View the User Manual - Star Electric Vehicles
Contents
1. Operation Manual for Electric Utility Vehicle JH1011 or JHU48 02 Thanks for purchasing the products For better use the product please read through this manual and keep them in the safe place for future reference Index 1 Brief Introduction 2 Technical Description 3 Operation System 4 Operational Process 5 Rules of Safe Operation 6 Maintenance 7 Schematic Diagram of the Electrical System 1 Brief Introduction It is a kind of environment friendly industry vehicle developed by our company used in air port sea port yard railway station workshop etc Our electric wagon is an ideal off road electric vehicle with excellent performance low noise pollution free and new design 2 Technical Description Description Electric Wagon Car Type 2 seats Dimensions mm 3475x1390x1 200 Length Width Height Range km h gt 80 smooth and straight road 20km h Maximum Speed km h 30 Minimum Turning 2 9 Diameter m Maximum Gradeability 20 loaded Min distance to ground 110 mm Rated loading capacity 800 kgs 3 Operation System 1 Schematic Figure of Operation System Steering wheel Emergency light Odometer Voltameter Ammeter Acceleration pedal Assembly switch for light Power key Clutch pedal Gear shift handle Brake pedal Parking brake controller 2 Functions of Operating System Power key to master switch of t2. al water and tap water into the battery ONLY the distilled water is allowed to fill in the battery Do not drive at high speed when going downhill slow down the car when turning and remind the passengers to hold on when turning and going downhill Children are not allowed to play in the car children should be seated between adults and cared by adults when the car is running 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 existent data At the same time our company reserves the right to alter the content of this manual and this manual is subject to change without prior notice in addition our company has the final say on the interpretation of this manual All rights reserved First Impression March 2003 First Edition 2003 Products are not in our warranty 11
3. d to use the battery should be recharged immediately Gearshift There is totally 5 positions Forward shift includes 1 2 3 and 4 Reverse shift is R It is recommended to use 1 for climbing use 2 and 3 for flat road It is not recommended to use 4 for driving 4 Operational Process 1 Switch on the power key 2 Step the clutch pedal to the bottom select the right shift and make sure to use right speed when driving Selection standard is to make sure that the working current of motor stays as small as possible as long as this current is enough for driving 3 Release the brake pedal 4 Release the clutch pedal slowly 5 Step down on the acceleration pedal smoothly in this case the vehicle starts running v Warning If you step down the acceleration pedal before switching on the power key the car will not run In this case you should release the acceleration pedal first and step it down again thus the vehicle will start running 5 Rules for Safe Operation The driver should have a good knowledge of the operation system of the vehicle and its features meanwhile follow the rules for safe operation as stated below y Warning Drive the vehicle off road unless it is allowed The vehicle cannot be over loaded otherwise the motor will be damaged the vehicle will lose control and its life will be shortened Unqualified persons are prohibited to drive the vehicle Make sure this vehicle run in its rated climbing ab
4. e control with smoothness silence high efficiency and energy save Periodical Maintenance a Check if the contact between contacting point of the contactor is in good condition check if any contact sticks or is jammed mechanically Check if the micro switch in the accelerator can be switched on and off properly Check if the switch for turn signal can be switched on and off properly Check if all the connections between the motor the battery and the controller are in good condition 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 Trouble Shooting Guide Symptoms Possible Causes The vehicle cannot be started A The controller has no power a There is something wrong with the battery or wire connections b the fuse of power connection is burnt c the resistance for pre charging is broken B No signal is transmitted to the controller a The power key is damaged or its wiring become disconnected The accelerator of the pedal is damaged There is something wrong with acceleration pedal The polarity diode is broken or has short cut The green wire connecting the acceleration pedal and the controll
5. er KSI is disconnected C The contacting point of the contactor becomes stick D The controller of the motor is damaged 2a oo The vehicle can only move forward and cannot be reversed or vice versa A The switch is damaged B The inserts on the commutators become loose C The commutators are damaged 9 Brake System step down the brake pedal with a force of 30kg or so keeping the vehicle moving not more than 2 3 of its rated range 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 this brake handle is released completely the brake function will stop Lubrication and Maintenance of the Whole Car Use 901 car brake oil DOTS as brake oil Use 1L of 85W 90GL lubrication oil for transmission case Use 1L of 90GL hypoid gear oil for the rear axle Lubrication points a steering gears b horizontal bars c steering ball joints d bearings Running in of New Vehicle In order to guarantee the performance of the vehicle and enhance its reliability and working lift all parts in motor should experience a certain period of running in before the motor works with its maximum capacity thus each new vehicle is required to give one month of running in time detail procedure as per the following Check the levels of oil water and liquids carefully before running in and f
6. fore the battery should be checked periodically and the electrolyte should be added in time usually it is only required to add some distilled water At the end of recharging adjust the density of electrolyte to a density of 1 280 0 005 25 C by distilled water or dilute sulphuric acid with a density of 1 400 special for lead acid battery in this case the added liquid cannot exceed the rated volume as specified on the battery After this adjustment the battery should be kept on charging for 0 5 hour to 1 hour to make the electrolyte become uniform everywhere 6 No foreign articles are allowed to enter inside the battery Keep the watering instruments clean to prevent any foreign articles from entering the battery 7 When driving the driver shall keep an eye on the indicator of batter power once the indicator of voltmeter comes to the red section this vehicle should be stopped immediately and the battery should be recharged Besides the driver shall estimate the mileage left to guarantee that the battery has enough power to make this vehicle return to be recharged otherwise the battery will be over discharged and its life will be shortened greatly 8 If the vehicle is out of use for long time the battery shall be fully recharged before being stored after that the battery should be fully recharged once every 0 5 month until the charger switches off automatically 9 During recharging the battery the vehicle shall be parked in a ve
7. h is incorrect The commutators turn black in a certain order and in groups The commutators turn black in disorder short circuit inner commutators or on the armature coil poor welding or disconnection between the commutators and the armature coil The central line of the commutator deviates or its surface is not round and not smooth The brush wears out turns colors and become broken The motor vibrates the clearance between the brush and its holder is too big the clearance between the brush and commutators is too big the mica between different commutators extrudes the brush is made by wrong materials the brush is wrong in type Big sparkles The motor is over loaded the commutators are not clean not round or not smooth mica orsome 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 The brush and its wires get hot big sparkles of the brush poor contact between brush and soft wires small section area of soft wires g The brush is noisy The surface of the commutators is not smooth Maintenance of the Speed Controller The speed controller of the car is wholly imported which adopts high frequency MOS technology to realize the speed torque and brak
8. he electric system When the key being inserted into it and turned clockwise it will switch on lights horn and the control system when the key being turned back the power will be switched off Acceleration pedal to control the speed It should be stepped down slowly The vehicle speeds up with the gradual stepping down and reaches the full speed when the pedal is stepped down to the bottom The vehicle slows down when the pedal being released gradually When the pedal is fully released electric brake works Brake pedal to decelerate or park the vehicle Clutch pedal to control the clutch When driving do not operate it not completely otherwise it will damage the clutch Parking brake controller to park and brake the vehicle Steering wheel to control the driving direction Ammeter to indicate the current of the working vehicle Voltameter to indicate the voltage of battery It ranges from 20V to 60V from left to right including 3 sections highlighted by Red Yellow and Green Green section represents the battery is full in capacity With the consumption of the power the indicator will fall from the right to the left gradually When the indicator comes to the intersection point of the red section and the yellow section it represents that the battery will come to the end in capacity now the battery should be re charged When the indicator comes to the red section the vehicle is prohibite
9. ility Don t overtake other vehicles at crossroad in blind area or in other dangerous zone 6 Maintenance Users should do maintenance as follows which will decide the performance of the car and life of battery Maintenance of Battery 1 The exterior of the battery the connection wires and bolts should always be kept clean and dry If there is any electrolyte it should be wiped off with clean cotton cloth then it should be rinsed by clean water and made dry WARNING During this process water is prohibited to enter the battery otherwise the battery will be damaged 2 The battery must be kept in good connection The tightening nuts for the wiring connection should be checked frequently to see if any nut becomes loose otherwise any loosing nut will result in sparkle or burnt terminals 3 Don t put any article on the battery And never connect the positive pole to the negative pole directly otherwise it will result in short circuit and damage the battery 4 After discharging in spite of the time it has run and the mileage it has run the battery must be recharged on the same day Never leave the recharging to next day or never doing the recharging more than 24 hours otherwise the life of the battery will be impacted 5 During the use of the battery the liquid density will increase and the liquid volume decreases due to the evaporation and electrolysis of water in the electrolyte it happens especially in summer there
10. ill them as requested if insufficient The tire should meet 145 80R12 with the air pressure of 5 5kgf cm During running in time the speed should be limited as follows Current Model EG1011 100A 50A 50A 55A If possible try your best to avoid driving on roads in poor conditions Check and tighten regularly the fixing parts of each connecting points Notes 10 11 Front parking brake should be released to its bottom to avoid any damage on the brake plate 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 the sake of safety disconnect the positive pole from the battery when maintenance is done Never step the accelerator hard and frequently which may shorten the life of the controller It is prohibited to fill any other liquids such as battery addictives miner
11. ntilating place with the battery cover open to avoid any accident 10 After recharging close the battery cover and check whether there is any jam in the outlet if any remove that 11 The life of a lead acid battery is over one year Toward the end of its life the battery capacity will shrink dramatically in this case a new battery should be used Only battery in same brand same capacity and same voltage can be used as a group for the replacement 12 Recharge the battery once each month to make the electrolyte uniform Instructions and Notes for the Use of the Charger An automation oriented design and easy operation Connect the power plug to a power of 110V 60Hz Connect the output plug to the battery When above procedures have been finished the POWER light turns on which indicates that the output and input are in good connection When battery is being charged the WORK Light turns on which indicates that the power output is okay and the charger starts working Some notes during the charging process There are three indicators of 0 E 80 7 100 ghowing how much has been charged and the charger will power off after the battery has been fully charged The charger case is prohibited to be opened during charging Non servicemen are not allowed to open the charger s box The charger should be placed in safe and dry atmosphere with good ventilation The charger should be packed for storage in case
12. of no use for long time During charging the charger will switch off automatically as self protection once the voltage does not stay within 90V 120V meanwhile the alarm light will switch on to remind the user The charger will recover once the voltage comes to the range of 90V 120V 00000 Maintenance of the Transmission Case The clearance for the clutch should be kept between 2 3mm The friction plate should be changed periodically the friction value on one side should not exceed 2mm 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 periodically half year inside the transmission case the kerogen is 85W 90GL WARNING Never mix different oils Maintenance of the Traction Motor This traction motor is designed to use at the sea level not beyond 1200 meters and in a temperature between 25 C and 40 C This motor can work properly with a voltage between 32V and 54V produced by battery in series Q Never keep the motor running idly No explosive gas shall exist in the air Any mud sand and other clinging objects shall often be cleaned away so as to provide good heat radiation Trouble Shooting for Motor Series Symptoms All copper plates turn black Possible Causes The pressure of brus
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