View the User Manual - Star Electric Vehicles
Contents
1. Front rear tread in 37 39 Brake Distance ft 10 Charger 48V 18A Charging time hours 8 10 Roof Installation Pre Installation preparation Check the kit list as per below 1 Backrest 2 Rear lid 3 Windshield trim cover 4 Roof kit 5 Backrest bracket 6 Rear column Right fe 7 Rear column Left Installation procedure First step Put the rear columns right and left into the corresponding holes Attach it to the chassis by M10 bolts Then install the backrest bracket with a M6 40 round screw tighten Second step Install the backrest and rear box according to the location shown left Attach the backrest by 4 M8 hex bolts and attach the rear box by the M5 oversized head break mandrel rivets Put the windshield trim cover to the location shown left for next installation Third step Install the roof and windshield Attach it with M8 45 Hexagon bolts at the indicated location Ensure the correct position after tightening all connections Take caution during the installation to avoid surface scratches or other damages of parts Operations Dashboard 1 Combination switch 2 Key switch 3 Dash display 4 Steering wheel 5 Glove Box 6 Cigarette lighter 7 High Low speed switch 8 Light switch 9 Accelerator pedal 10 Brake pedal 11 Parking brake pedal 12 F R Switch 1 High Beam 2 Left turn signal 3 Battery indicator 4 Speed 5 Right turn s2. Electric Vehicles Owner s Manual and Service Guide ACcel 2 DC and ACcel 2 AC May 2014 Notes Only authorized persons should be allowed to operate the vehicle It is recommended that the only persons allowed to operate the vehicle possess a valid motor vehicle driver s license Don t depress the accelerator pedal and parking pedal at the same time or it will damage the controller system and motor Release the parking pedal before starting the vehicle or it will damage the brake system as well as other parts Don t modify the vehicle or the performance and lifespan of the vehicle will be affected and can cause safety issues Don t add any electronic equipment such an on board phone to avoid interference with the control system Don t overload Table of Contents Specifications Roof Installation Operation Operation layout Dashboard Switches Pedals Charging Cigarette lighter User information Driver information Driving Operation procedure Safety Driving on slopes Parking notes Before initial use Maintenance Battery maintenance Charging the battery group Brake system maintenance Steering system maintenance Motor maintenance Lubrication maintenance Maintenance schedule Troubleshooting After Sale Service Monthly Maintenance Record Electrical Diagrams oO ODO FAN NN FW NN YN FP FP SB BP BP BP BP BP PP PB PP oP oP m NrPFRoOoONAnunuuiunwoenNNeeRP OC CO OO Vehicle Specifications AC
3. driver should operate vehicles in approved areas Driving Operation Procedure 1 Insert the key and turn it to ON position 2 Press the green head of the direction selector to the forward position 3 Release the parking brake and press the accelerator pedal The speed will get increase as pedal is pressed downwards 4 When stopping the cart release the accelerator pedal and depress the brake pedal slowly Then push down the parking pedal after stopping 10 Safety Release the parking pedal before driving to avoid any damage of the brake shoes or motor Don t depress the accelerator pedal too aggressively or frequently or it will shorten the life of the accelerator and controller system Don t start stop or turn in high speed Do not pass other vehicles traveling in the same direction at intersections blind spots or at other dangerous locations Avoid running over loose objects potholes and bumps to avoid the damage of the vehicle and the surroundings or hurting passengers Please observe and obey all traffic regulations including the carry capacity requirement authorized speed limits and other marks Keep a clear view of the path of travel Observe other traffic and pedestrians and maintain a safe distance based on speed of travel from a vehicle ahead Driving on Slopes Ascend or descend grades slowly Do not turn around when driving on a slope Be careful when driving near to the edge of the s
4. oil is low The gear oil should be changed once a year User can choose gear oil according to the climate e Summer GL 4 90 e Winter GL 80W 90 Replace the grease for the rear axle once a year using recommended oil type GL 5 90 and GL 5 80W 90 Fill the level to 1 2 liters 40 oz When changing first twist down the oil plug to discharge the gear oil Clean the oil plug and replace it then inject the new gear oil 16 Maintenance Schedule Item weekly monthly quarterly Check tire pressure Check tires for abrasions Check tightness of the bearing bolt and the tire nut Tire rotation Check braking and the parking function Check brake tube for leakage Check if brake shoes are worn Check if steering wheel works freely Check brake pump Check tightness for the turning ball joint and rod Check nut on the steering rack s spindle Check tightness of steering rack and bracket Inspect and adjust front wheel s toe in Checking tightness of front absorber and helix spring Check height of electrolyte Check density of electrolyte Check if the battery s pole is loose Clean battery pole by water Check light and relay performance Clean and fix wiring connector Check and adjust front tire s bearing Check or replace transaxle Check performance of gearbox and bearing after the first Check motor s bolts and nut
5. 5i sui wb Xoerq on q g Tg Pie pu yh 145 1ubr iub Suum fuum Suum Gum uneg Suyeaq P 2j aafeqd qo woy woy eal 102 woy Jea wo 1221 12a sea pe3 MoT Toa M A oyw woy quf yel NI y you Ern wi ual Wu yal jo o o umo1g 4 19 uwolg 91TQg 19 4 UooId MOTTO 5 1 AUB MO O 15 A K98 U99 I 3419 9 ony q pot TQ M Aoi pat 15 N OT Tym pat K Y o d nd 4 OI NEM A ups uou s yB Juo I pea y 38 es asueto yq g 9118AUO2 Aq zv du vor end q 24
6. ance the air pressure The front and rear wheel are not aligned Correct the assembly of the wheels Turning is difficult Tire pressure is too low Inflate tires Shaft is short of lubrication Add lubrication The direction shaft pin or joints are damaged Replace parts Turning excessively Tie rod is damaged Replace part Steering rack has not been adjusted well or abased Adjust or replace The direction shaft is Tighten direction shaft Lack of power slow response loose Low battery power Charge the battery Damaged drive gear Replace Speed control system is faulty Maintain speed control system Rear bearing is leaking oil Axle of the tire or the washer is damaged Replace parts Too much oil Reduce oil quantity 19 Abnormal noise Drive gear or the bearing is damaged Replace part Bearing of front or rear suspension is damaged Adjust or replace Wheel screw is loose Tighten Motor s bearing is damaged Replace part Low braking power Brake drum is damaged Replace part Brake shoe is not clean Keep clean These possible causes are just for your reference and do not include all causes that result in these listed issues After Sale Service Star EV will provide the friendly service and technical support for the users Users can report faulty proble
7. cel 2 AC Passengers 2 Battery group 48V 8 x 6V Trojan 105 Motor 7 HP KDS AC 64 PPR Encoder Controller power Curtis 48V 450 Amp AC Top speed mph 19 5 20 25 LSV Load Capacity Ibs 660 Weight including battery lbs 1360 Dimensions in 96x48x73 Ground clearance in 5 Turing Radius ft 11 Wheelbase in 66 Climbing capacity 30 Front suspension A arm style independent suspension Steering system Rack and pinion Brake system 4 wheel disc with mechanical foot e brake Tire size 205x50 10 CST DOT Tire pressure psi 30 Drive train Direct rear drive with 10 25 1 ratio Front rear tread in 37 39 Brake Distance ft 10 Charger 48V 17A Charging time hours 8 10 ACcel 2 DC Passengers 2 Battery group 48V 8x 6V 225AH Motor 5 9 HP KDS DC Motor Controller power Curtis 48V 400 Amp DC 1268 Top speed mph 19 5 20 25 LSV Load capacity 600 Weight including battery Ibs 1350 Dimensions in 96x48x73 Ground clearance in 5 Turing Radius ft 12 Wheelbase in 65 Climbing capacity 30 Front suspension A arm style independent suspension Steering system Rack and pinion Brake system 4 wheel disc with mechanical foot e brake Tire size 205x50 10 CST DOT Tire pressure psi 30 Drive train Direct rear drive with 10 25 1 ratio
8. ignal 6 Odometer Key switch C9 Normal park position only at this position can you remove the key Q All the power of your car is connected when key is at this position WARNING Do not take out the key when the vehicle is running Do not leave the key alone especially with children to avoid any accident Forward Backward switch The switch has three positions The vehicle goes forward when FWD is pressed down and backward when REV is pressed down When the switch is unmoved the vehicle is in the neutral position WARNING Strictly prohibit shifting forward and backward directly when the system is running or it will damage the transmission system Combination switch Turn the bar on the end of combination switch to turn on or off the lights The small lights and head light will be on when on this position All lights will be off when it is on the OFF position When the ignition light is on ACC or ON position pulling the switch forward will signal right Pushing it backward will signal left Pedals Depress the accelerator to move forward and backwards Depress the brake pedal to lower the speed until the vehicle stops Put down the parking brake pedal to engage the parking brake press again to release WARNING Before leaving the cart put the Forward Backward switch in the neutral position to park The Forward Backward switch should be on neutral position when releasing the parking as well Before running
9. lope Please keep at least a wheel distance from the vehicle to the edge of the platform Parking Notes Park the cart on the flat and solid ground Depress the brake pedal Keeping the direction switch in neutral position turn off the ignition switch and take out the key Fix the wheels when parking the cart on the slope 11 Before Initial Use Read understand and follow the safety label on the instrument panel Be sure you understand how to operate the vehicle its equipment and how to use it safely Maintaining good performance depends to a large extent on the operator New Vehicle Inspection Before a new vehicle is put into operation the items shown below must be performed 1 Check status of each spare part especially the screw and nut on the steering wheel and brake 2 Check for any leakage problems with the steering system turning system and transaxle 3 Check the electrolyte level of the battery 4 Check if tire inflation is correct Low pressure will lead to difficulty turning and bumpy riding 5 Check if there is any damage between the wiring and other locations where pieces rub against each other Maintenance Turn off the electricity take out the key and engage the parking brake When working underneath vehicles please use jack and triangle wood to fix the front and rear wheels in order to avoid accidents Keep the maintenance area clean and safe Please perform vehicle maintenance according t
10. ms by telephone fax and email Keep Star EV informed for the model number VIN number estimated delivery time contract number and date as well as a detailed description or photos of the faulty parts and problems and our team will handle it accordingly Do not disassemble 20 Monthly Maintenance record Record VIN NO Date Normal Abnormal Remarks Is tire pressure normal Are wing nuts tightened Is the batteries liquid level normal Any batteries or controller motor wirings loose Is the controller system normal Is the fixed screw for the steering system normal Are the wiring connectors clean Are the body and the frame of the vehicle normal Are the front axle and rear axle normal 21 Electrical Diagram for AC Controller 62 82 S2 01383u02 ureqy Burzzng P ema Iqeua 31507 ueipixny 40 0IN SV UMAS hey al J0jEJ9 922P e utjonpu 2s yns o D5o 10je2iIpul Asayeg 101 u03 Ajddns J9 Od 22 apeg a9 407 30 131 014U09 SIZE hw ae my w X VH Bunyed Ajddns uueye pajqeua samod pzemuoa asis eu Aqpueis uonnea peiqeue 103113992 10 58juo5 pajqeua 10 amp 2iput 101 u09 Buizzng 21804 Kreiixny yeg siepad s2uejonpuj uen hay Aueneg Ajddns samog Gnid eBaeu Electrical Diagram for DC Controller 23 Jada vbi 1i ET 1
11. n rain or hot weather Don t overcharge the battery or it the electrolyte will expel from the battery which can damage the vehicle and the storage performance of the battery Ensure that the AC power is consistent with the input power After connected the green light indicates the vehicle is charging The red light indicates that charging is complete At this time the power will be cut off automatically to avoid overcharging Charging should be monitored NOTE Don t remove the plug connected to the vehicle prior to disconnecting from the AC power source Brake System Maintenance Adjust the gap between the brake drum and brake shoes Dial up the adjusting ratchet wheel of the brake drum until the V wheel cannot turn freely then dial down the ratchet wheel 7 8 i A teeth A lt s Steering System Maintenance Check if there is any damage to the dust cover of the tie rod A broken dust cover will let water in and damage the tie rod and the steering system will not be flexible Replace a new one immediately once a worn one is found Make sure the front wheel toe in is between 3 5 mm 1 8 3 16 If it exceeds this value adjust the tie rod screw stem 15 Motor Maintenance Keep the motor surface clean at all times Clean the surface with a dry cloth Avoid any water entering into the motor Lubrication maintenance Check the brake once a month Fill it full if the
12. o safety guidance No smoking in the working sites The facility of extinguishing fire should exist in the working sites Don t use fire to check the height and leakage of the electrolytes in the reserve battery Don t use the flammable liquids to wash off parts 12 Maintain the ventilation of working sites Check and maintain under safe working conditions Check and maintain the braking steering speed direction control system emergency facilities head rear lights controller and safety equipment Check the battery cover as per the right methods Battery Maintenance The batteries for this vehicle have high current high capacity and a long lifetime To keep the vehicle in good performance it is very important to maintain it in the correct procedure The connectors on the batteries are the output connectors Keep the area clean and dry with no foreign matter or dust on it or the leakage or short circuit This will shorten the battery life or possibly burn it out WARNING Don t let tap water enter the battery Check the height of the electrolyte periodically Check it once per week in summer and once every two weeks the rest of the year Standard height level is 10 15mm higher than the battery plate If is too low please add the recommended distilled water or liquid Keep the wiring well connected After using the vehicle initially for 2 3 days the completed inspection for all connectors should be carried
13. out Inspect the vehicle once a week following Any loose or rusty connectors should be fixed Loose or rusty connectors can cause high temperature damage or possible sparking NOTE Don t over tighten terminals Charge the battery immediately after discharge or it will affect the battery life Keep the filling water container clean so no impurities will be put into the battery When the environment temperature is under 40 F the density of the electrolyte after charging is 1 28 1 29 g cm If it is more than 1 30 g cm the battery can be damaged badly Add water immediately to keep the electrolyte value to normal If the battery discharges by 8096 the electrolyte is between the range 1 13 1 15 g cm charge it immediately At this range the vehicle can only last 2 3 mi Don t discharge any longer or it will damage the battery Charge the battery fully before storage Charge it at least once a month for 24 hours 13 Battery Replacement Replace the batteries immediately when it approaching to the battery life as the capacity will decrease quite fast and can t meet the range requirement The detailed replacement way can be consulted with the supplier Remove battery hold downs and cables Lift out batteries with a commercially available lifting device If the batteries have been cleaned and any acid in the battery rack area neutralized as recommended no corrosion to the battery racks or surrounding area should be pre
14. s Clear and lubricate front wheel bearing Checking motor bearing Lubricate other parts use general oil 17 Troubleshooting The authorized qualification for repair the requirement for application safety and the maintenance requirement should be the same Problem Possible reason Processing methods Cart cannot move Operation procedure is wrong Refer to user manual Wiring connector is Cut off the power remove the nut eroded clean the connector and replace the nut Battery power is low Charge the battery Direction switch is Replace part damaged Accelerator is damaged Replace part Direction contactor is damaged Replace part Wiring is loose Repair or replace parts Vehicle moves slowly and or stops when climbing Vehicle is overloaded resulting in the shutting off the controller when temperature reaches 167 F Lighten the load of the vehicle to decrease the temperature Releasing the accelerator pedal does not slow down the vehicle The spring for the accelerator pedal is broken and the pedal cannot reposition Shut off the ignition lock step on the parking pedal then contact with the supplier 18 No indication LEDs on the dashboard Parts are loose Lock the inserted parts Fuse is burned out Replace the fuse Bumpy riding The tire pressure is unbalanced Bal
15. sent Any corrosion found should be immediately removed with a putty knife and a wire brush The area should be washed with a solution of sodium bicarbonate baking soda and water and thoroughly dried before priming and painting with a corrosion resistant paint The batteries should be placed into the battery racks and the battery hold downs tightened to 45 55 in Ibs 5 6 Nm torque to prevent movement but not tight enough to cause distortion of the battery cases Inspect all wires and terminals Clean any corrosion from the battery terminals or the wire terminals with a solution of sodium bicarbonate baking soda and brush clean WARNING To prevent battery explosion that could result in severe personal injury or death extreme care must be used with aerosol containers of battery terminal protectant Insulate the metal container to prevent the metal can from contacting battery terminals which could result in an explosion Use care to connect the battery wires as shown Tighten the battery post hardware to 50 70 in lbs 6 8 Nm torque Protect the battery terminals and battery wire terminals with a commercially available protective coating front of vehicle Battery Connections 14 Charging the Battery group In order to guarantee battery life please use the recommended charger to charge the cart Keep the key switch on OFF position during charging Keep the battery in cool dry location Don t use the charger i
16. the parking brake should be released or it may seriously damage the brake system and related parts Charging Charger Socket Plug one terminal of batter into charger socket see picture and plug the other terminal into main power when recharging the batteries Cigarette lighter The ignition power is DC12V User Information Read the specification of vehicles and use vehicles according to manufacturer recommendation Do not modify the vehicles without manufacturer s approval Any modifications will affect the function and safety of vehicles Any replacements of the spare parts such as changing the battery tires seats and so on shouldn t affect the safety requirements This is a low speed electric vehicle and should be used on approved roads and meet the road regulations Driver information Only authorized persons shall be allowed to operate the vehicle It is recommended that only persons with a valid motor vehicle driver s license be allowed to operate the vehicle The driver should pay close attention to road conditions passerby and the other vehicles on the road Remind passengers not to leave the seats and keep arms and legs inside the vehicle when it is moving Report to related departments once any accidents occur The driver should not modify add or remove any parts of the vehicle Do not add or install any additional handlebar on steering wheel if they are not original design The
Download Pdf Manuals
Related Search