View the User Manual - Star Electric Vehicles
Contents
1. Electric Vehicles Owner s Manual and Service Guide Roadster 2 2 Roadster 4 2 Roadster 6 2 August 2014 Table of Contents Specifications Operation Vehicle layout Dashboard Switches Pedals Charging Cigarette lighter User information Driver information Driving Operation procedure Safety Driving on hilly terrain Parking safety tips 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 aun AUU O NNN 11 12 12 12 12 13 14 16 17 18 Vehicle Specifications 2 2 Roadster 4 2 Roadster 6 2 Roadster Passengers 4 6 8 Hately eieup 48 V 8x 6V Trojan 48 V 8 x 6V Trojan 48 V 8 x 6V Trojan T105 T105 T105 Motor 7HP AC 7HP AC 7HP AC Controller Curtis 450A 1236 Curtis 450A 1236 Curtis 450A 1236 Top speed mph 19 5 20 25 LSV 19 5 20 25 LSV 19 5 20 25 LSV Load capacity Ibs 800 1080 1800 Dimensions in 140 x53 x 46 156x 53x50 187 x 56x50 eo aoe 1205 1580 1300 Ground Clearance in 5 9 5 9 5 9 Turing Radius ft 14 17 19 Wheelbase in 67 95 125 Climbing capacity 25 25 25 Front suspension Leaf spring and shock Leaf spring and shock Leaf spring and shock Steering system Rack and pinion Rack and pinion2. Please see authorized dealer in your area for help The driver should operate vehicles in approved areas Driving Operation Procedure 1 Insert the key and turn it to ON position 2 Press the green forward switch or reverse 3 Release the parking brake by lightly pressing on the accelerator pedal The speed will increase as pedal is pressed downward 4 When stopping the vehicle release the accelerator pedal and depress the brake pedal slowly Then push down the parking pedal after stopping to engage the parking brake Safety Release the parking pedal before driving to avoid any damage to the brake shoes or motor Do not depress the accelerator pedal too aggressively or frequently or it will shorten the life of the drive train and components Do not start stop or turn at high speeds Do not pass other vehicles traveling in the same direction at intersections blind spots or at other dangerous locations Follow all traffic laws Avoid running over loose objects potholes and bumps to avoid damage to the vehicle and possible injury to passengers Please observe and obey all traffic regulations including the passenger and weight capacity requirements authorized speed limits and other regulations 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 hilly terrain Ascend or descend grades sl
3. Rack and pinion Brake system Rear drum 4 wheel hydraulic 4 wheel hydraulic Tire size 225 55 12DOT 225 55 12DOT 225 55 12DOT Tire pressure psi 30 30 30 Wheel type 12 inch aluminum 12 inch aluminum 12 inch aluminum Operation Vehicle Layout 1 2 3 Al 5 6l 7 1 Dashboard 89 2 Steering wheel o J 3 Combination switches 4 CD player optional 5 Brake pedal b 6 Forward reverse switch 7 Accelerator pedal V 8 Key switch 17 9 Cigarette lighter 10 Speakers optional 11 Charger socket 12 Turn signal lever horn and light switch 13 Cup holders Speed gauge mounting point Speedometer Lights on indicator Left turn signal indicator Power display Right turn signal indicator Brake light Low battery voltage alarm light Red when battery voltage is low Turn signal The turn signal lever has a button on the end Push in to sound horn pull lever back to turn on lights High beam The indicator will light up yellow when high beams are on 3 Switches Key switch amp Normal off position key can only be removed in this position Q All power systems are on when in this position WARNING Do not take out the key when the vehicle is running Do not leave key in ignition to avoid theft or accidental operation by a child Forward Reverse switch The switch has three positions The vehicle goes
4. 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 nuts Clear and lubricate front wheel bearing Checking motor bearing Lubricate other parts use general oil 13 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 corroding 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 tempera
5. 12 V DC accessories into outlet Ideal for use of MP3 phone chargers mini fans and other accessories User Information Read all vehicle specifications and use vehicles according to manufacturer recommendations Do not modify the vehicles without manufacturer s approval Any modifications will affect the function safety and warranty of vehicles Any replacements of spare parts by an authorized STAR EV dealer i e changing batteries tires seats etc shouldn t affect the safety requirements Do not attempt to lift the suspension of this vehicle as serious injury could occur and the vehicle will no longer be warranted by the manufacturer This is a low speed electric vehicle and should be used on approved roads and meet the road regulations Carefully review the laws for golf car and low speed vehicle use in the city and state you are operating the vehicle in Driver Information 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 pedestrians and other vehicles on the road Remind passengers to buckle seat belts and keep arms and legs inside the vehicle at all times when itis moving Report accidents to your insurance company The driver should not modify add or remove any parts of the vehicle Do not add or install any optional steering wheel unless they are designed to fit this vehicle
6. damaged Wheel screw is loose Tighten Motor s bearing is Replace part damaged 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 has authorized local dealers that will provide the friendly service and technical support for end users Be sure to visit www starev com to find a dealer in your area Users can report faulty problems by telephone fax and email Keep Star EV dealers informed of 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 16 Monthly Maintenance record Record VIN NO Date Normal Abnormal Remarks Is tire pressure normal Are wing nuts tightened Is the batteries water 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 17 i 1030W SV av JA JOIUOD OSZL Ta YIIMS a KBoL UMS
7. exceeds this value adjust the tie rod screw stem Motor Maintenance The drive motor is an AC motor Keep the motor surface clean at all times Clean the surface with a dry cloth Avoid any water contact inside motor Lubrication Maintenance Check the brakes once a month Fill it full if brake fluid is low in master cylinder The front hub front wheel bearing brake system and steering system should be filled once every year with 3 general lithium based lubricant The gear oil should be changed once a year User can choose gear oil according to the climate Summer GL 4 90 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 12 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
8. forward when FWD is pressed down and backward when REV is pressed down When the switch is centered vehicle is in the neutral position WARNING Do not shift between forward and reverse when vehicle is running or damage to the transmission and or motor can occur Turn signal Push lever up to illuminate right turn signal push down to illuminate left turn signal Headlight switch Pull turn signal lever into back position to turn lights on Push back forward for lights to be in off position Horn Press down the horn button on the end of the turn signal lever to engage horn Pedals Parking brake vee gt A AS aa Accelerator Brake pedal D7 Parking brake The parking brake will click and lock in the down position to indicate that the parking brake is engaged Lightly push on the accelerator pedal to release the parking brake Braking Depress the brake pedal to brake Accelerating Press the pedal and control speed by force applied to the pedal WARNING Before leaving the cart put the Forward Reverse switch in the neutral Before moving forward or reverse the parking brake should be released to prevent serious damage to the brake system and related parts Charging Charger Socket Plug the larger round plug end into the vehicle charge port Plug the power cord end into a standard outlet 110 V to begin the recharging cycle See charging section p 11 Cigarette lighter Plug in any
9. arge the batteries and charge it once again before use See an authorized dealer for further help and maintenance Battery Replacement Replace the batteries immediately when approaching the end of the battery s life The capacity of a battery at the end of its life will decrease quickly and won t meet the standard range miles on full charge Consult with the supplier or dealer for a detailed battery replacement Remove battery tie 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 has been neutralized as recommended no corrosion to the battery racks or surrounding area should be present 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 tie downs tightened to 45 55 in lbs 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 clean with a wire brush 10 WARNING To prevent battery explosion that could result in severe personal injury or death
10. ells Use distilled water only 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 2 higher than the battery plate Ifis too low please add the recommended distilled water Keep the wiring well connected After using the vehicle initially for 2 3 days the completed inspection for all connectors should be carried 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 Charge the batteries that are in long storage or non fully charged separately 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 80 the electrolyte is between the range 1 13 1 15 g cm3 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 Disch
11. 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 wires with a commercially available protective coating front of vehicle Battery Connections Charging the Battery group In order to optimize battery life please use the recommended charger to recharge the batteries Keep the key switch in OFF position during charging Keep the charger in a cool dry location and avoid moisture Charging should be monitored NOTE When disconnecting the charger be sure to unplug cord from AC power source first then unplug cord connected to vehicle 11 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 wheel cannot turn freely then dial down the ratchet wheel 7 8 teeth rea 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
12. fey al oy amp guos wueje ice Ajddns piem sno dnyoeg uoljned pajqeus 40 e19 899e p jqeu s0 e21Ipul BHulzzn 10 4 2e sjepe wepj Buyzzng 31607 uenrxny yoeg sieped suey npu hay Asayeg 18 34511 uje
13. n is correct Low pressure will lead to difficulty turning and bumpy riding Keep the normal air pressure for the tire to prevent premature wear Recommended tire pressure is 30 PSI 5 Check for any worn items between the wiring and other locations where parts rub against each other Maintenance Turn off the electricity take out the key and push down on 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 to safety guidance Refer to STAR EV preventative maintenance schedule or visit an authorized dealer Maintain the ventilation of working sites Check and maintain 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 caps to ensure they are snapped into place 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 Proper care will ensure batteries performance and longevity WARNING Do not use tap water when filling c
14. owly Do not turn around when driving on a sharp incline or decline Be careful when driving near to the edge of the slope Parking safety tips Park the cart on 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 Make sure that the brake pedal is locked in park You will hear a load click when the parking brake is engaged Keep the vehicle stored inside of a garage if possible Don t leave it outside in snow or rain as water can get into the electrical system which will cause damage Check with your local dealer about the advantages of a car cover if you cannot park the vehicle in a garage car port or similar covering 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 proper operation of the vehicle 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 nut on the steering wheel and braking system 2 Check for any leakage problems with the steering system turning system and transaxle 3 Check the water level of each battery Maintain proper levels see Trojan battery guide and do not overfill battery cells 4 Check if tire inflatio
15. ture 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 14 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 Balance 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 15 Abnormal noise Drive gear or the bearing is damaged Replace part Bearing of front or rear suspension is Adjust or replace
Download Pdf Manuals
Related Search