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Summary of Contents for Hisun Motors HS5D-EV
- Page 1 WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death.
- Page 2 INTRODUCTION Congratulations on your purchase of the HS5D-EV. 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 HS5D-EV operation.
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Page 3: Table Of Contents
TABLE OF CONTENTS Introduction ..........5 Important manual information…………………………………………………………..5 Vehicle Identification Numbers……………………………………….………………..7 Safety . - Page 4 Cleaning and Storage………………………………………………………………….….…..71 Storing the Vehicle ……………………………………………………………………..…..74 Specifications Table ……………………………. .………………………..75...
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Page 5: Introduction
INTRODUCTION 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. - Page 6 Failure to follow the warnings contained in this manual can result in severe injury or death. Your HS5D-EV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as cars, trucks or other off-road vehicles. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.
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Page 7: Vehicle Identification Numbers
INTRODUCTION Vehicle Identification Numbers Record your vehicle's identification numbers in the spaces provided. Remove the spare key and store it in a safe place. Vehicle Model Number: ______________________________________________________ Frame VIN: _________________________________________________________________ Motor Serial Number (on side of motor): ________________________________________... -
Page 8: Safety
SAFETY Safe Riding Gear The driver and all passengers must wear helmet, eye protection, gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat belt at all times. Protective gear reduces the chance of injury. Helmet Wearing a helmet can prevent a severe head injury. Whenever riding this HSUN vehicle, always wear a helmet that meets or exceeds established safety standards. -
Page 9: Safety Labels And Locations
SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection. Read and follow the instructions of the labels on the vehicle carefully. If any of the labels depicted in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle. -
Page 11: Passenger/Tire Pressure Warning
SAFETY Safety Labels and Locations Passenger/Tire Pressure Warning WARNING • Passengers can be thrown off. This can cause serious injury or death. • Never carry passengers in cargo box. WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH. -
Page 13: Battery Charging Warning
SAFETY Safety Labels and Locations Battery Charging Warning WARNING • Explosive gases are released when batteries are charged. Keep sparks, flames and cigarettes away. Shield eyes when working near batteries. • Do not charge batteries in a non-ventilated enclosed area or near flammable materials. •... -
Page 14: Warning And Caution Labels
SAFETY Battery Caution CAUTION • Do not drive through water above the floor of the vehicle. Battery damage will occur. • Batteries require regular maintenance. • Failure to maintain batteries in accordance with the owners manual can result in battery damage, vehicle malfunction, fire and/or severe injury or death. - Page 15 （5） （6） （7） (8）...
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Page 16: Operator Safety
SAFETY Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual. • Read this entire manual and all labels carefully. Follow the operating procedures described. •... - Page 17 SAFETY Operator Safety • Always follow proper procedures for climbing hills as described in this manual. See page Check the terrain carefully before attempting to climb a hill. Never climb hills with excessively slippery or loose surfaces. Never go over the top of a hill at high speed. •...
- Page 18 Operator Safety WARNING Failure to operate the HS5D-EV properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures.
- Page 19 Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always perform the pre-ride inspection before each use of your HS5D-EV to make sure it's in safe operating condition. See...
- Page 20 SAFETY Operator Safety Operating on Pavement This vehicle's tires are designed for off-road use only, not for use on pavement. Operating this vehicle on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the vehicle and may increase the risk of loss of control and accident or rollover. Avoid operating the vehicle on pavement.
- Page 21 SAFETY Operator Safety Improper Hill Climbing Climbing hills improperly can cause loss of control or vehicle rollover. Always follow proper procedures for climbing hills as described in this owner's manual. See page Descending Hills Improperly Improperly descending a hill could cause loss of control or rollover. Always follow proper procedures for traveling down hills as described in the owner's manual.
- Page 22 SAFETY Operator Safety Unauthorized Use of the Vehicle Leaving the keys in the vehicle can lead to unauthorized use of the vehicle by someone under the age of 16, without a drivers license, or without proper training. This could result in an accident or rollover.
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Page 25: Features And Controls
FEATURES AND CONTROLS Meter Battery energy meter, indicates the current, remaining energy. ① battery energy indicator Motor temperature meter, indicates the temperature values inside motor. ① motor temperature indicator Current meter, indicates the current values of working motor. ① motor current reading... - Page 26 FEATURES AND CONTROLS The speedometer indicates the traveling speed ① Speed Meter The hour meter indicates in five digits the hours the vehicle has been used; the last digit indicates 1/10 of an hour. ① Hour meter Note: this meter also indicates accumulated mileages and electric drive system’s failure codes.
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Page 27: Indicator
FEATURES AND CONTROLS INDICATOR ① Left turn indicator ② Beam indicator ③ High-speed mode indicator ④ Saving mode indicator ⑤ Climbing mode indicator ⑥ Neutral mode indicator ⑦ safety belt indicator ⑧ Emergency indicator ⑨ Mechanical parking lights ⑩ Position indicator 11 Right turn indicator... -
Page 28: Console
FEATURES AND CONTROLS Console Parking Release 1. Set the direction switch to the “N” position and To release the parking brake, depress the brake pedal. ① Parking brake. ② Brake pedal. 2. Avoid stopping the vehicle on a slope. If stopping on a slope make sure the vehicle is stationary before exiting. - Page 29 FEATURES AND CONTROLS Console Drive Mode Switch Maximum Range CAUTION! Changing the drive mode switch position while driving could result in an automatic increase or decrease in speed without a change to accelerator pedal pressure. High Press the top of the switch to select high mode. Use high mode for most trail-riding conditions.
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Page 30: Direction Selector Switch
FEATURES AND CONTROLS Console Direction Selector Switch When the direction selector is in the center position, the vehicle is in gear. The vehicle will not move if the accelerator pedal is depressed. Push the top of the switch to choose forward operation. Push the bottom of the switch to choose reverse operation. - Page 31 FEATURES AND CONTROLS Headlight Switch Turn on the key switch and toggle the head light switch to the “ON” position. Toggle the head light switch to the “OFF” position to turn off the head light. NOTE： Turning the head light switch to the “ON” position causes the following lamps to light simultaneously.
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Page 32: Failure Code
FAULT CODE failure code Message Description Handbrake is active when 4481 Handbrake Fault direction selected. No speed feedback from 4541 Fan Fault external heatsink fans 4542 Low Oil Low Oil 4543 Hydraulic filter Hydraulic Filter Pump motor is not drawing 4544 Pump Current Low sufficient current... - Page 33 (0x2790,1) is less than BDI Cutout level (0x2C30,4) Battery voltage (0x5100,1) is less than Under Voltage limit 45C3 Low Battery Cut (0x2C02,2) for longer than the protection delay (0x2C03,0) Battery voltage (0x5100,1) is greater than Over Voltage limit 45C4 High Battery Cut (0x2C01,2) for longer than the protection delay (0x2C03,0) Capacitor voltage (0x5100,3) is...
- Page 34 operation. 46C1 Encoder Alignment Warning Encoder is not aligned properly. SinCos Encoder Min Max Values are heading towards a 46C2 SinCos Tracking Warning voltage rail or converging together. A fault ride through event has been encountered, but 46C3 Fault Ride Through operation is allowed to continue although the system may be derated...
- Page 35 Inch switch active along with any drive switch active (excluding inch switches), seat 0x4886 Inch Fault switch indicating operator present or handbrake switch active. 4887 Overload Fault Vehicle overloaded Scissor lift platform raised and 4888 Raised and Tilted Fault tilted Scissor lift pothole protection 4889 Pothole Fault...
- Page 36 allowed number of slaves 4D01 Circuit Breaker Open 4D02 Circuit Breaker Welded 4D03 DC Link Collapsed Time to close breaker of GpAC 4D04 Circuit Breaker Timeout has expired Motor isolation contactor is 4D41 Motor Isolation Fault open circuit Motor terminal is open circuit or 4D42 Motor Open Circuit Fault disconnected from controller...
- Page 37 Motor rotation detected as 4F56 Motor in wrong direction wrong direction. No longer supported Motor rotation stalled. No longer 4F57 Motor stalled supported EMCY message received from non-Sevcon node and 4F81 CANopen anon EMCY level 3 anonymous EMCY level (0x2830,0) is set to 3. EEPROM or flash configuration 5041 Bad NVM Data...
- Page 38 Controller heat sink has reached critical high 5201 Heatsink overtemp temperature, and has shut down. Encoder input wire-off is 52C1 Encoder Fault detected. Motor current exceeded 52C2 Motor Overcurrent Fault controller rated maximum Motor controller unable to 52C3 Current Control Fault maintain control of motor currents Motor control tripped due to...
- Page 39 5319 Motor slave in wrong state Motor slave in wrong state CAN device on Renault Twizy 531A Ren Protocol not responding DSP reports invalid protocol 5341 Invalid DSP Protocol version on dual processor platform 5342 OSC Watchdog Fault Internal hardware fault Attempting to set too many 5343 Fault List Overflow...
- Page 40 non-Sevcon node and anonymous EMCY level (0x2830,0) is set to 5.
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Page 41: Batteries
FEATURES AND CONTROLS Batteries This vehicle is equipped with eight 6-volt batteries that supply the power needed to operate the vehicle. The batteries are located under the seat. See page 69 for battery access instructions. Always observe all battery safety warnings and safe handling procedures as outlined on vehicle safety labels and in this manual. - Page 42 FEATURES AND CONTROLS Batteries Battery Conditioning New batteries cannot initially hold all of their capacity. The approximate capacity of the battery pack increases as the number of charge cycles increases. # of Charge Cycles: Percent of Full Capacity: 100% Ambient Temperature Implications on Batteries Battery range decreases as ambient temperature decreases.
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Page 43: Main Power Connector
FEATURES AND CONTROLS Main Power Connector NOTICE: Damage to electrical connections and components will occur if they are unplugged before the main power connector is disconnected. Always disconnect the main power connector before servicing or unplugging any electrical components. When disconnected, the main power connector Main Power Connector disconnects the battery pack from all electrical components, with the exception of the contactor. -
Page 44: Checking The Brake Pedal
FEATURES AND CONTROLS Checking the brake pedal. Brake Pedal ① Brake pedal Brake Pedal CAUTION: To avoid personal injury: If the operator suddenly brakes, an accident may occur due to loss of control or the shifting forward of heavy loads. When driving on icy, wet or loose surface, make sure the vehicle is correctly loaded to avoid skidding or loss of steering The brake pedal is the left pedal on the foot board. - Page 45 FEATURES AND CONTROLS The accelerator pedal will function only when the key is ON and the direction selector switch is set to either forward or reverse. To begin moving or to increase vehicle speed, gradually push the accelerator pedal toward the floor. Holding the accelerator pedal down continuously will accelerate the vehicle to the maximum speed.
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Page 47: Seat Belts
OPERATION WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual. Pre-Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. -
Page 48: Driving Procedure
OPERATION Driving Procedure Disconnect the charging cable (if connected). Wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots. Sit in the driver's seat and fasten the seat belt. Apply the brakes. Turn the key to the ON position. Wait about a second for the contactor to close before continuing. -
Page 49: Driving On Slippery Surfaces
OPERATION Driving On Slippery Surfaces WARNING Skidding or sliding can cause loss of control or rollover (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control. Do not operate on excessively slippery surfaces. -
Page 50: Driving Uphill
OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: Always travel straight uphill. Avoid excessively steep hills. Keep both feet on the floor. Always check the terrain carefully before ascending any hill. Never climb hills with excessively slippery or loose surfaces. Proceed at a steady rate of speed. -
Page 51: Driving Through Water
OPERATION Driving Through Water Your HSUN vehicle can operate through water up to a maximum recommended depth equal to the floorboards. NOTICE: Serious damage can occur to the electrical system and batteries if the vehicle is operated in water deeper than the floorboards. -
Page 52: Driving In Reverse
Turn the key off. Block the rear wheels on the downhill side. Parking the HS5D-EV Apply the brakes. Stop the vehicle on a level surface. When parking inside a garage or other structure, be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights. -
Page 53: Hauling Cargo
5 MPH (8 km/h) when towing loads in rough terrain, while cornering, or while ascending or descending a hill. HS5D-EV has been designed to carry or tow specific capacities. Always read and understand the load distribution warnings listed on the warning labels. Move the drive mode switch to low mode if needed. - Page 54 OPERATION WARNING! Driving with passengers in the cargo box can result in severe injury or death. Never allow passengers to ride in the cargo box. A passengers must always ride in the cab with seat belt fastened securely.
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Page 55: Towing Loads
500lbs.(227kg) 150 lbs.(68.1 kg) 10 MPH(16 kph) Towing the HS5D-EV NOTICE: When towing the vehicle, the key MUST be in the OFF position or severe motor damage will occur. Follow these procedures when towing the vehicle: Turn the key off. -
Page 56: How To Raise The Cargo Bed
OPERATION HOW TO RAISE THE CARGO BED CAUTION To avoid personal injury: ● When servicing under raised bed, make sure safety support is properly mounted. ● Do not touch muffler or exhaust pipes while they are hot; Otherwise, severe burns could result. ... - Page 57 OPERATION Transporting the HS5D-EV When transporting the HS5D-EV for a long distance or on public streets, always use a trailer with an approved load rating greater than the HS5D-EV curb vehicle weight of 1700 lbs. (830 kg) plus any installed accessories or cargo.
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Page 58: Checking Wheel Bolt Torque
OPERATION Checking wheel bolt torque CAUTION To avoid personal injury Never operate vehicle with a loose wheel bolts. Any time these bolts are loosened they should be retightened to the specified torque. Check all bolts frequently and keep them tight. Check wheel bolts regularly especially when new if they are loose tighten them as follows: ①... -
Page 59: Maintenance
MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine HSUN parts available from your... - Page 60 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Remarks Maintenance Interval (whichever comes first) Calendar Headlamp/tail lamp Daily Check operation; apply dielectric grease if replacing Brake pad wear Monthly Inspect periodically Battery terminals Monthly Inspect and clean (page 69) Battery fluid levels...
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Page 61: Gear Cases
MAINTENANCE Gear cases Gear case Specification Chart Gear case Lubricant Capacity Fill Plug Torque Drain Plug Torque Main Gearcase ATV Angle Drive Fluid 30.4 oz. 14 ft. Lbs. 14 ft. Lbs. (Transaxle) (900 ml) (19.4 Nm) (19.4 Nm) Front Gearcase Demand Drive Fluid 5.1 oz. -
Page 62: Front Gear Case
MAINTENANCE Gear cases Front Gear case Always check and change the front gear case oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 59. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart on page 54 for recommended lubricants, capacities and torque specifications. -
Page 63: Brake Fluid
MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. See page44. Brake Fluid Inspect the brake system routinely. Inspect the level of the brake fluid before each operation. WARNING! After opening a bottle of brake fluid, always discard any unused portion. -
Page 64: Steering Wheel Inspection
MAINTENANCE Steering Wheel Inspection Check the steering wheel for specified free play and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 59. Position the vehicle on a level surface. Lightly turn the steering wheel left and right. There should be 0.8"-1.0" (20-25 mm) of free play at the outer rim of the steering wheel. - Page 65 MAINTENANCE ① Locknut ② Spring preload adjusting nut ③ Special wrench ·A special wrench can be obtained at a HSUN dealer to make this adjustment. ·The spring preload setting is determined by measuring distance A, shown in the illustration. The shorter distance A is, the lower the spring preload; the longer distance A is, the higher the spring preload.
- Page 66 ① Rebound damping force adjusting screw Compression damping force Turn the compression damping force adjusting screw (use 3.0 allen wrench) in direction ⓐ to increase the compression damping force and thereby harden the damping, and in direction ⓑ to decrease the compression damping force and thereby soften the damping. ①...
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Page 67: Tires
MAINTENANCE Tires WARNING Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. -
Page 68: B A T T E R
MAINTENANCE Batteries WARNING Battery posts, terminals and related components contain lead and lead compounds, chemicals known to cause cancer and reproductive harm. Always wash your hands after touching or handling the batteries. WARNING Charging a damaged battery can result in serious injury. Never attempt to charge a frozen or bulging battery. - Page 69 MAINTENANCE Batteries Battery Charging When not in use, park the vehicle and connect the battery charger. The vehicle’s charging cord is located inside the right Storage box WARNING! Failure to provide adequate ventilation while charging batteries can result in an explosion. Hydrogen gas is emitted during charging and will rise and accumulate at the ceiling.
- Page 70 MAINTENANCE Batteries Battery Access To access the batteries, remove the seat. See page 46. Remove the storage tray (if equipped). NOTICE: Before removing the seat to access the batteries, make sure any wire or metal items (including seat belt latches) remain clear of the battery compartment to avoid causing a short circuit to the electrical system.
- Page 71 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your HSUN vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: High water pressure may damage components. HSUN recommends washing the vehicle by hand or with a garden hose, using mild soap.
- Page 72 MAINTENANCE Cleaning and Storage Polishing the Vehicle HSUN recommends the use of common household aerosol furniture polish for polishing the finish on your HSUN vehicle. Follow the instructions on the container. Polishing Tips • Avoid the use of automotive products, some of which can scratch the finish of your vehicle. •...
- Page 73 MAINTENANCE Cleaning and Storage Storage Tips Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 71. Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 59.
- Page 74 MAINTENANCE Storing the Vehicle Any time the vehicle will be parked for more than a few hours, follow the recommended storage procedures: Make any necessary repairs and clean the vehicle. See page 71. Clean the batteries. See page70. Store the vehicle out of the sun in a cool, dry place. Be sure the storage area is well ventilated.
- Page 75 SPECIFICATION TABLE Motor type AC induction motor Motor peak 27HP Power battery pack voltage 48VDC 12.4kw/H Single battery parameter 6V/280Ah@20hr Controller 450 - Amp Sevcon GEN4 controller with multi-mode driving regenerative braking Max.speed 25 MPH (40.2 km/h) Range (in Max Range mode on 50 miles (80.5 km) (may vary with driving flat ground) conditions)
- Page 76 Model Specification 1305 (51.38) Width mm (in.) 775（29.72） Length mm (in.) 285（11.22） Depth mm (in.) Cargo bed Volume 0.23（8.11） (cu.ft.) Bed height 927（36.50） mm (in.) (unloaded) Cargo 159（350） kg (lbs.) capacity (1 row/2 row) 26×9-14 20psi (138kPa) Front Tire 26×11-14 6PR 20psi (138kPa) Rear Red, Black, White, Blue, Yellow,...
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