View the User Manual - Star Electric Vehicles
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1. Cargo capacity lbs 550 1100 Dimensions in 105 x 46 5 x 74 138 x 47 x75 Weight including batteries lbs 1710 2300 Ground Clearance in 5 5 Turing Radius ft 11 5 15 Wheelbase in 67 96 Climbing capacity 20 20 Front suspension Independent A arm with coil over shocks Independent A arm with coil over shocks Rear suspension Leaf spring and shock Leaf spring and shock Steering system Rack and pinion Rack and pinion Brake system 4 wheel hydraulic disc 4 wheel hydraulic disc Tire size 205 50 10 6 ply DOT 205 50 10 6 ply DOT Tire pressure psi 32 32 Important Labels WARNING Please read the following labels carefully before operating the vehicle and promptly replace any labels which become unreadable or removed Security Warning label under the dashboard Security Warning ithout the permission of the read and understand e systems must be vehicle if repairs and pants and or damage e perly trained are xplosive items are not icle can only be operated in urely seated All the vehicle at all ges in speed Warning label under the dashboard arning iter in contact with any electrical parts j area when charging to reduce the risk s functioning properly during chargi ads It should only be operated i Warning label besides the parking brake handle Operation System Schematic Fig2. Electric Vehicles Owner s Manual and Service Guide C Series AC48 2 AC UB L D and AC48 2 AC UB S D February 2015 Table of Contents Introduction Vehicle Specifications Important Labels Operation System Operational Process Rules for Safe Operation Maintenance Storage Troubleshooting 11 12 24 25 Introduction Thanks for purchasing a STAR EV C Series For your better use please read through this manual before operate the C Series to avoid any possible damage due to improper operation and keep it after reading for future reference Important Information Important information is showed in following way in this manual to arouse your attention WARNING Fail to follow Warning instructions could result in severe injury or death to the vehicle occupants bystanders or persons inspecting or repairing the vehicle CAUTION Fail to follow Caution instructions could cause damage to the vehicle Special Notice Because the seat AND backrest wrapping film may stick to the seat vinyl and cause seat vinyl fading or stained please remove the seat amp backrest wrapping film when you start to use your STAR Vehicle Specifications C Series Standard C Series Long Passengers 2 2 Battery group 8 x 6V Trojan T105 8 x 6V Trojan T105 Motor 7 HP 7 HP Controller Power amps 450 Amp AC Curtis 450 Amp AC Curtis Maximum speed mph 19 5 20 25 LSV 19 5 20 25 LSV
3. the positive pole from the battery when maintenance is done Never step on the accelerator pedal hard and frequently which may shorten the life of the controller It is prohibited to fill any other liquids such as battery addictives mineral water and tap water into the battery ONLY the distilled water is allowed to fill in the battery Check periodic maintenance charts below Regular maintenance is required for the best performance and safe operation of the vehicle WARNING Make sure to turn off the power key and apply the park brake when you do the maintenance unless specified If the owner is not familiar with the maintenance of this vehicle the dealer should do the work D perday W per week M permonth Q per quarter Y per year Item Descriptions D W M Q Y Battery 1 Check the liquid level Please add the distilled water if 7 necessary 2 Charge the battery v 3 Tighten the nut on the battery cable v 4 Check if the battery is over discharged the battery power meter flashing 5 Check the liquid density of the battery standard density should be 1 275 0 005 25 Q 21 6 Check if the battery is charged fully by 3 ways a using the hydrometer b checking the battery power meter 7 Clean the surface of battery Charger 8 Observe the charging status check if the charger plug becomes hot 9 Clean the surface of the charger
4. too tight Adjust or Change Spring shock absorber is abnormal Change Front suspension loose Change Abnormal Tire Fray Tire pressure is abnormal or tires need to be rotated Inflate or rotate Toe in is improper Adjust Drum bearing loose Change U type Bolt of Leaf Spring loose Tighten Rim distort frame distort Tighten Brake force of each wheel is aise different Overexert accelerate or brake frequently Alter operation Brake System Master cylinder and or wheel Check eliminate cylinder damage vitta leak oil change Brake fluid is insufficient or empty Add fluid Air enters into oil pipe Let air Brake fail Free travel of Brake pedal is too long Adjust or the clearance of arrester is too big Brake drum wears out or distort Change Master cylinder leaks oil internally Change The clearance of left brake drum shoe and right brake drum shoe is Adjust Braking deviation different Oil on one arrester s brake shoe Dispose or change 28 Tire pressure is different Repair or Change One wheel cylinder s piston blocks Adjust Wheel alignment improperly Adjust Brake drum becomes out of round Change Brake pedal has no free travel Adjust Clearance between brake shoe and drum is too small or releasing spring Adjust or Change is disable Braking drag Piston of wheel cylinder is Check Change ineffective Piston of maste
5. Change Solenoid Failure Check repair change Accelerator Failure Repair or Change Motor Failure Repair or change Parking brake doesn t loosen Loosen parking brake Over heat protection Check eliminate 2 Loses control when vehicle starts running speed cannot be adjusted Malfunction Possible reason Troubleshooting Vehicle runs at full speed when it starts Terminals of Solenoid stick together Check repair Controller failure Change Potentiometer failure Repair change Vehicle stops immediately after Internal short of Motor Repair change Motor is assembled too tight or blocked Repair change 25 it starts Controller failure Repair change Accelerator Failure Repair change Normal at low speed Weak power at high speed Controller Failure Check change Motor Failure Check change Accelerator Failure Check change 3 Vehicle cannot change direction only runs in one direction Malfunction Possible reason Troubleshooting Vehicle can only run in F amp R switch failure Change one direction Controller Failure Change 4 Malfunction of electro mechanic system System Malfunction Possible reason Troubleshooting Clearance of rear axle decelerating gear is too big or the decelerating Adjust change gear is broke
6. Do not get any water inside the charger Controller 10 Check if all terminals are tightened properly Please do this after the power is off 11 Clean the surface of the controller 12 Check if the solenoid is in order checking its touching point Motor 13 Check if any water gets in Check if it becomes too hot 14 Check if the carbon brush should be replaced 15 Check if the accelerator pedal works well and if it can be released freely and automatically Chassis 16 Check if the brake drum and the brake shoe should be and body replaced or not 17 Check if the hand brake functions 18 Check if the hose and tube for the brake liquid leaking 19 Check if the brake liquid inside the brake liquid tank is enough 20 Check the air pressure inside the tire check if the tire surface is worn check if the nuts are tightened properly 21 Check if the shock absorber has any oil leaking flat or abnormal noise 22 22 Check if there is oil leaking on the gear box and the rear end 23 Add the lubricant inside the wheel hub steering system 24 Adjust the toe in of the front end 25 Clean the body and seat After above maintenance drive the vehicle to check if the vehicle works properly 23 Storage Please follow the steps as below when the vehicle is stored 1 Check the liquid level inside the battery recharge it
7. caps CAUTION Never add acid to a battery 14 Testing Visual inspection alone is not sufficient to determine the overall health of the battery Both open circuit voltage and specific gravity readings can give a good indication of the battery s charge level age and health Routine voltage and gravity checks will not only show the state of charge but also help spot signs of improper pro such as undercharging and over watering and possibly even locate a bad or weak battery The following steps outline how to properly perform routine voltage and specific gravity testing on batteries Specific Gravity Test Flooded batteries only e Do notadd water at this time e Fill and drain the hydrometer 2 to 4 times before pulling out a sample e There should be enough sample electrolyte in the hydrometer to completely support the float e Take a reading record it and return the electrolyte back to the cell e To check another cell repeat the 3 steps above e Check all cells in the battery e Replace the vent caps and wipe off any electrolyte that might have been spilled e Correct the readings to 80 F Add 004 to readings for every 10 above 80 F Subtract 004 for every 10 below 80 F e Compare the readings e Check the state of charge using Table 1 The readings should be at or above the factory specification of 1 277 007 If any specific gravity readings register low then follow the steps below e Check and reco
8. cialist for further evaluation or retired from service 16 State of charge as related to specific gravity and open circuit voltage Specific Gravity Open Circuit Voltage Percentage of Ui Corrected to arge 8 80 F 6V 36V 48V a ps ee fs fir ee pcr foe fare fes foor feo fea for fen o fpe fe for fas fao fse faes fue fo poe as fos foa ras poe pe por fase aoe for fc fo pos rs por ast poe fase fen Battery installation Tighten the battery cables to battery terminals with torque of 95 105lbs inch or 10 7 11 9 N M Make sure there is nothing else between the battery cable lug and battery terminal post WARNING When working with the battery DO NOT put wrenches or any other metal objects across the battery terminals An arc can occur and it may cause explosion of the battery and physical injury Batteries should be installed or replaced only by a qualified electrician Gear Box Maintenance 1 The clearance for the clutch should be kept between 2 3 mm 17 The friction plate should be changed periodically the friction value on one side should not exceed 2 mm Adjust the flatness of the platen spring plate feeling manually first tighten the screws diagonally use your hand to check the flatness of the spring plate If not flat tighten the screws for the non flat part Change the gear oil inside the gear box periodically for new vehicle change the oil after one month or accumulated running distance exceed 1 200 km change the o
9. e motor and loss of control of the vehicle e Unqualified persons are prohibited to drive the vehicle e Make sure this vehicle runs in its rated climbing ability e Don t overtake other vehicles at crossroads blind spots or in other dangerous areas WHILE OPERATING THE VEHICLE e Keep your entire body inside the vehicle keep seated and holding on while the vehicle is moving e Donot start the vehicle until all occupants are securely seated e Keep your hands on the steering wheel and your eyes on the path ahead e Always reverse the vehicle slowly and watch the back carefully e Avoid starting and stopping suddenly e Avoid turning the vehicle too sharply at high speeds e Always drive slowly up and down slopes e Donot make any modification or addition which may affect the capacity or safety of the vehicle e Children are not allowed to play in the vehicle Children should be seated between adults and protected while the vehicle is moving 11 Maintenance Users should perform regular maintenance as follows Battery Maintenance WARNING Battery electrolyte is poisonous and dangerous and may cause severe burns injury etc Always wear protective clothing gloves and goggles when handling batteries electrolyte and charging your battery KEEP IT OUT OF REACH OF CHILDREN Cleaning e The exterior of the battery connection wires and bolts should always be kept clean and dry When cleaning make sure all vent caps are tight
10. efore using the charger please check if the battery charger you are using is correctly rated as per your local AC electricity network e Do not disconnect the DC output cord from the battery receptacle when the charger is ON In this case an arc can occur which may cause an explosion e Itis prohibited to open the housing of the charger e Only a qualified electrician is allowed to open the housing of the charger e The charger should be stored in safe and dry room with good ventilation e The charger should be packed properly if not used for long time Charging procedure e Turn off the power of the whole vehicle e Exterior charger o Connect charger to the DC receptacle on the vehicle Connect the charger to AC power Turn on the charger o Turn off the charger when the batteries are fully charged Disconnect the charger from AC power first then disconnect the charger with DC receptacle e Onboard built in charger o Connect the charger s with AC power o Turn on the charger s o Turn off the charger s when the batteries are fully charged and disconnect the charger s with AC power 10 Rules for Safe Operation The driver should have a good knowledge of the operation system of the vehicle and its features Follow the rules for safe operation WARNING e Drive the vehicle off road unless it is a street legal vehicle NEV LSV e The vehicle cannot be overloaded Overloading the vehicle can cause damage to th
11. fully before storing the vehicle WARNING Charge the battery once a month if your vehicle will be stored more than one month 2 Turn the power key to OFF position remove the key and store the key in a safe position Engage the parking brake Check the tire pressure to make sure its pressure is set to recommended pressure Clean the exterior of the vehicle and apply the rust inhibitor Cover the vehicle with a breathable cover and store it in a dry safe and well ventilated place If the vehicle is to store for a longer time check the liquid level inside the battery once a month and recharge the battery 24 Trouble Shooting There is no settled mode to diagnose and eliminate the malfunction of electric shuttle buss During maintaining and checking we suggest you first listen then look and feel Below is the diagnoses and maintenance of some common malfunctions 1 The vehicle doesn t move Malfunction Possible reason Troubleshooting Turn on power key Connector s in Circuit is loose or open Tighten or connect Fuse of controller or main circuit is open Change fuse Battery cable s is loose or disconnected Tighten or change Turn on power key Voltmeter has signal Voltmeter has no signal Power key is broken Change Voltmeter is broken Change Battery terminals connect improperly Adjust Improper operating procedure Operate properly Controller Failure Check or
12. il again two months later then change the oil every six months The oil type is 85W 90GL Clean the gear box before changing the oil CAUTION Never mix different oils Traction Motor Maintenance This traction motor is designed for use up to 4 000 ft altitude and at temperatures between 15 F and 100 F This motor can work properly with a voltage produced by batteries in series Never keep the motor running idly Any mud sand and other clinging objects should be cleaned away so as to provide good heat radiation Check the carbon brush every three months change the worn carbon brush and weaken carbon brush press spring Trouble Shooting for Motor WARNING Only a qualified electrician should change and adjust the carbon brush and commutator Item Symptoms Possible Causes 1 All copper plates turn black The pressure of brush is incorrect 2 The commutator turns Short circuit in the commutator or armature coil black in a certain order and poor welding or disconnection between the in groups commutators and the armature coil 3 The commutator turns The central line of the commutator deviates or its black in disorder surface is not round and not smooth 4 The brush wears out turns The motor vibrates the clearance between the brush and its holder is too big the clearance between the 18 colors and become broken brush and commutators is too big the mica between different comm
13. it need not be fully discharged before recharging e Ifthe vehicle is going to be kept unused for a certain long time the battery should be fully recharged first After that the battery should be fully recharged every 2 weeks e When driving the driver should be always aware of the drop level of the battery power from the battery power meter any drop means the battery power is diminishing The driver should estimate the distance needed to be taken and recharge the battery at a proper time in case that the vehicle cannot get back to the recharging station in time for recharging WARNING Make sure the battery is recharged before the battery power meter shows 20 power is left inside the battery An over discharged battery will have a shortened service life and will make recharging difficult WARNING During recharging the vehicle should be parked in a well ventilated area with the fill caps tightly secured Keep far away from any flame and sparks to avoid any explosion or fire that could cause physical injury or damage to the property During recharging always lift the seat bottom to Keep the battery compartment open to the air 13 Watering Flooded batteries need water More importantly watering must be done at the right time and in the right amount or else the battery s performance and longevity suffers Water should always be added after fully charging the battery Prior to charging there should be enough water to cover
14. lease always check the status of this switch to make sure that it is on OFF position Digital Combination meter Please refer to following figure System Voltage Speedometer Working Current Rotation Speed Range Battery Power Meter Operational Process Starting the vehicle e Select F for Forward or R for Reverse from F amp R Switch e Switch on Power Key e Release the Parking Brake lever e Step down on the Acceleration Pedal smoothly WARNING e Ifyou switch on Power Key first before selecting Forward or Reverse on F amp R switch the vehicle will not run In this case please switch off Power Key select Forward or Reverse and step down on the Acceleration Pedal to start the vehicle e Ifyou step down on the acceleration pedal before switching on the power key the vehicle will not run Stopping the Vehicle e Step on the Brake Pedal to decelerate the vehicle until it stops completely and shift F amp R switch to the Neutral position e Engage the parking brake lever to park the vehicle e Release the service brake e Switch off all lights e Switch off the power and take out the key Charging the batteries CAUTION e There are two different kinds of charger for you to choose an exterior charger and a built in on board charger Before you use the charger please read the charger operation manual e Explosive hydrogen gas is produced while the batteries are charged Only charge in well ventilated areas e B
15. ly in place Clean the battery top with a cloth or brush and solution of baking soda and water When cleaning do not allow any cleaning solution or other foreign matter to get inside the battery This should be done every week e Clean battery terminals and the inside of cable clamps using a post and clamp cleaner Clean terminals will have a bright metallic shine This should be done as needed e Reconnect the clamps to the terminals and thinly coat them with petroleum jelly Vaseline to prevent corrosion WARNING Before you disconnect any battery cable from any terminal on the battery please always remove the power by disconnecting the main battery cable from the controller Checking the terminals and nuts The connection of the battery should always be kept in good condition Check weekly on whether any battery cable terminal or nut has become loose in order to prevent sparks or damage to terminals Check weekly on whether any battery cable is damaged and a damaged battery cable should be replaced immediately 12 Foreign matter Do not place any objects on the battery and do not connect the positive pole to the negative pole This may cause a short circuit dangerous sparking or damage to the battery or injury to your body Recharging e As long as you use the vehicle regardless of how long you have used it the battery should be recharged fully on the same day Note the lead acid battery does not develop a memory so
16. n t exceed 2 3 of the full free pedal travel e The clearance for the brake plate is self adjusted Under a force of around 20kgs the parking brake handle should be fixed in one gear from 5 to 10 ratchet When the brake handle is released completely the brake function will stop e Inspect and change brake shoe add lubrication into the brake bearing periodically Lubrication of the Whole Vehicle e Use 901 vehicle brake oil DOT3 as brake oil e Use 1L of 85W 90GL lubrication oil for gear box e Use 1L of 90GL hypoid gear oil for the rear axle e Lubrication points a steering gears b horizontal bars c steering ball joints d bearings 20 Lubrication Notes To avoid any damage on the brake shoe handbrake should be released before staring the vehicle The lubricant for rear power assembly must be applied and changed as per user s manual The brake system must be adjusted once every 3 months The electricity system must be checked once every 3 months especially main circuit for its fastening parts and wiring connections Meanwhile the contactor should be checked any defective parts should be replaced immediately Its dust should be cleaned by low pressure air The electric contactors easily become hot if their mutual contact is not in good condition so special attention should be paid regularly to the electric contactors When changing the fuse make sure that the new fuse is right in rated current For safety disconnect
17. n Transmission cross shaft wear out Change Abnormal sound Gear of transmission wear out or when running damage Change Transmission System Flange bearing damage Change Motor bearing damage Change Gear liquid is deficient or empty Add Gear liquid Hard to shift gear Clutch cannot separate smoothly Adjust and or gear shift Gear shift cable damage Change jumps in different 26 positions Gear inside transmission case wear Change out Orientation pin loosen Change Check the pressure Pressure of front tire is deficient and Inflate Screw plug of Redirector is too tight Adjust Lack of lube in redirector Maintain add lube Toe in abnormal Adjust Steering heavy Clearance of tension rod ball is too Change big Steering knuckle and master pin is Add Lube not lubricating Steering System Steering shaft or its plastic cover Change wear out Rack of redirector wear out Change Redirector Screw plug of Redirector is too tight Adjust Toe in adjust improperly Adjust Steering unstable Bearing of front wheel wear out Change Tie rod ball and joint wear out Change tie rod Redirector loose Tighten The pressure of the two front tires is Inflate different Driving System Deflected Running Toe inis too big or too small Adjust Tightness of the left and right drum Adjust bearing of front wheels is different 27 Brake of one wheel is
18. nts of the contactor are in good condition and check if any contact sticks or is jammed mechanically e Check if the micro switch in the accelerator can be switched on and off properly 19 e Checkifthe turn signal switch can be switched on and off properly e Check if all the connections between the motor the battery and the controller are in good condition Please use the following cleaning procedure for routine maintenance e Turn the power key to OFF position e Remove power by disconnecting the battery e Discharge the capacitors in the controller by connecting a load such as a contactor coil or a horn across the controller s B and B terminals e Remove any dirt or corrosion from the connector areas The controller should be wiped clean with moist rag Dry it before reconnecting the battery The controller should not be subjected to pressured water flow from either a standard hose or a pressure washer e Make sure the connections are tight but do not over tighten them NOTES All above checks shall be performed under power off Above checks shall be carried out once every 3 months after the power key turns off the wave filter capacitor in the controller unit shall keep discharging for a few minutes more don t wash the electrical parts with water It is allowed to remove dust with a brush or high pressure air Brake System Maintenance e Step the brake pedal with a force of 30kg or so the pedal travel should
19. r cylinder is Change ineffective Parking brake is ineffective Change spring Shoes distort Change Brake facing wear out Change Braking noise Brake drum breach scrape to Change uneven This manual tries to be as sound and elaborate as possible in literal and figurative description as well as technical description on the basis of existing data At the same time JH Global reserves the right to alter the content of this manual and this manual is subject to change without prior notice in addition JH Global has the final say on the interpretation of this manual All rights reserved 29
20. rd voltage level s e Put battery s on a complete charge e Take specific gravity readings again If any specific gravity readings still register low then follow the steps below e Check voltage level s e Perform equalization charge Refer to the Equalizing section for the proper procedure e Take specific gravity readings again 15 If any specific gravity reading still registers lower than the factory specification of 1 277 007 then one or more of the following conditions may exist 1 The battery is old and approaching the end of its life 2 The battery was left in a state of discharge too long 3 Electrolyte was lost due to spillage or overflow 4 A weak or bad cell is developing 5 Battery was watered excessively previous to testing Batteries in conditions 1 4 should be taken to a specialist for further evaluation or retired from service Open Circuit Voltage Test For accurate voltage readings batteries must remain idle no charging no discharging for at least 6 hours preferably 24 hours e Disconnect all loads from the batteries e Measure the voltage using a DC voltmeter e Check the state of charge with Table 1 e Charge the battery if it registers 0 to 70 charged If battery registers below the Table 1 values the following conditions may exist e The battery was left in a state of discharge too long e The battery has a bad cell Batteries in these conditions should be taken to a spe
21. the plates If the battery has been discharged partially or fully the water level should also be above the plates Keeping the water at the correct level after a full charge will prevent having to worry about the water level at a different state of charge Depending on the local climate charging methods application etc it is recommended that batteries be checked once a month Important things to remember e Do not let the plates get exposed to air This will damage corrode the plates e Do not fill the water level in the filling well to the cap This most likely will cause the battery to overflow acid consequently losing capacity and causing a corrosion e Do not use water with a high mineral content Use distilled or de ionized water only WARNING The electrolyte is a solution of acid and water so skin contact should be avoided Watering procedure e Open the vent caps and look inside the fill wells e Check electrolyte level the minimum level is at the top of the plates e Ifnecessary add just enough water to cover the plates at this time e Put batteries on a complete charge before adding any additional water refer to the Charging section e Once charging is completed open the vent caps and look inside the fill wells e Add water until the electrolyte level is 1 8 below the bottom of the fill well e A piece of rubber can be used safely as a dipstick to help determine this level e Clean replace and tighten all vent
22. ure of Operation System Power key Digital combination meter F amp R switch CD player Brake pedal Steering wheel pa Hand brake lever Acceleration pedal headlight switch Turn Signal Switch Functions of Operating System Power Key Controls the power supply of the whole vehicle When the key is inserted and turned clockwise it will switch on lights horn and the control system when the key is turned back the power will be switched off 6 Acceleration Pedal Controls the speed It should be depressed slowly The vehicle speeds up with the gradual depressing and reaches full speed when the pedal is stepped down completely The vehicle slows down when the pedal being released gradually When the pedal is fully released electric brake works Brake pedal Decelerates and stops the vehicle F amp R switch This switch is a three position button Pressing the upper part causes the vehicle to move forwards while depressing the lower part causes the golf car move in reverse and the middle is neutral NOTE The buzzer will beep when the Reverse is pressed Parking brake Lever Park and brake the vehicle Steering Wheel Controls the driving direction Headlight Switch Controls the headlights Turn Signal Switch Controls the turning signal Wiper amp Horn Switch Controls the wiper and horn Emergency Stop Switch Stops the power of the whole vehicle in case of an emergency NOTE Before you switch on the vehicle p
23. utators extrudes the brush is made by wrong materials the brush is wrong in type 5 Sparking The motor is over loaded the commutators are not clean not round or not smooth mica or some commutators extrude the brush is not ground properly the brush is big in pressure the brush is wrong in type the brush is jammed in the brush holder the brush holder become loose or vibrating the polarity and sequence of magnetic poles become wrong 6 The brush and its wires get hot Sparking of the brush poor contact between brush and soft wires small section area of soft wires 7 The brush is noisy The surface of the commutators is not smooth Speed Controller Maintenance The speed controller of the vehicle uses high frequency MOS technology to accomplish the control of speed torque and brake with smoothness silence high efficiency The speed controller prevents the vehicle from running way when starts When the vehicle starts the controller will inspect the signal from the accelerator if signal exceeds 20 the HPD protection unit in the controller will prohibit the output of controller When the vehicle starts the SRO protection unit in the controller will effect The controller will self check when the vehicle is running If any defect is inspected the controller will stop the vehicle to protect the operator and the vehicle Periodical Maintenance e Check if the contacting poi
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