Hisun SECTOR 1000, Owner'S Manual

Page 1: ...lds 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...

Page 2: ...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 CA...

Page 3: ...l 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 bysta...

Page 4: ...re 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 p...

Page 5: ...6 2 7 2 7 2 7 2 8 3 1 4 1 4 2 4 3 4 4 4 5 4 6 4 6 4 6 4 7 4 7 4 8 4 8 4 9 4 9 4 10 5 1 5 1 6 1 6 1 6 2 6 3 6 3 6 3 6 3 6 5 6 6 6 6 Subject Wheel bolt torque Cleaning the air filter Evacuator valve Ba...

Page 6: ...General 2 1 LOCATION OF PARTS Instrument Panel and Controls...

Page 7: ...General 2 2 LOCATION OF PARTS...

Page 8: ...General 2 3 ILLUSTRATED CONTENTS...

Page 9: ...ury to occur 5 You should always wear protective equipment such as helmet boots eye protection ear protection and gloves etc 6 Only a qualified driver with driving license should operate this UTV Neve...

Page 10: ...ose attention to your surroundings and check for streets trail intersections or other obstacles 12 Always use signals in advance of turns 13 Do not allow entrance or exit of the vehicle while it is mo...

Page 11: ...el Otherwise you could be burned by hot fluid or steam 3 No smoking when adding electrolyte or refueling Fuel tank and battery should be kept away from sparks Battery produces hydrogen and oxygen in c...

Page 12: ...General 2 7 Warning and caution labels 1 2 3 4 5 6 7 8 9...

Page 13: ...General 2 8 10 11 12 13 14...

Page 14: ...wever 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...

Page 15: ...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...

Page 16: ...0 hrs 17 Radiator hose and clamp Check Every 200 hrs Replace Every 2 years 18 Intake air line Check Every 200 hrs Replace Every 1 years 19 Brake hose lines Check Every 200 hrs Check Every 4years 20 Ti...

Page 17: ...el system Bleed Service as required 33 Fuse Replace Service as required 34 Light bulb Replace Service as required NOTE Engine Oil 15W 40SL Oil used in the engine should have an American Petroleum Inst...

Page 18: ...ally 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 dusty areas Check brake and...

Page 19: ...or s seat Never start the engine while standing on ground Make it a rule to set gear shift lever to NEUTRAL position before starting the engine IMPORTANT Do not use starting fluid or ether To protect...

Page 20: ...e key into the key switch and turn it to START OFF Engines stop ON Engine run or headlight on START Engine start Display Warning Lights 1 When the key is turned to START lamps 1 engine oil pressure sh...

Page 21: ...ery 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 WARMIN...

Page 22: ...prescribed On rough roads slow down to suitable speeds Do not operate the vehicle at fast speed The above precautions are not limited to new vehicles but to all vehicles It should be especially obser...

Page 23: ...e instrument panel Press the bottom half of the hazard light switch to turn off the hazard lights Note The hazard light switch is operated when the key switch is in the ON or OFF position Be careful t...

Page 24: ...anging gear shift range lever when ascending or descending a slope Before ascending or descending a slope shift to the L range to control the vehicle speed If you shift gears while ascending or descen...

Page 25: ...icy wet or loose surfaces make sure the vehicle is correctly balanced to avoid skidding and loss of steering control Reduce the speed and engage front wheel drive An accident may occur if the vehicle...

Page 26: ...key switch is on the fuel gauge indicates the fuel level Be careful not to empty the fuel tank Otherwise air may enter the fuel system Fuel gauge Coolant Temperature Gauge CAUTION To avoid personal i...

Page 27: ...he hourmeter indicates in five digits the hours the vehicle has been used the last digit indicates 1 10 of an hour Hourmeter The speedometer indicates the traveling speed The speedometer indicates the...

Page 28: ...undry box cover Operator s Seat To open the seat raise the seat to the forward position Operator s seat HOW TO RAISE THE CARGO BED CAUTION To avoid personal injury When servicing under raised bed make...

Page 29: ...ydraulics are not operating shift the lever to the FLOAT position and raise or lower the bed manually Knob bolt U UP D DOWN Hydraulic lift cylinder level JACK UP POINT WARNING To avoid personal injury...

Page 30: ...Fuel tank cap Fuel tank capacity 34L 8 9 U S GALS IMPORTANT If the oil level is low do not run the engine Checking the engine oil level 1 Park the vehicle on a flat surface raise the cargo bed mount t...

Page 31: ...e all foreign materials Radiator screen DETACH IMPORTANT Radiator screen must be clean from debris to prevent engine from overheating Checking brake fluid level CAUTION TO avoid personal injury Never...

Page 32: ...ion Brake pedal FREE TRAVEL PEDAL STROKE Checking parking brake NOTE Make sure the parking brake warning lamp on the display goes off when parking brake lever is down Parking hand bar Checking gauges...

Page 33: ...ibed level it naturally drops slowly in the course of time thus check it everyday and inflate as necessary tire sizes inflation pressure Front 27x9 14 Rear 27x11 14 179kPa 0 7kgf cm2 26psi EVERY 50 HO...

Page 34: ...L H or REVERSE position 3 Turn the key to START position 4 The engine must not crank 5 If it cranks consult your local dealer for this service Range gear shift lever accelerator pedal Checking wheel...

Page 35: ...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 Ev...

Page 36: ...while the engine is running Keep electrolyte away from eyes hands and clothes If you are spattered with it wash it away completely with water immediately and get medical attention Wear eye protection...

Page 37: ...ct sunlight 2 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 Adjusting toe in Proper toe in 0 to12 mm 0...

Page 38: ...n or welds are discovered the assembly must be replaced 5 Return the spark arrester to the muffler body and refasten the bolts IMPORTANT Visually check the muffler for cracks or holes in the body weld...

Page 39: ...al stroke 3 If brake pedal stroke is outside of the specifications contact your local dealer for adjusting the brake Brake pedal FREE TRAVEL PEDAL STROKE Checking Brake Hose and Lines 1 Check to see t...

Page 40: ...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 caus...

Page 41: ...m speed for a few minutes to prevent damage to the transmission Changing Front and Rear Axle Case Oil 1 Park the vehicle on a firm flat and level surface To drain the used oil remove the drain the oil...

Page 42: ...ze until the coolant level is just below the radiator cap Install the radiator cap securely 7 Fill with fresh water up to the FULL mark on the recovery tank 8 Start and operate the engine for few minu...

Page 43: ...ers according to the make of the antifreeze and the ambient temperature Refer to SEA J1034 standard more specifically also to SAE J814c IMPORTANT When the antifreeze is mixed with water the antifreeze...

Page 44: ...al Consult your local dealer for this service Replacing Intake Air Line Consult your local dealer for this service EVERY 4 YEARS Replacing Brake Hose Consult your local dealer for this service Replaci...

Page 45: ...H Lo range Forward Neutral Reverse Brakes Front Rear Hydraulic disk brake Parking brake Rear wheel Foot Pedal Steering Electronic power Suspension Front Independent A arm type Rear Independent A arm...

Page 46: ...1102 Sound level operator ear db A 85 Tire Front 27 09X14 6PR 27 09X14 6PR Rear 27 11X14 6PR 27 11X14 6PR Body color Orange Camo NOTE The values in Ground clearance and Weight are those of the machin...

Page 47: ...ilures 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 warra...

Page 48: ...ressure a little higher than usual 5 Change the engine oil and run the engine to circulate oil throughout the engine block and internal moving parts for about 5 minutes 6 With all implements lowered t...

Page 49: ...nd 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 idl...

Page 50: ...from the vehicle charge and store it indoors install it on the vehicle only when the vehicle is going to be used Engine power is insufficient Insufficient fuel The injector is clogged Crankshaft posi...

Page 51: ...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 Malfunc...

Page 52: ...tes look whitish Refillable type battery only Battery was used with an insufficient amount of electrolyte Add distilled water and charge the battery Regularly check the electrolyte level Battery was u...

Page 53: ...clearance for the inner and outside gears of transmission shaft Replace the gears Misalignment of transmission gears Replace the gears Incorrect connection of gear end face Replace the gears Less veh...

Page 54: ...y decreased 5 No pollution to environment For the traditional hydraulic power steering system the hydraulic circuit has hydraulic hose and fittings inside the system so oil leaks may occur and hydraul...

Page 55: ...er works together with the EPS system and monitors working condition of the EPS system Faults can be displayed by a fault indicator light and fault indicator of EPS system so the driver can acknowledg...

Page 56: ...easing fuel consumption 3 The power of Hisun s EPS system is controlled by software so that the UTV can be operated with power steering at various speeds 4 Hisun s EPS system uses a rigid connection s...

Page 57: ...em hereinafter referred to as the ECU many sensors and actuators monitoring UTV speed the operating force of the steering wheel as well as temperature of the ECU and motor to provide an accurate power...

Page 58: ...ll the power performance of EPS so do not repair the ECU by yourself If any problem happens on the ECU please contact your local dealer to repair it Upper housing ECU unit Seal ring Lower housing Inst...

Page 59: ...nd accepts signals for torque P5 connected with motor 4 Reducer The reducer is installed on the frame of UTV A motor and steering torque sensor is also installed on the reducer Outside view of reducer...

Page 60: ...F00001 1 fault of steering torque sensor lit 2 F00002 2 fault of steering torque sensor lit 3 F00006 ECU overheating lit 4 F00005 low voltage battery alarm lit 5 F00003 Dynamic motor without power ala...

Page 61: ...t power torque depending on the speed and steering angle T1 steering resistant torque which is checked by steering power sensor T2 power torque on steering gear which is supplied by EPS system Power T...

Page 62: ...SYSTEM S INSPECTION MAINTENANCE REPAIR The EPS system has already been inspected by strict quality restriction before delivery so it has high reliability But if there is no inspection or maintenance...

Page 63: ...e rod ball head showing signs of wear Swizzle ball of knuckle worn Gear rack on steering wheel worn Spline on steering drive shaft is loose Between input and output shaft s reducer whether had idle ru...

Page 64: ...00005 Low voltage in storage battery Charge storage battery replace it if necessary 4 Meter warning fault code F00003 Motor is damaged or driving circuit in motor is damaged or power motor special fus...

Page 65: ...e loose or damaged Retighten loose bolts Replace damaged spare parts 2 Mechanical parts without gap ECU damaged or the ECU software program has error To dealers for repair Bring the UTV to dealer for...

Page 66: ...d to turn left or right the power of steering to left and right is different S N Fault phenomenon Fault point Solution 1 No meter alarm Two channels parameters of sensor changed Replace sensor or go t...

Page 67: ...EPS system has many monitoring functions used to identify the sensors actuators and the involvement of the EPS system to check for malfunctions If a malfunction leads to the interruption of motor con...

Page 68: ...PS system relevant parameters CAUTION Before adjusting ECU please check the clearance of mechanical parts first and adjust four wheels position of UTV EPS SYSTEM PARAMETER TABLE EPS system basic techn...

Page 69: ...Options 11 1 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...

Page 70: ...you to read the instruction manual attached to the winch thoroughly before using it Winch mount plate Transporting Vehicle Pay attention to the following points when transporting the vehicle 1 Use a...

Page 71: ...STEM 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 vehicl...

Page 72: ...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 a...

Page 73: ...s 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 p...

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Page 75: ...TM HISUN MOTORS 310 East University Dr McKinney Texas 75069 PH 972 446 0760 TF 877 838 6188 hisunmotors com...