Hisun HS700UTV-4 Manuals

Manuals and User Guides for Hisun HS700UTV-4. We have 2 Hisun HS700UTV-4 manuals available for free PDF download: Maintenance Handbook, Owner's Manual

Hisun HS700UTV-4 Maintenance Handbook (388 pages)

Brand: Hisun | Category: Utility Vehicle | Size: 41 MB

Table of Contents
2
Chapter 1 General Information

14
Watnings , Cautions and Notes

14
Description

15
Identification Code

16
- Frame no
  16
- Engine no
  16
Safety

17
- Handing Gasoline Safely
  18
- Cleaning Parts
  18
- Warning Labels
  19
Serial Numbers

19
Fasteners

19
- Torque Specifications
  19
- Self-Locking Fasteners
  19
- Washers
  20
- Cotter Pins
  20
- Snap Rings and E-Clips
  20
Shop Supplies

21
- Lubricants and Fluids
  21
- Engine Oils
  21
- Greases
  22
- Brake Fluid
  22
- Coolant
  22
- Cleaners, Degreasers and Solvents
  22
- Gasket Sealant
  23
- Gasket Remover
  23
- Thread Locking Compound
  23
Basic Tools

24
- Screwdrivers
  24
  - Wrenches
    25
  - Adjustable Wrenches
    25
  - Socket Wrenches, Ratchets and Handles
    26
  - Impact Drivers
    27
  - Allen Wrenches
    27
  - Torque Wrenches
    27
  - Torque Adapters
    28
  - Pliers
    29
  - Snap Ring Pliers
    29
  - Hammers
    30
  - Ignition Grounding Tool
    30
Precision Measuring Tools

30
- Feeler Gauge
  31
- Calipers
  31
- Micrometers
  32
- Adjustment
  33
- Care
  33
- Metric Micrometer
  33
- Standard Inch Micrometer
  34
- Telescoping and Small Bore Gauges
  35
- Dial Indicator
  35
- Compression Gauge
  36
- Multimeter
  36
- Cliop-On Ammeter
  37
- Magneto Puller
  37
Electrical System Fundamentals

37
- Voltage
  37
- Resistance
  37
- Amperage
  38
Basic Service Methods

38
- Removing Frozen Fasteners
  39
- Removing Broken Fasteners
  40
- Repairing Damaged Threads
  40
- Stud Removal/Installation
  40
- Removing Hoses
  41
- Bearings
  41
- Removal
  42
- Installation
  42
- Interference Fit
  43
- Seal Replacement
  45
Storage

45
Trovbleshooting

46
Engine Principles and Operating Requirements

47
Starting the Engine

47
- Engine Is Cold
  48
- Engine Is Warm
  48
- Flooded Engine
  49
Engine will Not Start

49
Poor Engine Performance

51
- The Engine Starts Slowly or Difficultly
  51
Fuel System

55
- Rich Mixture
  55
- Lean Mixture
  56
Engine

56
- Engine Smoke
  56
- Black Smoke
  56
- Blue Smoke
  56
- White Smoke or Steam
  56
- Low Engine Compression
  56
- High Engine Compression
  57
- Engine Overheating (Cooling System)
  57
- Engine Overheating (Engine)
  57
- The Ignition Advance Angle Is too Large
  58
  - Detonation
    58
  - Power Loss
    58
- Engine Noises
  58
Englne Lubrication

59
High Oil Consumption or Excessive

59
- Exhaust Smoke
  59
- Low Oil Pressure
  59
- High Oil Pressure
  59
- No Oil Pressure
  60
- Oil Level too Low
  60
- Oil Contamination
  60
Cylinder Leak down Test

60
Electrical Testing

63
- Preliminary Checks and Precautions
  63
- Intermittent Problems
  63
- Electrical Component Replacement
  64
- Test Equipment
  65
- Ammeter
  65
- Self-Powered Test Light
  65
- Ohmmeter
  65
- Jumper Wire
  66
Test Procedures

67
- Voltage Test
  67
Brake System

69
- Soft or Spongy Brake Lever or Pedal
  69
- Brake Drag
  70
- Hard Brake Lever or Pedal Operation
  71
- Brake Grabs
  71
- Brake Squeal or Chatter
  71
- Leaking Brake Caliper
  71
- Leaking Master Cylinder
  72
Chapter 2 Specifications

73
How to Use Conversion Table of Unit

73
- How to Use Conversion Table
  73
- Definition of Unit
  73
Geberar Specifications

74
Engine Specifications

77
Chassis Specifications

83
Electrical Specifications

85
Tightening Torques

87
- Engine Tightening Torques
  87
- Chassis Tightening Torques
  90
General Tightening Torque Specifications

92
Lubrication Pionts and Lubricant Types

93
- Engine
  93
- Chassis
  94
Hydrographic Chart

95
Lubrication Oil Way

96
Maintenance Schedule

97
CHAPTER 3 Adjusting the Valve Clearance

99
- Checking the Spark Plug
  102
- Checking the Ignition Timing
  102
- Measuring the Compression Pressure
  104
- Checking the Engine Oil Level
  105
- Changing the Engine Oil
  106
Engine

99
Chassis

109
- Cleaning the Air Filter
  109
- Checking the Coolant Level
  110
- Changing the Coolant
  111
- Checking the Coolant Temperature Warning Light
  114
- Checking the V-Belt
  115
- Cleaning the Spark Arrester
  116
- Adjusting the Brake Pedal
  117
- Adjusting the Parking Brake
  118
- Checking the Brake Fluid Level
  118
- Checking the Front Brake Pads
  119
- Checking the Rear Brake Pads
  119
- Checking the Brake Hoses and Brake Pipes
  120
- Bleeding the Hydraulic Brake System
  121
- Adjusting the Select Lever Shift Rod
  122
- Adjusting the Brake Light Switch
  122
- Checking the Final Gear Oil Level
  123
- Changing the Final Gear Oil
  123
- Checking the Differential Gear Oil
  124
- Changing the Differential Gear Oil
  124
- Checking the Constant Velocity Joint Dust Boots
  125
- Checking the Steering System
  126
- Adjusting the Toe-In
  127
  - Adjusting the Front Shock Absorbers
    128
- Adjusting the Front and Rear Shock Absorbers(Option 1)
  128
- Adjusting the Front and Rear Shock Absorbers(Option 2)
  129
- Spring Preload
  130
- Rebound Damping Force
  130
- Compression Damping Force
  131
  - Checking the Tires
    131
  - Checking the Wheels
    133
  - Checking and Lubricating the Cables
    133
  - Checking and Charging the Battery
    134
  - Checking the Fuses
    140
  - Adjusting the Headlight Beam
    141
  - Changing the Headlight Bulb
    142
  - Changing the Tail/Brake Light Bulb
    143
Chapter 4 Engine

144
Engine Note

144
Engine Removal

145
Cylinder Head and Cylinder Head Cover

148
Rocker Arms and Camshaft

153
Valves and Valve Springs

159
Cylinder and Piston

164
Engine Cooling Fan and A.C. Magneto

168
Balancer Gears and Oil Pump Gears

173
Primary and Secondary Sheaves

176
- Primary Sheave
  177
- Secondary Sheave
  178
Clutch

183
Clutch Housing

184
Crankcase Starter Motorand Oil Filter

187
Crankcase

189
- Crankcase Bearings
  190
Crankshaft and Oil Pump

194
- Oil Pump
  195
- Transmission
  198
- Drive Axle Assembly
  199
Middle Gear

203
- Middle Drive Shaft
  204
Chapter 5

210
Malfunction Inspection

210
DIRECTION SYSTEM the Steering Wheel Parts(EPA Type)

213
- The Steering Wheel Parts(E-Mark Type)
  216
Brake System

226
- Disk Brake Components
  227
  - Front and Rear Brake Discs
    229
  - Front and Rear Brake Pads
    231
  - Front and Rear Brake Caliper
    233
  - Parking Brake Disc
    238
  - Parking Brake Caliper and Brake Pads
    240
  - Brake Master Cylinder
    248
Footrest Assembly

251
Wheel and Tyre Parts

254
- Front Wheels
  254
- Rear Wheels
  255
Transmission System

258
- Front Axle
  258
  - Front Bridge
    259
  - Rear Axle
    269
- Rear Bridge
  270
- Speed Reducer Component with Differential
  274
Reverse Mechanism Parts

280
Suspension

284
- Front Suspension and Arm
  284
- Rear Suspension
  290
- Rear Arm Shaft
  292
- Rear Suspension and Arm
  294
Cooling System

296
- Radiator 1
  296
- Radiator 2
  298
  - Oil Cooler
    301
  - Water Pump
    302
Seat

307
Oil System

309
Fuel Tank

309
Chapter 6 Electrical Components

314
Electrical System Malfunction Inspection

314
Electrical

315
Electricalcomponents

315
- Checking the Switch
  317
- Checking the Switch Continuity
  318
Checking the Bulbs and Bulb Sockets

319
Ignition System

319
- Circuit Diagram
  319
- Troubleshooting
  320
Electric Starting System

323
- Circuit Diagram
  323
- Troubleshooting
  324
Starter Motor

327
- Checking the Starter Motor
  328
- Assembling the Starter Motor
  329
Charging System

329
- Circuit Diagram
  329
- Troubleshooting
  330
Lighting System

331
- Circuit Diagram
  331
- Troubleshooting
  332
Checking the Lighting System

333
Signaling System

334
- Circuit Diagram
  334
- Troubleshooting
  335
- Checking the Signal System
  336
Cooling System

345
- Circuit Diagram
  345
2Wd/4Wd Selecting System

348
- Circuit Diagram
  348
Chapter 7 Engine Management System

353
- Ems (Engine Management System)
  353
- Typical Components of EMS
  353
- Layout of EMS Components
  354
Components of Ems

354
- Electronic Control Unit
  354
- Multec 3.5 Injectors
  355
- Throttle Body Assembly(with Stepper Motor)
  359
- Engine Coolant Temperature Sensor
  361
- Intake Air Pressure and Temperature Sensor
  361
- Oxygen Sensor
  362
- Ignition Coil
  362
- Fuel Pump Module
  366
Ems Fault Diagnosis

372
- EME Fault Diagnosis
  372
- Fault Code List
  372
Chapter 8 Troubleshooting

374
Starting Failure/Hard Starting

374
- Fuel System
  374
- Electrical System
  374
- Compression System
  375
Poor Idle Speed Performance

375
Poor Medium and High-Speed Performance

376
Faulty Gear Shifting

376
- Shift Lever Does Not Move
  376
- Jumps out of Gear
  376
Engine Overheating

377
- Overheating
  377
Faulty Brake

377
- Poor Braking Effect
  377
Shock Absorber Malfunction

378
- Loss of Damping Function
  378
Unstable Handling

378
Lighting System

378
- Head Light Is out of Work
  378
- Bulb Burnt out
  379
- Error Display of Meter
  379

Hisun HS700UTV-4 Owner's Manual (216 pages)

Brand: Hisun | Category: Utility Vehicle | Size: 7 MB

Important Manual Information
4
Important Notice
5
Table of Contents
6
Specification Labels 1-1

18
Location of the Warning and

18
Safety Information

18
- Description and Vehicle Identification
  23
Identification 3-1

25
Description and Vehicle

25
- Identification Number Records
  25
Control Functions

26
- Indicator and Warning Lights
  27
- Use of EPS System
  29
- Speedometer Unit
  31
- Clock Time Adjustment
  32
- Fault Code Indicator
  33
- Fuel Level Indicator
  34
- On-Command Four-Wheel-Drive and Differential Gear Lock Switches
  35
- Accelerator Pedal
  39
- Brake Pedal
  40
  - Drive Select Lever
    41
- Fuel Tank Cap
  42
- Seat Belts
  43
- Glove Compartment
  46
- Opening and Closing the Tailgate
  47
- Front and Rear Shock Adjustment
  49
- Spring Preload
  52
- Rebound Damping Force
  53
- Compression Damping Force
  54
- Trailer Hitch Bracket
  55
- Auxiliary DC Jack
  56
Pre Operation Checks

58
- Brakes
  59
- Brake Fluid Leakage
  60
- Fuel
  61
- Engine Oil
  62
- Coolant
  63
- Final Gear Oil
  64
- Throttle Pedal
  65
- Throttle Freeplay
  66
- Steering Wheel Inspection
  67
  - Switches
    68
  - How to Measure Tire Pressure
    69
Specifications

70
Operation

71
- Starting the Engine
  72
- Warming up
  73
- Drive Select Lever Operation and Driving in Reverse
  74
- Parking
  78
  - Vehicle Break-In Period
    79
  - Engine Break-In
    80
  - Accessories
    81
  - Loading
    82
Driving Your Vehicle

86
- Learning to Operate Your Vehicle
  90
- Turning Your Vehicle
  91
- Operating Improperly in Reverse
  92
- Braking
  93
- Going Downhill
  95
- Crossing through Shallow Water
  97
- Vehicle Immersion
  98
- Riding over Rough Terrain
  100
- Riding in Brush or Wooded Areas
  102
- Hood
  110
- Console
  111
- EFI System
  112
- EFI System Inspection
  115
- To Check the Engine Oil Level
  116
- To Change the Engine Oil
  117
- Final Gear Oil
  120
- Changing the Final Gear Oil
  121
- Differential Gear Oil
  122
- Changing the Differential Gear Oil
  123
- Coolant
  124
- Axle Boots
  126
- Inspection
  127
- Installation
  128
- Cleaning the Engine Air Filter Elements
  129
- V-Belt Cooling Duct Check Hose
  133
- Cleaning the Spark Arrester
  134
- Valve Clearance
  136
- Rear Brake Pad Check
  137
- Brake Fluid Replacement
  138
- Cable Inspection and Lubrication
  142
- Brake Pedal and Accelerator Pedal Lubrication
  143
- Steering Shaft Lubrication
  144
- Wheel Installation
  145
- Battery
  146
- Battery Maintenance
  148
- Replacing a Headlight Bulb
  150
- Headlight Beam Adjustment
  153
- Tail/Brake Light Bulb Replacement
  154
- Troubleshooting
  156
- Electric Power Steering System
  
  169
  - Important Information for Safety
    170
  - Introduction of EPS System
    171
  - Typical Parts of EPS System
    172
  - Operation and Use of EPS System
    178
  - Solutions for Common Fault
    187
  - Maintenance and Repair's Supplemental Description
    194
  - EPS System Periodic Maintenance
    196
  - EPS System Parameter Table
    197
Cleaning and Storage

198
- Storage
  200
Fault Code of Electronic Injection

209

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Hisun HS700UTV-4 Manuals

Hisun HS700UTV-4 Maintenance Handbook (388 pages)

Table of Contents

Chapter 1 General Information

Watnings , Cautions and Notes

Description

Identification Code

Safety

Serial Numbers

Fasteners

Shop Supplies

Basic Tools

Precision Measuring Tools

Electrical System Fundamentals

Basic Service Methods

Storage

Trovbleshooting

Engine Principles and Operating Requirements

Starting the Engine

Engine will Not Start

Poor Engine Performance

Fuel System

Engine

Englne Lubrication

High Oil Consumption or Excessive

Cylinder Leak down Test

Electrical Testing

Test Procedures

Brake System

Chapter 2 Specifications

How to Use Conversion Table of Unit

Geberar Specifications

Engine Specifications

Chassis Specifications

Electrical Specifications

Tightening Torques

General Tightening Torque Specifications

Lubrication Pionts and Lubricant Types

Hydrographic Chart

Lubrication Oil Way

Maintenance Schedule

CHAPTER 3 Adjusting the Valve Clearance

Engine

Chassis

Chapter 4 Engine

Engine Note

Engine Removal

Cylinder Head and Cylinder Head Cover

Rocker Arms and Camshaft

Valves and Valve Springs

Cylinder and Piston

Engine Cooling Fan and A.C. Magneto

Balancer Gears and Oil Pump Gears

Primary and Secondary Sheaves

Clutch

Clutch Housing

Crankcase Starter Motorand Oil Filter

Crankcase

Crankshaft and Oil Pump

Middle Gear

Chapter 5

Malfunction Inspection

DIRECTION SYSTEM the Steering Wheel Parts(EPA Type)

Brake System

Footrest Assembly

Wheel and Tyre Parts

Transmission System

Reverse Mechanism Parts

Suspension

Cooling System

Seat

Oil System

Fuel Tank

Chapter 6 Electrical Components

Electrical System Malfunction Inspection

Electrical

Electricalcomponents

Checking the Bulbs and Bulb Sockets

Ignition System

Electric Starting System