the vehicle under full load
engine fails to start after 5 seconds, turn
until it is sufficiently warmed up.
off the key for 30 seconds and start again.
■ Cold Starting When the ambient temperature is below 15℃( 5℉), the engine is very cold. If the engine fails to start after 5 seconds, turn off the key for 30 seconds and start again.
STOPPING THE ENGINE 1. After slowing the engine to idle, turn the key to “OFF”. 2. Remove the key.
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.
1-24
Introduction HS 200UTV-2/HS 250UTV-2 OPERATING NEW VEHICLE
The lubricating oil is especially important for
How a new vehicle is handled and maintained
a new vehicle. Various parts need time to
determines the life of vehicle.
wear and polish themselves to the correct
A new vehicle just off the factory production
operating clearances. Small pieces of metal
line has been, of course, tested, but the
grit may develop during the operation of the
various parts are not aligned to each other, so
vehicle; and this may wear out or damage
the operator should pay more attention to
the parts. Therefore, change the lubricating
operating the vehicle for the first 50 hours at a
oil a little earlier than would ordinarily be
slower speed and avoid excessive work or
required. For further details of change
operation until the various parts become
interval
“broken-in.” The manner to which you handle
section
hours,
see
“MAINTENANCE”
the vehicle during “breaking-in” period greatly affects the life of your vehicle. Therefore, to
STARTING
obtain the maximum performance and the 1. Fasten the seat belts during operation. longest life of the vehicle, it is very important ■ Seat Belt to properly break-in your vehicle. For better
WARNING
handling of a new vehicle, the following precautions should be observed.
To avoid personal injury:
■ Do not operate the vehicle at full speed
your seat belts. The lap-style seat belts
for the first 50 hours.
Seat belts reduce injury. Always wear may not provide adequate protection
Do not start quickly nor apply the brakes
for
suddenly.
attention
In winter, operate the vehicle after fully
passenger.
small
children. when
Pay
carrying
special a
child
belts
when
warming up the engine.
Do not run the engine at speeds faster than prescribed.
On rough roads, slow down to suitable speeds. The above precautions are not limited to new vehicles. However, they should be especially observed for new vehicles.
■
CAUTION： To avoid personal injury:
Always
use
the
seat
operating and riding the vehicle. Adjust the seat belts for proper fit and connect the buckle. This seat belt is an auto-locking retractable type.
Changing Lubricating Oil for New
Vehicles
1-25
Introduction HS 200UTV-2/HS 250UTV-2 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
■ Emergency Light Switch Press the top half of the emergency light switch, the light flash along with the indicator on the instrument panel. Press the bottom half of the emergency light switch to turn off the 2. Selecting light switch position.
light.
■ Head Light Switch Turn on the key switch and toggle the head Note: The emergency light switch will operate light switch to the “ON” position. Toggle the head light switch to the “OFF”
when the key switch is in the “ON” position
position to turn off the head light.
and "OFF" position. Keeping the switch “ON” causes the battery to run out. ■ Turn Signal Light Switch To indicate a right turn, push on the lower half of the turn toggle switch. To indicate a left turn, push on the upper half of the turn toggle switch. When the left or right signal is activated, the indicated turning light will flash and the other will stay on.
① Head light switch
The indicator lamp at the instrument panel also
② Low beam; High beam
flashes indicating the direction of the turn.
NOTE： Turning the head light switch to the “ON” position causes the following lamps to light simultaneously.
NOTE:
The turn signal light switch is only operative when the key switch is in the
1-26
Introduction HS 200UTV-2/HS 250UTV-2
“ON” position. If the emergency light switch is pressed to the “ON” position while the turn signal is activated, the indicated turning light will flash and other will stay on.
Be sure to return switch to center position after turning.
① Head light
② Head turn signal lamp;
③ Tail turn signal lamp
3. Checking the brake pedal. ■ Brake Pedal
CAUTION: To avoid personal injury: ①
Engine Speedometer
② Emergency light lamp
accident may occur due to loss of
③ Speedometer
control or the shifting forward of heavy
④ Low beam, High beam
loads.
⑤ headlight switch ⑥ Key switch
If the operator suddenly brakes, an
When driving on icy, wet or loose surface, make sure the vehicle is correctly loaded to avoid skidding or loss of steering control. Reduce the speed.
The brake pedal is the left pedal on the foot board. Depress the pedal to slow or stop the vehicle.
1-27
Introduction HS 200UTV-2/HS 250UTV-2 4.
Before exiting vehicle, shift the gear shift lever to the “NEUTRAL” position and set parking brake.
① Brake pedal
4. Selecting the correct gear. ■ Gear Shift Lever
CAUTION:
① Range gear shift lever
To avoid personal injury:
(L) LOW Range
(H) HIGH Range
Avoid changing gears when ascending or descending a slope.
(N) NEUTRAL” POSITION (R) “REVEREE”
Before ascending or descending a slope, shift to the “L” range to control NOTE:
the vehicle speed.
1.
2.
If you shift gears while ascending or
do not force the lever. Set the parking
descending a slope, be prepared to
brake, slightly depress the accelerator
use the brake to maintain control.
pedal and release it to neutral position,
Operate in reverse at slow speeds to
then shift the lever.
maintain control.
When the lever is hard to disengage, do
The gear shift lever can only be shifted
not force the lever.
when the vehicle is completely stopped
Depress the brake pedal fully, then shift
and the brake pedal is pressed.
the lever. Damage may occur with wrong
To avoid transmission and shift linkage
shifting operation.
damage, completely stop the vehicle
AN accident could occur through improper
using the brake pedal before shifting
use of the gear shift lever
gears. 3.
When gear shift lever is hard to engage,
5. Release the parking brake and start
Select proper gear depending on the slowly. To release the parking brake, depress the types of job. brake pedal, push release button and push 1-28
Introduction HS 200UTV-2/HS 250UTV-2 release button and push down on the parking 1.
Release the speed accelerator pedal
brake lever. Make sure that the indicator in the 2.
Step on the brake pedal.
CHECK DURING DRIVING
instrument panel goes off.
■ Immediately Stop the Engine if：
The engine suddenly slows down or accelerates.
Unusual noises are suddenly heard.
Exhaust fumes suddenly become very white.
While driving, check the following items to see if all parts are functioning normally.
① Parking brake lever ② “RELEASE”
■
Accelerator Pedal
The Accelerator pedal is used to increase the engine and vehicle speed. Push down on it for ■ Fuel Gauge higher speed. Park the vehicle on a flat place. When the key switch to “ON”, the fuel gauge will indicate the fuel level. Be careful not to fully empty the fuel tank. Otherwise air may enter the fuel system.
①
Accelerator pedal
STOPPING ■ STOPPING
①
Fuel gauge
■ Coolant Temperature Gauge
1-29
Introduction HS 200UTV-2/HS 250UTV-2 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 pressure before removing cap completely.
1.
With the key switch “ON” the temperature gauge indicates the temperature of the coolant. White Zone for “cold” and Red ① Speedometer zone for “hot”.
2.
If the indicator reaches the Red zone, the engine coolant is overheated. Check the vehicle
by
ref erring
to
“TROUBLESHOOTING” section.
■ Speedometer The hour meter indicates in five digits the hours the vehicle has been used.
① Hour meter
The speedometer indicates the traveling speed.
1-30
Introduction HS 200UTV-2/HS 250UTV-2
WINCH MOUNT PLATE Always read and follow the instructions in the winch owner’s manual before attempting to install or use a winch.
■ Transporting Vehicle Pay attention to the following points when transporting the vehicle. 1.
Use a suitable truck or trailer.
2.
Apply the parking brake and place chocks against the front and rear tires.
MAINTENANCE 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.
1-31
Introduction HS 200UTV-2/HS 250UTV-2 *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 with a * mark are emission related critical parts by the U.S.EPA. 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 for more information. Indication of
No.
Items 50 100 150 200 250 300 350 400 450 500 550 600 650 700
1
Engine oil
Change
◎
○
○
○
2
Engine oil filter
Replace
◎
○
○
○
3 4
Transmission fluid Engine start system
○
Change Check
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
5
Greasing
Apply
○
○
6
*Muffler
Clean
◎
○
○
○
○
○
○
○
7
Spark arrester
Clean
○
○
○
○
○
○
○
8
Wheel bolt torque
Check
○
○
○
○
○
○
○
9
Battery condition
Check
○
○
○
○
○
○
○
10
Toe-in
Adjust
○
○
○
○
○
○
○
Fuel filter element
Check
○
○
○
○
○
○
○
11
◎
○
Replace Check
12
○
○
○
○
○
○
○
○
○
○
○
○
○
○
*Fuel line Replace
13
14 15 16
17
*Air cleaner element Brake pedal Parking brake lever Brake light switch Radiator hose and clamp
Clean Replace Check
◎
○
○
○
Adjust
◎
○
○
○
Check
◎
○
○
○
○
○
○
○
○
○
Check Replace Check
18
*Intake air line Replace
1-32
After 700 hrs Every 200 hrs Every 200 hrs Every 400 hrs Every 50 hrs Every 50 hrs Every 100 hrs Every 100 hrs Every 100 hrs Every 100 hrs Every 100 hrs Every 100 hrs Every 100 hrs Every 500 hrs Every 100 hrs Every 1 years Every 100 hrs Every 1 years Every 200 hrs Every 200 hrs Every 200 hrs Every 2 years Every 200 hrs Every 1 years
Introduction HS 200UTV-2/HS 250UTV-2 Indication of No.
Items 50 100 150 200 250 300 350 400 450 500 550 600 650 700
19
20
Brake hose & pipe
Check
Tire wear
Check
◎
○
○
○
Check ◎
○
Front axle case Change oil Knuckle case 22 Change oil Engine valve 23 Adjust clearance *Fuel injection
Check
25
*Injection
Check
26
Brake fluid
Change
○ ○ ○
Remote Replace hydraulic hose Rear brake 28 Replace cylinder seal Front brake 29 Replace seal 27
30
Cooling system Flush
31
Coolant
Change
32
Fuel system
Bleed
33
Fuse
Replace
34
Light bulb
Replace
Every 200 hrs Every 4years
21
24
After 700 hrs
Every 300 hrs Every 400 hrs 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:（10W/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.
1-33
Introduction HS 200UTV-2/HS 250UTV-2 make sure safety support is properly
CAUTION:
mounted.
To avoid personal injury:
●
Do not touch muffler or exhaust pipes while they are hot; Otherwise, they may
HOW TO OPEN THE HOOD AND TILT THE SEAT
cause severe burns. ■ Tilting and Lowering the Cargo Bed ◆ To tilt the cargo bed
CAUTION
To avoid personal injury from contact with 1. Pull up the handle on the cargo bed. ◆ To lower the cargo bed moving parts:
Never open operator’s seat while the 1. Push down the bed forcedly to lower the bed in place. engine is running.
Depress the hood with your other hand while unlocking the hood.
■ Hood To open the hood, turn the switch to release the latch and lift the hood off.
1. Handle 2-3. Pull up the handle from ② to ③.
HOW TO TILT THE CARGO BED CAUTION To avoid personal injury: ●
When servicing under the tilted bed, 1.Gas Spring
1-34
Introduction HS 200UTV-2/HS 250UTV-2 JACK-UP POINT WARNING To avoid personal injury, death or vehicle damage: Do not work under the vehicle unless it is
secured by safe stands or suitable blocking.
■ Front End Jack stand at the front bumper only.
① Jack
DAILY CHECK For your own safety and maximum service life of
the vehicle,
make a thorough daily
inspection before starting the engine or operating the vehicle.
CAUTION To avoid personal injury:
Be sure to check and service the vehicle on a flat surface with the engine off and the parking brake “ON”.
① Jack
② Front bumper
■ Rear End Jack the rear only after placing a wooden block under the right and left frame tubes for securing the engine and then supporting it. Do not apply jack pressure on the steel plate directly under the engine.
■ Walk Around 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
1-35
Introduction HS 200UTV-2/HS 250UTV-2
refueling.
1.
Turn the key switch to “ON”, check the
TO avoid personal injury
amount of fuel by the fuel gauge. 2.
CAUTION
Fill fuel tank when fuel gauge shows1/4 or
Do not remove radiator cap while
less fuel in the tank.
coolant is hot .when cool, slowly rotate to the first stop and allow sufficient
Fuel tank capacity
time for excess pressure to escape
13.5 (3.6±0.1U.S.GALS)
before removing the cap completely. Park the vehicle on a flat surface, IMPORTANT
access the panel under the hood,
If oil level is low, do not run the engine.
set the parking brake, and shut
Checking engine oil level 1.
off the engine.
Park the vehicle on a flat surface, remove
Check to see that the coolant
the seat, open the adjust hatch cover.
level is between the “FULL” and” LOW” marks of recovery tank.
To check the oil level, draw out the dipstick,
When the coolant level drops due
wipe it clean, replace it, and draw it out again,
to evaporation, add coolant only
check to see if the level is too low, add new oil 2.
up to the full level.
to the prescribed level on the dipstick.
leakage
add
In case of
anti-freeze
and
water in the specified mixing ratio up to the full level.(see flush cooling system and changing coolant in EVERY 2 YEARS in PERIODIC SERVICE section)
①~② Oil level is acceptable within this range ②
Oil Level
③
Oil dipstick
④ Oil cap
IMPOTTANT If oil level is low, do not run engine ■ Checking Coolant Level
① Recovery tank ② FULL ③ LOW
1-36
Introduction HS 200UTV-2/HS 250UTV-2 IMPORTANT
CAUTION
If the radiator cap has to be removed,
follow the cautions above and securely TO avoid personal injury: Never operate the vehicle if the brake retighten the cap.
Use clean fresh water and anti-freeze to
fill the recovery tank.
fluid is below the minimum mark. Use
only
DOT3
from
a
sealed
If water should leak, consult your local
container. Other types of brake fluid
Hisun Dealer.
may ruin synthetic resin or rubber installed in brake system components
■ Cleaning radiator screen
and may cause brake failure.
CAUTION
thoroughly clean before removing the
TO avoid personal injury:
Avoid contamination of the brake fluid filler cap. Do not open the brake fluid
Be sure to stop the engine before
reservoir
removing the screen
cap
unless
absolutely
necessary.
1.
Park the vehicle on a flat surface,
2.
Remove the radiator cover,
3.
Detach the screen and remove all foreign If brake fluid spills on the power steering hose, wash it off with water immediately, as materials.
Use extreme care when filling the reservoir.
brake fluid quickly ruins synthetic resin or rubber hoses. 1.
Park the vehicle on a level ground and open the hood.
2.
Check to see that the brake fluid level is up to the MIN mark.
3.
If it is below the “MIN” mark add brake fluid .
① Radiator screen
IMPORTANT
Radiator screen must be cleaned from debris to prevent engine from overheating
■ Checking brake fluid level
1-37
① MAX
② MIN
Introduction HS 200UTV-2/HS 250UTV-2 ■ Checking brake pedal
and tilt the lever down.
CAUTION
NOTE
TO avoid personal injury:
Make sure the parking brake warning lamp on Stop the engine and chock the wheels the display goes off when parking brake lever before checking brake pedal. is down.
1.Inspect the brake pedals for free play and smooth operation. Adjust if incorrect free play is found. (see checking brake pedal in” EVERY 200 HOURS in PERIODIC SERVICE section)
① Parking brake lever ③ RELEASE
② Release button
④ PULL
■ Checking gauges meter and warning lamps 1.
Inspect the instrument panel for broken gauges meter and warning lamps.
2. ① Brake pedal
Replace if broken.
② FREE TRAVEL
③ PEDAL STROKE
■ Checking head light turn signal light etc
■ Checking parking brake
1.
Pull the parking brake lever to apply the 2.
Inspect lights for broken bulbs and lenses Replace if broken
brakes with the key switch in the "ON" position ■ Checking seat belt and ROPS
and the parking brake indicator should come on.
To release the brake, push in the button on the 1.
Always check condition of seat belt and
tip of the parking brake lever and tilt the lever
ROPS
down.
operating vehicle. 2.
attaching
hardware
before
Replace if damaged.
NOTE Make sure the parking brake warning lamp on ■ Checking tire inflation pressure the display goes off when parking brake lever Though the tire pressure is factory-set to the 1-38
Introduction HS 200UTV-2/HS 250UTV-2 prescribed level, it naturally drops slowly in the course of time, thus check it every day and inflate as necessary. tire sizes
inflation pressure
22×7-10
49kPa(0.49kgf/cm2,7psi)
22×10-10
49kPa(0.49kgf/cm2,7psi)
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 lubricate grease fittings ① Parking brake pivot (spray type grease ) more often.
① Cargo brace rod turning point(spray type grease ) ② Cargo bed rotating axle (spray type grease)
1-39
Introduction HS 200UTV-2/HS 250UTV-2
① Gear shift lever pivot (spray type grease )
① Gear shift lever
■ 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.
◆ Preparation before testing 1.
Place all control levers in the “NEUTRAL” ① Accelerator pedal position.
2.
Set the parking brake and stop the engine.
■ Checking wheel bolt torque
CAUTION
◆ Test gear shift range lever safety switch
To avoid personal injury
1.
Sit on the operator's seat.
2.
Shift the gear shift range lever to: “L”, “H”,
Never operate vehicle with a loose
“N” or REVERSE position.
wheel bolts.
Any tine these bolts are loosened they
3.
Turn the key to “START” position.
4.
The engine must not crank.
should be retightened to the specified
5.
If it cranks consult your local dealer for this
torque.
service.
Check all bolts frequently and keep them tight.
Check wheel bolts regularly especially when 1-40
Introduction HS 200UTV-2/HS 250UTV-2 new if they are loose tighten them as follows:
① Torque wheel bolts to 75 to 90 N.m ① First air cleaner
■ Cleaning air cleaner primary element 1. 2.
② Air cleaner case
③ Air cleaner element
④ Cover
Remove the air cleaner cover and primary element.
IMPORTANT
Clean the primary elements.
The air cleaner uses a dry element never apply oil.
1） When dry dust adheres to the element blow compressed air from the inside
Do not run the engine with filter element
turning
removed.
the
element.
Pressure
of
compressed air must be under 205kpa.
Be sure to refit the cower with the arrow
2） When carbon or oil adheres to the element
(on the rear of cower ) upright. if the cover
soak the element in detergent for 15
is improperly fitted the evacuator valve will
minutes then wash it several times in
not function and dust will adhere to the
water rinse with clean water and dry it
element.
naturally after element is fully dried inspect inside of the element with a light and check if it is damaged or not.
Open the air cleaner cover once a week under
3） Replace the primary element
ordinary conditions –or daily when used in a
Once yearly or after every sixth cleaning, whichever comes first.
◆ Evacuator Valve
dusty place-to get rid of large particles of dust and dirt. Check fuel line and fuel filter.
CAUTION To avoid personal injury: 1-41
Be sure to stop the engine and remove
Introduction HS 200UTV-2/HS 250UTV-2
the key when attempting to make the ① Pipe clamp ③ fuel pump
following checks and changes.
Never fail to check the fuel lines periodically the fuel lines are subject to
■ Checking battery condition
wear and aging fuel may leak out onto
DANGER
the running engine causing a fire.
The fuel line connections should be If you store a battery in a diminished state checked annually or every 100 service of charge you will probably have to replace the battery.
hours whichever comes first. 1.
② fuel line
Park the vehicle on a flat surface and tilt
CAUTION
the cargo bed. 2.
The fuel line is made of rubble and ages To avoid personal injury Never remove the battery while the regardless of service period.
3.
If the fuel line and clamps are found to be
damaged or deteriorated replace them. 4.
engine is running. Keep
electrolyte
away
from
eyes,
Check fuel filter if it is clogged by debris or
hands and clothes. If you are spattered
contaminated with water replace it.
with it, wash it away completely with water immediately and get medical
IMPORTANT
attention.
When the fuel line is disconnected for
Wear eye protection and rubber gloves
maintenance or repair, close both ends of the
when working around the battery.
fuel line with a piece of clean cloth or paper to prevent dust and dirt from entering. Particular,
The factory –installed battery is non-refillable
care must be taken not to admit dust and dirt
type if the battery is weak, charge the battery
into the fuel pump entrance. Even a small
or replace it with new one
amount of dust or dirt will cause premature wear and malfunction of the fuel pump and ◆ Battery charging injector components.
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, especially when
1-42
Introduction HS 200UTV-2/HS 250UTV-2 charging the battery.
When disconnecting the cable from the 1. battery start with the negative terminal
When storing the vehicle for a long period,
first; when connection the cable to the
in a dry place out of direct sunlight.
battery start with the positive terminal
2.
first.
remove the battery from the vehicle, store The battery will self-discharge while it is shored; recharge it once every three
Always check battery charge by using
months in hot seasons and once every six
a voltmeter.
months in cold seasons. ■ Adjusting toe-in Proper toe-in
0 to12 mm (0 to 0.47 in)
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
between
front
tire
beads at rear of tire at hub height.
① Battery
5. 1.
distance
Front distance should be shorter than rear distance if not adjust tie rod length.
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 ① Wheel-to-wheel distance at front one use battery of equal specification ② Wheel-to-wheel distance at rear ③ FRONT
shown in table 1. Battery type
Volts
◆ Adjusting procedures 1.
12V8Ah
12
Loosen the lock nut and turn the tie rod to adjust the rod length until the proper toe-in measurement is obtained.
◆ Direction for storage 1-43
Introduction HS 200UTV-2/HS 250UTV-2 2.
Retighten the lock nut.
4.
If any breaks in the screen or welds are discovered,
the
assembly
must
be
IMPORTANT
replaced.
Keep the equal length of the left and right 5.
Return the spark arrester to the muffler
tie-rod.
body and refasten the bolts.
■ Cleaning Muffler
IMPORTANT:
CAUTION
Visually check the muffler for cracks or holes in the body, welds or pipes at
To avoid personal injury:
regular intervals.
Before touching any part of an exhaust system, be absolutely sure that it has
USDA
sufficient time to cool!
body to be no larger than 0.023”(0.584
Always wear safety goggles and face
mm).
mask.
approval
requires
clearance
between spark arrester sleeve and muffler
Replace the entire muffler if it is damaged.
The particulate matter contained in the muffler contains chemicals that are
Do not operate the vehicle with a damaged muffler.
harmful to people, animals and marine life.
If you are unable to do this work, have it done by your dealer.
Cleaning spark arrester of muffler.
Maintenance & cleanout procedure: The screen type spark arrester should be removed, cleaned, and inspected after ① Muffler every 100 hours of use. 1.
The spark arrester is located inside of the muffler body, and fastened with bolts.
2.
Loosen the bolts and remove the spark
④ Bolt
EVERY 200 HOURS ■ Changing Engine Oil
arrester. 3.
② Gasket
③ Spark arrester
CAUTION
Shake loosened particles out of the screen To avoid personal injury: assembly and lightly clean the screen with Be sure to stop the engine before wire brush. Soak in solvent and again replacing oil. clean with wire brush if necessary.
1-44
Allow engine to cool down sufficiently,
Introduction HS 200UTV-2/HS 250UTV-2
oil can be hot and can burn.
1.
Park the vehicle on flat surface and
① Drain plug
remove the seat, open the adjust hatch ■ Replacing Engine Oil Filter cover. 2.
CAUTION
To drain the used oil, remove the drain
plug at the bottom of the engine and To avoid personal injury: Be sure to stop the engine before completely drain the oil into an oil pan. 3.
After draining, reinstall the drain plug.
changing the oil filter cartridge.
4.
Fill with the new oil up to the upper notch
Allow engine to cool down sufficiently,
on the dipstick.
oil can be hot and can burn.
(See
“LUBRICANTS,
FUEL
AND 1.
raise the cargo bed.
COOLANT” in “MAINTENANCE” section.)
[Filter exchanged]
Park the vehicle on a flat surface and
1.8L (1.89U.S. qts.)
2.
Remove the oil filter.
3.
Put a film of clean engine oil on the rubber seal of the new filter.
Oil capacity [Filter non-exchanged] 1.6L (1.68U.S. qts.)
4.
After the new filter has been replaced, the engine oil normally decreases a little. Make sure that the engine oil does not leak through the seal and check the oil level on the dipstick. Then replenish the engine oil up to the prescribed level.
①~② Oil level is acceptable within this range ③ Dipstick
④ Oil inlet
① Bolt; ③ “O” seal ring;
② Cover ④ Engine oil filter
IMPORANT: To prevent serious damage to the engine, use only a genuine filter.
1-45
Introduction HS 200UTV-2/HS 250UTV-2 ■ Checking Brake Pedal
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 brake. ◆ Checking the brake pedal free travel ① Brake pedal
Proper brake pedal
② “FREE TRAVEL”
7 to 14mm(0.3 to in.)
free travel
③ “PEDAL STROKE”
On the pedal
■ Checking Brake Hose and Pipe 1.
Release the parking brake.
2.
Slightly depress the brake pedal and
are not swollen, hardened or cracked.
measure free travel at the top of the pedal 2. stroke.
Check the brake hose and pipe joints for
If brake pedal free travel is outside of the 3. specifications, contact your local dealer for
If there is any abnormality, consult your
3.
1.
Check to see that brake hose and lines
oil leaks. local dealer for this service.
adjusting the brake. ■ Checking Brake Light Switch 1.
◆ Checking the brake pedal stroke
Park the vehicle on a flat surface and raise the cargo bed.
Pedal stroke
Less than 120mm (4.7in.)
2.
Turn the key switch to the “ON” position.
On the pedal
3.
Step on the brake pedal to check if the
1.
Release the parking brake.
brake light comes on.
2.
Step on the pedal and measure the pedal 4. stroke.
If it does not, check the bulb or brake light
3.
switch.
If brake pedal stroke is outside of the specifications, contact your local dealer for ■ Checking Radiator Hose and Clamp Park the vehicle on a flat surface and raise the adjusting the brake. cargo bed. Check to see if radiator hoses are properly fixed every 200 hours of operation or six months, whichever comes first. 1.
If hose clamps are loose or water leaks, tighten bands securely.
1-46
Introduction HS 200UTV-2/HS 250UTV-2 2.
Replace hoses and tighten hose clamps 2.
clamps are tight and not damaged.
securely, if radiator hoses are swollen,
If hoses and clamps are found to be worn
3.
hardened or cracked. Replace hoses and
or damaged, replace or repair them at
hose clamps every 2 years or earlier, if
once.
checked
and
found
that
hoses
are
swollen, hardened or cracked.
① Hose
② Hose clamp
EVERY 300 HOURS ① Radiator hose
■ Checking Tire
② Clamp bands
1.
◆ Precaution at Overheating
Check to see if tires are not damaged.
Take the following actions in the event the 2.
If the tires are cracked, bulged, or cut, or
coolant temperature is close to or more than
they are worn out, replace or repair them
the boiling point, which is called “Overheating”.
at once.
1.
Stop the vehicle operation in a safe place ◆ Tire Tread Depth
and keep the engine unloaded idling. 2.
Don’t stop the engine suddenly, but stop it Always replace the tires when the tread depth is worn to minimum allowable. 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
overheating
rid
of
the
according
causes to
of the
“TROUBLESHOOTING” section of the manual, and then start the engine again. ■ Checking Intake Air Line 1.
Check to see if the hoses and hose ① 3mm(0.12in) 1-47
Introduction HS 200UTV-2/HS 250UTV-2 EVERY 500 HOURS
radiator
■ Replacing Fuel Filter
completely drain the coolant.
Consult your local dealer for this service.
3.
cap
must
be
removed
to
After all coolant is drained, close the drain plug.
EVERY 600 HOURS
4.
■ Adjusting Engine Valve Clearance
Fill with clean water and cooling system cleaner.
Consult your local dealer for this service.
EVERY 1500 HOURS
5.
Follow directions of the cleaner container.
6.
After flushing, fill with clean water and
■ Checking Injection and Fuel Pump
anti-freeze until the coolant level is just
Consult your local dealer for this service.
below the radiator cap. Install the radiator
EVERY 1 YEAR
cap securely.
■ Replacing Air Cleaner Primary Element
7.
on the recovery tank.
and Secondary Element (See
“Cleaning
Element”
in
Air
“every
Cleaner 100
Fill with fresh water up to the “FULL” mark
Primary
HOURS”
8.
minutes.
in 9.
“PERIODIC SERVICE” section.)
Start and operate the engine for few Stop the engine and let it cool.
10. Check coolant level of recovery tank and
EVERY 2 YEARS
coolant if necessary.
■ Changing Brake Fluid Consult your local Dealer for this service.
Coolant capacity
(See “Checking Brake Fluid Level” in “DAILY CHECK” in “PERIODIC SERVICE” section. ■ Flushing Cooling System and Changing Coolant
CAUTION 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 removing the cap completely. ① Recovery tank
1.
Stop the engine and let it cool down.
2.
To drain the coolant, open the radiator
③ “ LOW”
drain plug and remove radiator cap. The 1-48
②“ FULL” ④Radiator cap
2.2(2.3U.S.qts)
Introduction HS 200UTV-2/HS 250UTV-2 IMPORTANT:
antifreeze.
Do not start engine without coolant.
Use clean, fresh water and anti-freeze to and radiator. If the ambient temperature falls
If it freezes, coolant can damage the cylinders below 0℃(32°F) or before a long-term storage,
fill the radiator and recovery tank.
When the anti-freeze is mixed with water, let out cooling water completely, or mix fresh the antifreeze mixing ratio must be less water with long-life coolant and fill the radiator than 50%.
and recovery tank with the mixture.·
Securely tighten radiator cap. If the cap is 1.
Long-life coolant (hereafter LLC) comes in
loose or improperly fitted, water may leak
several types. Use ethylene glycol(EG)
out and the engine could overheat.
type for this engine. 2.
■ Anti-Freeze
Before
employing
LLC-mixed
cooling
water, fill the radiator with fresh water and empty it again.
CAUTION
Repeat this procedure 2 or 3 times to
To avoid personal injury:
clean up the inside.
When using antifreeze, put on some 3. protection such as rubber 4.
Mixing the LLC
gloves.(Antifreeze contains poison.)
antifreeze differs according to the make of
If you should drink antifreeze, throw up at
the
once and take medical attention.
temperature.
When antifreeze comes in contact with the
standard, more specifically also to SAE
skin or clothing, wash it off immediately.。
J814c.
The procedure for the mixing of water and antifreeze
and
Refer
the to
SEA
ambient J1034
Do not mix different types of Antifreeze.
The mixture can produce chemical reaction IMPORTANT: causing harmful substances. When the antifreeze is mixed with water, Antifreeze is extremely flammable and the antifreeze mixing ratio must be less explosive under certain conditions. Keep
than 50%.
fire and children away from antifreeze.
place some container underneath the
Anti-freeze
℃
°
F
℃
°
40
-24
-12
106
222
50
-37
-34
108
226
F
Do not pour waste onto the grounds, down a drain, or into any water source.
Boiling point
VOL%
engine body.
Freezing point
When draining fluids from the engine,
Also, observe the relevant environmental
*At 1.013×105Pa (760mmHg) pressure (atmospheric).
protection regulations when disposing of A higher boiling point is obtained by using a 1-49
Introduction HS 200UTV-2/HS 250UTV-2 radiator
pressure
cap
which
permits
the
Replace the hoses and clamps.
development of pressure within the cooling (See “Checking Radiator Hose and Clamp” in “EVERY
system.
200
HOURS”
in
“PERIODIC
SERVICE” section.) 5.
Adding the LLC
1)
Add only water if the mixture reduces in ■ Replacing Fuel Hose
2)
amount by evaporation.
Consult your local Hisun Dealer for this
If there is a mixture leak, add the LLC of
service.
the same manufacturer and type in the ■ Replacing Brake Master Cylinder (Inner
same mixture percentage. * Never add any long-life coolant of
parts)
different manufacturer.(Different brands Consult your local dealer for this service. may have different additive components, and the engine may fail to perform as ■ Replacing Front Brake Seal specified.) 6.
Consult your local dealer for this service.
When the LLC is mixed, do not employ any radiator cleaning agent. The LLC ■ Replacing Rear Brake Cylinder Seal contains anticorrosive agent. If mixed with Consult your local dealer for this service. the cleaning agent, sludge may build up, ■ Replacing Intake Air Line The vehicle’s genuine long-life coolant has Consult your local dealer for this service. adversely affecting the engine parts.
7.
a service life of 2 years. Be sure to change
EVERY 4 YEARS
the coolant every 2 years.
■ Replacing Brake Hose Consult your local Dealer for this service.
NOTE:
The
above
data
represent
industry
standards that necessitate a minimum ■ Replacing Mini Fuses glycol content in the concentrated The Mini fuses are intended to protect the electrical cabling. If any of them have blown
antifreeze.
When the coolant level drops due to out, be sure to pinpoint the cause. evaporation, add water only to keep the antifreeze mixing ratio less than 50%. In ◆ Replacing procedure case of leakage, add antifreeze and water 1) Disconnect the negative cable of the battery.
in the specified mixing ratio before filling into the radiator. ■ Replacing Radiator Hose (Water pipes)
2)
Open the Mini fuse box cover.
3)
Pull out the Mini fuse.
4)
Insert a new Mini fuse into the box.
1-50
Introduction HS 200UTV-2/HS 250UTV-2 5)
Close the Mini fuse box cover.
6)
Connect the negative battery cable.
ventilation.
When storing, remove the key from the key
switch
to
avoid
unauthorized
persons from operating the vehicle and getting injured.
VEHICLE STORAGE If you intend to store your vehicle for an extended period of time, follow the procedures outlined below. These procedures will insure that the vehicle ① Mini fuse box cover
is ready to operate with minimum preparation when it is removed from storage.
■ Replacing Light Bulb
1.
Head lights
and tighten if necessary.
Take the bulb out of the light body and 2.
Apply grease to vehicle areas where bare
replace it with a new one.
metal will rust also to pivot areas.
Other lights
3.
Unload from cargo bed.
Detach the lens and replace the bulb
4.
Inflate the tire to a pressure a little higher
Light
Capacity
Head lights
2x35W/2×55W
Tail light
2 x0.6W/2 x0.6W
Brake light
2x1W/2 x1W
Instrument panel light
0.02W
than usual. 5.
and internal moving parts for about 5 minutes. 6.
With all implements lowered to the ground, coat any exposed rods with grease (if equipped).
7.
Remove the battery from the vehicle. Store the battery following the battery
CAUTION
storage procedures.
To avoid personal injury: Do not clean the vehicle when the
8.
To avoid the danger of exhaust fume poisoning, do not operate the engine in
Keep the vehicle in a dry place where the vehicle is sheltered from the elements.
engine is running.
Charge the engine oil and run the engine to circulate oil throughout the engine block
STORAGE
Check the bolts and nuts for looseness.
Cover the vehicle. 9.
a closed building w ithout proper 1-51
Keep the vehicle indoors in a dry area that is protected from sunlight and excessive
Introduction HS 200UTV-2/HS 250UTV-2 heat. If the vehicle must be stored
and make a visual inspection looking for
outdoors. Cover it with a waterproof
evidence of oil or water leaks.
tarpaulin.
6. With the engine fully warm up. Release the
Put boards under the tires to keep
parking brake and test the brakes for
dampness away from tire.
proper adjustment as you move forward.
Keep the tries out of direct sunlight and
Adjust the brake as necessary.
extreme heat. IMPORTANT:
When washing the vehicle, be sure to stop the engine. Allow sufficient time for the engine to cool before washing.
Do not wash with a high-pressure carwashing machine.
Cover the vehicle after the muffler and the engine have cooled down.
REMOVING THE VEHICLE FROM STORAGE 1.
Check the tire air pressure and inflate the tires if they are low.
2.
Install battery before installing the battery, Be sure it is fully charged.
3. Check to see if the fan works. 4.
Check
all
transmission
fluid oil,
levels
(engine
engine
oil,
coolant,
transmission coolant and any attached implements). 5.
Start the engine. Observe all gauges. If all gauges are functioning properly and reading 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 work around vehicle
1-52
Introduction HS 200UTV-2/HS 250UTV-2 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 Bad. The air cleaner is clogged. Spark plug is dirty or fouled. Ignition coil is bad. 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 cannot start.
Engine power insufficient
is
Engine stops suddenly
Engine overheats
If you have any questions, consult your local dealer.
1-53
Introduction HS 200UTV-2/HS 250UTV-2 Diagnostic Trouble Code 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.
1-54
Introduction HS 200UTV-2/HS 250UTV-2 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
When viewed from the
with an insufficient
top
amount
plates,
look
* Refillable type battery
only
of
Battery was used with
too
new
Charge
battery
much
Battery life expired.
Charge
the
battery
corroded and heat up.
Poor
terminal
connection
Regularly check the
Charge
battery
Replace battery. Keep the terminal
Clean the terminal
clean and tight.
and
Apply
grease
and
treat
with
anti-
tighten
securely.
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.
1-55
properly
properly
Terminals are severely
be
electrolyte level.
Insufficiently
must
before initial use
Add distilled water charge
Battery serviced
battery.
without recharging. Recharging is impossible.
Apply grease and treat with anti-corrosive.
Replace
and
electrolyte.
whitish.
clean and tight.
Insufficiently
Battery was used
Keep the terminal
battery
charging
of
tighten
securely.
lights soon become dim
Clean the terminal
Introduction HS 200UTV-2/HS 250UTV-2 MACHINE TROUBLESHOOTING Trouble
Cause
High idling speed of engine
High rotary speed for clutch connection.
Non good adjust for gearshift stay wire.
Non agility for Gearshift
Transmission noise
Gear abrasion Big matching clearance for the inner and outside gears of transmission shaft Big clearance of transmission gears. Non good connection of gear end face Parking brake Non full Uncoupling for disc brake
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. Consult your local dealer for further details. 1.
Roof；
2.
Windshield；
Replace the gears
Replace the gears
Replace the gears
Loosen the lay-up rod
Contact the distributor.
Less vehicle power
No good brake or noise
Countermeasure Replace throttle cable; Replace throttle petal Replace the 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
1-56
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
Introduction HS 200UTV-2/HS 250UTV-2 3.
Windlass
4.
Motor Scan KF90121;
1-57
