View the User Manual - Star Electric Vehicles
Contents
1. 12 Lifted Vehicle 2 2 Lifted Vehicle 4 2 Voltage v 48V 48V Battery Setup 8pcx 6V 8pcx 6V Dimension mm LxWxH 2950x1340x1990 3500x1340x2100 Range km based on flat road at a speed of gt 0 gt 55 20km h with 22 flat teeth tire Maximum Speed km h for Gear Ratio of 32 for 4kw and 5 3kw motor 32 for 4kw and 5 3kw motor 12 49 1 35 for 4KW AC motor 35 for 4KW AC motor 40 for 56KW AC motor 40 for 56KW AC motor Minimum Turing Diameter m EA CO Maximum Loading Capacity kg Maximum Gradeability Noise dB 13 4 Controls 1 Schematic Figure of Controls Note There are two types of dashboard on the vehicles The cup holder on the 08 amp 09 Style Dashboard is on top of the instrument panel and the cup holder on the 06 Style Dashboard is below the instrument panel Fuse Box Forward Reverse Switch Turn Signal and Horn Switch Ignition Key Steering Wheel Parking Signal option ai ad ke E 2 o I Headlight Button Parking Brake Pedal Service Brake Pedal Accelerator Pedal 08 amp 09 Style Dashboard Turn Signal and Horn Switch Battery Power Meter Forward Reverse Switch Fuse Box les gt Parking Signal Option Steering Wheel Headlight Button Parking Brake Pedal Service Brake Pedal Accelerator Pedal 06 Style Dashboard 15 O ss 3 y 3 x E O Turn Signal and Horn Switch 16 17 12V accessory plug Left headlight an2. breaking force Repair the leakage or 4 The brake pipe leaks replace 5 The brake shoes worr Adjust the brake 6 The brake cable is too long or is blocked cable 1 The brake pedal cannot bounce back Replace a new one smoothly The brake is difficult to release 2 The brake shoe is warped or broken Refit or replace completely 3 There is blockage on the transmission Refit or replace 31 1 The oil seal Is damaged The oil leaks 2 Too much oil Adjust the oil level Wheel Replacement WARNING Before doing anything to the wheel and tire make sure the power key is positioned in the OFF position Read the tire manufacturer s instructions and never exceed their recommendation Protect face and eyes from escaping air when removing the valve core Be sure the mounting demounting machine Is anchored to floor Wear safety equipment when mounting demounting the wheel and tire To remove a wheel on the vehicle 1 Block the wheel then loosen the wheel nuts 2 Use a jack to lift the vehicle then remove the wheel nuts and the wheel To install a wheel on the vehicle 1 Use a jack to lift the vehicle then put the wheel onto the wheel hub 2 Finger tighten the lug nuts then tighten lug nuts to 50 85 ft lbs 70 115 Nm in 20 ft Ibs 30 Nm increments following the cross sequence pattern Cross Sequence 3 3 Remove the jack If the tire is flat remove the wheel and inflate the tir
3. discharging current from the battery to reduce the speed of the vehicle If it fails to charge the battery it will cut the current from the battery and stop the vehicle to force the user to charge the battery Note When the grid voltage is out of range of 90 260V the charger will stop charging At the same time the failure code light will come on When the voltage returns to the correct voltage range of 90 260V it will automatically start to charge Note The charger will automatically start equalizing charge after 30 charging cycles z Maintenance of the Traction DC Motor WARNING Before operating the vehicle make sure that no explosive gases are present in the area as a spark from the motor could ignite the gas and cause serious injury and damage to the surrounding area 1 ForaDU motor the carbon brush should be checked for wear every 3 month as it is an easily worn part If it is not replaced in time before it wears out it will damage the motor 2 Do not keep the motor running idly for long periods of time Any idle running of the motor should be avoided 28 3 Removal of mud sand and other debris should be done frequently 4 Periodically use low pressure air to remove dust from the carbon brush and the commutator Periodically check the connection of the carbon brush and the commutator Main malfunction and possible reason of DC motor Symptoms Possible Causes All copper plates turn black The pressure of brush is i
4. in good condition MAINTENANCE OF BATTERY NOTE Our standard vehicles are equipped with deep cycle flooded lead acid batteries If your vehicle is equipped with other types of batteries follow the maintenance instructions provided by the battery manufacturer Below maintenance instruction is especially for deep cycle flooded lead acid battery 22 WARNING Battery electrolyte is poisonous and dangerous and may cause severe burns or injury Always wear protective clothing gloves and goggles when handling batteries electrolyte and charging your battery KEEP OUT OF REACH OF CHILDREN 1 Cleaning a The exterior of the battery the connection wires and bolts should always be kept clean and dry When cleaning make sure all vent caps are tightly 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 of the battery This should be done every week b 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 c 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 always remove the power by disconnecting the main battery cable from the controller 2 Checking the
5. sure you observe the following safe operation instructions BEFORE OPERATING Read the user manual thoroughly before operating the vehicle Allow only authorized people to operate the vehicle and only from the driver s side Drive the vehicle only in areas where it is allowed by law or local regulations DO NOT allow more people than is permitted on the vehicle DO NOT overload the vehicle otherwise the motor may be damaged The vehicle may also lose control and or the driver and passengers will be in danger if overloaded DO NOT operate the vehicle under the influence of alcohol or drugs DO NOT climb any slope steeper than the vehicle s climbing ability DO NOT overtake other vehicles at crossroads in blind spots or in any dangerous areas WHILE OPERATING THE VEHICLE Keep your entire body inside the vehicle keep seated and hold on while the vehicle is moving Do not start the vehicle until all occupants are securely seated Keep your hands on the steering wheel and your eyes on the path ahead Always back up slowly and watch carefully Avoid starting or stopping suddenly Avoid turning the steering wheel sharply at high speed Always drive slowly up or down on a slope Do not make any modification or addition which may affect the safety of the vehicle 3 Technical Specifications The data below has been confirmed by an independent authority lab Standard Golf Car TEMS Votage 36v _ ry Battery 6pcs x 6V 6
6. 0 for 5KW AC motor 40 for 5KW AC motor of 12 49 1 Minimum Turning Diameter 7 7 m Maximum Loading 320 20 370 Capacity Kg lt 4 fi B Capacity of 3 Loading the rear 210 cargo bed kg Maximum N 20 20 20 Gradeability Noise dB lt 70 7 i s Maximum Brake Distance V 20km h A IN O Utility car based on 4 passenger golf car 4 2 with Jumper 4 seat with Cargo ITEMS 4 2 with Flip Seat Box a 2 seat with Cargo Box Voltage V 48V 48V 48V 48V Batter 8pcs x 6V 8pcs x 6V 8pcs x 6V 8pcs x 6V Setup Dimensions mm 3420 1180 1940 3620 1180 1940 3430 1180 1890 3180 1180 1890 LxWxH Range km based on flat road at a speed of 20km h Maximum Speed km h for Gear Ratio of 12 49 1 Minimum 32 for 4KW DC motor 32 for 4KW DC motor 32 for 4KW DC motor 32 for 4KW DC motor 40 for 4KW AC motor 40 for 4KW AC motor 40 for 4KW AC motor 40 for 4KW AC motor Turning Diameter Maximum Loading Ena adr Capacity of the rear cargo bed Maximum Gradeability Noise 28 Maximum Brake Distance V 20km h Utility car based on 6 passenger golf car ITEMS 6 2 with Jumper Seat 6 2 with Flip seat Voltage V Battery Setup 8pcs x 6V 8pcs x 6V A gt 60 gt 60 gt 5 AC system gt 75 AC system Maximum Speed km h for Gear Ratio of 12 49 1 25 for 5KW DC motor 25 for 5KW DC motor 040 Lifted Vehicle Range km based on flat road at a speed of 20km h
7. Check the exterior temperature of the brake drum 6 Check the breather valve if oil has leaked on the floor below the rear differential 7 Check if the there is any section in the parking brake cable broken or loose and replace if 30 necessary 2 Periodic maintenance The axle should be maintained every month two months and six months Monthly maintenance focuses on lubricate fixation and gear oil replacement Maintenance every two months focuses on check adjustment and gear oil replacement Semiannual maintenance focuses on the cleaning assembly and gear oil replacement 7 Troubleshooting Symptom s Possible cause s Troubleshooting 1 The gear oil is insufficient or used Oil gear or replace improperly 2 The bearing is assembled incorrectly Assemble correctly 3 Adjust the brake shoe pin shim or the Adjust or replace interval The axle Housing 4 The gear between axle 1 and 2 is not se y gear and bearing are tightly connected just correctly damaged and noisy 5 The final drive is too noisy 1 Check if Remove the impurity replace the gear there is any impurity 2 check the if the gear is damaged 6 Axle 1 grinding gears Adjust or replace 7 The rear axle is bent check if it is Replace the rear axle over loaded 1 There Is space between the brake shoes Adjust and drum 2 There is oily dirt on the brake shoes or Remove dirt drum 3 There is air in the brake pipe Dispel the air Lack of
8. Operation Manual for Electric Golf Car and Lifted Vehicle Thanks for purchasing our electric golf car and lifted vehicle This manual contains information for proper operation and maintenance of your vehicle A thorough understanding of this manual will helo you obtain maximum enjoyment from this vehicle Keep this manual handy for future reference Important Information Particularly important information is distinguished by the following notations WARNING Failure to follow Warning instructions could result in severe injury to the vehicle occupants bystanders or persons inspecting or repairing the vehicle CAUTION Failure to follow Caution instructions could cause damage to the vehicle Special Notice Because the seat amp backrest wrapping film may stick to the seat vinyl and cause seat vinyl to fade or stain remove the seat amp backrest wrapping film when you start to use the vehicle Even if you plan to store the vehicle for a long time remove the seat amp backrest wrapping film Pictures for reference Standard Golf Car gt x de a tu el y 4 2 Jumper Seat 4 2 Flip Seat 4 seats Cargo Box 2 seats Dumping Cargo BOX Utility car based on 6 passenger golf car 2 2 Lifted Car 4 2 Lifted Car TABLE OF CONTENTS ONCE Word teta doit ottobre ao oo 5 2 Ale Operation INS IUCN eieee mos cack cos eaahi S eae 6 3 TECNICA Data peer nc ee ne siii 7 OM Seat EE t E E t an E E O r o
9. ake pedal to release the park brake and slowly press down the accelerator pedal If the vehicle is equipped with the hydraulic brake system release the hand brake first before you press the accelerator pedal CAUTION lf the vehicle is equipped with mechanical brake system pressing the accelerator pedal will release the parking brake if it is engaged Pressing the accelerator pedal is not the preferred method of releasing the parking brake Pressing the lower section of the brake pedal is the preferred method of releasing the parking brake to assure the longest service life of brake components If the key switch is ON and parking brake is set pressing the accelerator inadvertently will release the parking brake and will cause the vehicle to move which could cause severe injury or death CAUTION If the accelerator pedal is stepped down before the power key is on the vehicle will not run In this case you should release the accelerator pedal first and then turn the power key ON Then press down the accelerator pedal again and the vehicle will start to move STOPPING To stop the vehicle gradually press down the brake pedal When the vehicle has come to a stop apply the parking brake pedal and turn the power key to OFF and press the F R switch on Neutral position CAUTION Do not hold the vehicle on an incline with the accelerator use the brake 6 Maintenance Users should perform regular maintenance to ensure the vehicle is
10. and tighten regularly the fixing parts of each connecting point 10 Periodic Maintenance Charts 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 parking brake when you do maintenance unless otherwise specified If the owner is not familiar with the maintenance of this vehicle this work should be done by a dealer 1D per day 1W per week 1M per month 1Q perquarter 1Y per year 33 Descriptions Battery 1 Check the liquid level Add distilled water if Y necessary 2 Charge the battery 3 Tighten the nut on the battery cable 4 Check if the battery is over discharged the battery power meter is flashing 5 Check the liquid density of the battery standard density should be 1 277 0 007g cm 80 F or 25 C when the battery is fully charged 6 Check if the battery is charged fully by a using Y the hydrometer or b checking the battery power meter 7 Clean the surface of battery Charger 8 Observe the charging status check if the charger Y plug becomes hot 9 Clean the surface of the charger Do not get any water inside the charger Controller 10 Check that all terminals are tightened properly Do this after the power is off 11 Clean the surface of the controller 12 Check that the solenoid is in order by checking its touching point 13 Ensure that no water gets in and that it does not Y b
11. ay be the result of loose wires contractor wiring should be carefully checked Faults such as overheating may be caused by operator habits or by overloading After a problem has been diagnosed and corrected it is a good idea to clear the fault history file This allows the controller to accumulate a new file of faults By checking the new history file at a later date you can readily determine whether the problem was indeed fixed When checking problems according the flashing of the STATUS light on the top of the controller refer to the details mentioned in our service manual which is available separately Contact your local dealer or a qualified electrician to work on the problems related to the motor controller or electrical system of the vehicle when you are not able to fix them Maintenance of Rear Axle While using your vehicle the rear axle should be maintained daily periodically and randomly 1 Periodic maintenance means the driver should do some daily maintenance before during or after driving The maintenance is focused on clearance and examine as followed 1 Clean the dust and mud on the cover to keep the axle clean 2 Make sure all connections are in good condition Rotate rear tire to see if the gears connecting the motor are rear differential are operating smoothly 3 Make sure the gear is sufficiently oiled 4 Check if there is any gap in the connection and transmission units or any unusual sound inside the axle 5
12. cur and this can cause an explosion of the battery and physical injury Only a qualified electrician should install or replace batteries 8 BATTERY CHARGING NOTE The standard charger on the vehicle is an onboard charger It is either installed in the 26 WARNING Before you use the charger read the operation manual provided with the charger WARNING Explosive hydrogen gas is produced while the battery is charged Only charge the battery in well ventilated areas WARNING Before using the charger check if the battery charger you are using is correctly rated as per your local AC electricity network WARNING When using a new battery make sure the new battery has the same specifications as the Original and is appropriate in application The following is the charging steps 1 Turn the power key to OFF 3 The charger will turn off automatically when the battery is fully charged 5 Do not open the housing of the charger 6 Only a qualified electrician should open the housing of the charger 7 The charger should be stored in safe and dry room with good ventilation 8 The charger should be packed properly if not in use for an extended time 9 Carefully read the operation manual for the charger for detailed operation instructions Equalizing charge Equalizing is an overcharge performed on flooded lead acid batteries after they have been fully charged It reverses the buildup of negative chemical effects like
13. d MN left rear position light Parking signal and Turn signal brake light Right headlight and right rear position light 2 Functions of Controls Power Key The power key is used to switch on the electrical system of the vehicle To engage the motor and start the vehicle insert the key and turn it clockwise to the ON position At this time the 12V accessory system headlights turn signals taillights brake lights and horn will be engaged too To switch the power off turn the key counterclockwise to the OFF position CAUTION When the key is in the ON position it cannot be pulled out DO NOT try to remove the key when it is in the ON position Forward Reverse Switch This is a three position switch The switch is used to shift the golf car into forward or reverse Press the switch up to move forward down for reverse or in the middle for neutral WARNING This switch must be fully pressed into the proper position or the electric system and motor will be damaged NOTE The buzzer will beep when the lower part of this switch is pressed to warning people around your vehicle Accelerator Pedal The accelerator pedal is used to control speed while driving Press it down slowly to increase speed The vehicle will soeed up with the gradual depression of the accelerator pedal eventually reaching top speed when the pedal is completely pressed down The vehicle slows 18 down with th
14. d in a well ventilated area with 23 filling 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 property 5 Battery water maintenance Flooded batteries need water 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 Prior to charging there should be enough water to cover 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 ensure that you will not have to worry about the water level at a different state of charge Depending on the local climate charging methods and application Trojan recommends that batteries be checked once a month until you get a feel for how thirsty your batteries are Important things to remember 1 Do not let the plates become exposed to air This will damage corrode the plates 2 Do not fill the water to the cap This most likely will cause the battery to overflow acid consequently losing capacity and causing a corrosive mess 3 Do not use water with a high mineral content Use distilled water only CAUTION The electrolyte is a solution of acid and water so skin contact should be avoided Step by step watering procedure 1 Open the vent caps and look inside the filling w
15. e lifting of the pedal When the pedal is fully lifted the electric brake will engage and the vehicle will come to a stop Service Brake Pedal The service brake pedal is used for braking The shape of the pedal of the mechanical brake system and the hydraulic brake system is different refer to the figures below NOTE On the mechanical brake system the service brake pedal is combined with the parking brake pedal Parking Brake Pedal Service Brake Service Pedal Step down 2 Step down Mechanical Brake Hydraulic Brake Parking Brake Pedal The parking brake pedal is used in braking for parking The parking brake of the mechanical brake system is different from hydraulic brake system The parking brake of mechanical brake system is engaged by foot as shown in above picture refer to Mechanical Brake The parking brake of the hydraulic brake system is engaged by hand as shown in the figure below The parking brake should be engaged into parking position whenever the vehicle is left unattended Hand Brake How to engage and disengage the parking brake a Mechanical brake system To engage the parking brake press down the service brake pedal completely then press down the parking brake pedal until it locks To disengage the parking brake press down the service brake pedal until the parking brake pedal is unlocked WARNING 19 The foot park brake will automatically release when the accelerator pedal
16. e to the maximum recommended pressure for the tire Immerse the tire in water to locate the leak and mark with chalk Place tire plug according to the manufacturer s specifications Brake Adjustment WARNING If you have any problem with the brakes consult with a dealer Brake failure can result in serious accident or physical danger The brakes on the vehicle are self adjusting Before you operate the vehicle press down on the brake pedal several times to make sure the brakes are functioning properly 32 8 Lubrication 1 Use 1 liter of 90GL hypoid gear oil for the rear end 2 Lubrication points a Spindle assembly driver side and passenger side b Middle shaft c Rear end la L Spindle Passenger Side Spindle Driver Side Rear End Middle Shaft 9 Running in of New Vehicle In order to guarantee the performance of the vehicle and enhance its reliability and working life its parts should experience a certain period of running in before it works under peak load Each new vehicle is required to give one month of running in time or 1 000 kms 620 mi running in distance i Before running in check the capacity of oil electrolyte and brake oil If there is an insufficient amount of any of these refill accordingly li The tire pressure should comply with the rated pressure marked on the tire li Limit the speed of the vehicle to control the current of the vehicle under 40A during driving iv Often check
17. ecome too hot 14 Check if the carbon brush should be replaced 15 Check that the accelerator pedal works well and that it can be released freely and automatically Chassis and 16 Check if the brake drum and the brake shoe body should be replaced 17 Check that the hand brake functions applicable for vehicle with hand brake 18 Check if the hose and tube for the brake liquid leak applicable for vehicle with hydraulic brake 19 Check if the brake liquid inside the brake liquid tank is sufficient applicable for vehicle with hydraulic brake lt a 7 Clean the surface of battery a a 20 Check the air pressure inside the tire check if the tire surface is worn and check that the nuts are tightened properly 21 Check if the shock absorber has any oil leaking or emits an abnormal noise 22 Check if there is oil leaking on the gear box and the rear end pp TT TT nia MN MA 1 mia mia mia LU MEN MIN 124 Adjustthe toein of ine frontend 125 Clean the body and seat OL After above maintenance drive the vehicle to check that the vehicle works properly 23 Add lubricant inside the wheel hub and steering Y system 11 Storage Follow the steps as below when the vehicle Is stored 1 Check the liquid level inside the battery recharge it fully before storing the vehicle WARNING Charge the battery once a month if your vehicle will be stored more than one month 2 Turn
18. ells 2 Check electrolyte level the minimum level is at the top of the plates 3 If necessary add just enough water to cover the plates 4 Put batteries on a complete charge before adding water refer to the Charging section 5 Once charging is completed open the vent caps and look inside the fill wells 6 Add water until the electrolyte level is 1 8 below the bottom of the fill well 7 Apiece of rubber can be used safely as a dipstick to help determine this level 8 Clean replace and tighten all vent caps WARNING Never add acid to the battery 6 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 life span and health Routine voltage and gravity checks will not only show the state of charge but also help spot signs of improper care 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 I Specific Gravity Test Flooded batteries only 1 Do not add water 2 Fill and drain the hydrometer 2 to 4 times before pulling out a sample 3 There should be enough sample electrolyte in the hydrometer to completely support the float 24 4 Take a reading record and return the electrolyte back to the cell 5 To check anothe
19. is located under the seat on the passenger side either on the controller cover or just under the rear body as showed below picture Cont Oller Coy er Tow Run Switch WARNING Whenever the TOW RUN switch is moved from the RUN position to the TOW position move it back to the RUN position there is a delay of approximately 30 seconds before the vehicle will run TURN SIGNAL HORN SWITCH This switch is used to operate the turn signals and horn 1 Lift up the handle lever to activate the horn 2 Push the handle lever up to activate the right turn signal 3 Pull the handle lever down to activate the left turn signal Push forward Pull out Pull down Headlight Switch Pull out the button to switch on the headlight 5 Operation STARTING a With the Forward Reverse switch on the Neutral position turn the power key to ON position CAUTION The car will not run if the F R switch is set to Forward or Reverse position before turning the key to 21 the ON position WARNING Do not step down the accelerator pedal when turning the power key Otherwise the vehicle may suddenly start moving b With the parking brake applied press the Forward Reverse switch and lock it in the desired position CAUTION Do not shift from Forward to Reverse while the vehicle is moving c Make sure that your path is clear If the vehicle is equipped with the mechanic braking system press the lower section of the br
20. is stepped down If the power key is in ON position stepping down the accelerator pedal may suddenly cause the vehicle to move b Hydraulic brake system To engage the parking brake pull up the hand brake lever to the end Engage the hand park brake To disengage the parking brake pull the hand brake lever up completely and press the button on the top of the brake lever Return the brake lever to the down position Press down this button when you pull up the hand lever with the button being pressed down push down the hand lever Disengage the hand park brake WARNING Always release the brake handle completely before driving the vehicle WARNING Do not press both the brake pedal and the accelerator together this will damage the motor Steering Wheel The steering wheel is used to control the driving direction Avoid sudden and sharp turns Battery Power Meter There are 10 calibration marks on the meter The meter will decline from the top to the bottom as the battery discharges When the battery is too low the red indicator light will flash reminding you to recharge the battery 20 NOTE Refer to your Battery Charger s Owners Manual for how to recharge the batteries TOW RUN SWITCH available for Curtis 1266 and 1268 controller Before operating the vehicle make sure the TOW RUN switch is on RUN position Make sure the TOW RUN switch is on the TOW position if towing the vehicle The TOW RUN switch
21. n ta nn 15 SS pera UO a eerste KN ONO o 21 o MAMA Cn an a 22 Ze LNOUDI SSIIO NM dal 31 S etc LL OF ami a r lo i o 33 9 RUNDING TEO New VENICE rinitis dd nuvi 33 10 Periodie Mamtenance Ciara 33 SO A An O Oe 35 12 A A IN 35 1 Overview Our vehicle is environmentally friendly and it can be used as people mover or utility car WARNING Always confirm whether there are restrictions in the area where you intend to use the vehicle It is recommended that only people who possess a valid motor vehicle driver s license be allowed to operate golf cars IMPORTANT LABELS SAFETY LABEL Read carefully and understand the contents on the safety label WARNING Failure to comply with all safety warnings may cause bodily injury to the vehicle operator and or passengers Keep entire body in vehicle and hold on when vehicle is in motion Only qualified people should operate this vehicle Do not operate this vehicle while under the influence of drugs or alcohol lake sure all passengers are securely seated before driving Apply park brake into the locked position when the car 15 parked or unattended The label above is attached on the dash panel as below Vehicle Information Name Plate The name plate is either on the back of the seat pod Fig 1 or below the dashboard Fig 2 Fig 1 Fig 2 Chassis number of the vehicle 2 Safe Operation Instructions Our vehicle is designed for simple operation however make
22. ncorrect The commutating copper Short circuit between the commutating copper and the armature turns black in a certain order coil poor welding or disconnection between the commutating and in groups copper and the armature coil The commutating copper The central line of the commutator deviates or its surface is not turns black randomly round and smooth 4 The brush wears out The motor vibrates the clearance between the brush and its holder changes colors and breaks is too big the clearance between the brush and commutator is too big the mica between different commutator extrudes the brush is made with wrong materials the brush is wrong in type The motor is over loaded the commutator is not clean round or smooth mica or some commutator extrude the brush is not ground properly the brush is the wrong type the brush is jammed the brush holder is loose or vibrating the polarity and sequence of magnetic poles is wrong The brush and its wires get Sparks from the brush poor contact between brush and soft wires hot small section area of soft wires The brush is noisy The surface of the commutator is not smooth Maintenance of the Traction AC Motor If your vehicle is equipped with AC motor then the motor is maintenance free Maintenance of the Controller CAUTION Only qualified electrician is allowed to perform maintenance for the controller WARNING There are no spare parts available inside the co
23. ntroller No attempt should be made to open repair or otherwise modify the controller Doing so may damage the controller and will void the warranty 29 CLEANING It is recommended that the controller be kept clean and dry and that its fault history file be checked and cleared periodically Periodically cleaning the controller exterior will help protect it against corrosion and possible electrical control problems created by dirt grime and chemicals that are part of the operating environment and that normally exist in battery powered systems Use the following cleaning procedure for routine maintenance 1 Turn the power key to the OFF position 2 Remove power by disconnecting the battery 3 Discharge the capacitors in the controller by connecting a load such as a contactor coil across the controller s B and B terminals 4 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 cleaned with pressured water flow from either a standard hose or a power washer 5 Make sure the connections are tight but do not over tighten them Fault History File The handheld programmer to be ordered separately can be used to access the controller s fault history file The programmer will read out all the faults the controller has experienced since the last time the history file was cleared Faults such as contactor faults m
24. pcs x 8V 8pcs x 6V 6pcs x 6V 8pcs x 6V 8pcs x 6V Setup 6pcs x 8V km h based on flat road at a speed of 20km h Maximum Speed km h for Gear Ratio of 12 49 1 Maximum Speed km h for Gear Ratio of 10 25 1 Minimum Turning Diameter m 2350 1180 1800 25 for 3KW motor 32 for 4KW motor 27 for 3KW motor 40 for 4KW motor gt 80 gt 100 AC system 32 for 4KW DC motor 32 for 3KW AC motor 40 for 5KW AC motor 40 for 4KW DC motor 3110 1180 1890 25 for 3IKW motor 32 for 4KW motor 27 for 3KW motor 40 for 4KW DC motor gt 80 gt 100 AC system 32 for 4KW DC motor 32 for 3KW AC motor 40 for 5KW AC motor 40 for 4KW DC motor 3860118071940 gt 70 gt 90 AC system 32 for 4KW DC motor 40 for 4KW AC motor 40 for 5KW AC motor Maximum Loading Capacity Kg Maximum 20 20 20 20 20 rej 20 3KW AC system wep Brake lt 4 Distance V 20km h Utility car based on 2 passenger golf car ITEMS 2 2 with Jumper seat 2 2 with Flip Seat 2 seats with Cargo Box Voltage V Batter 6pcs x 6V 8pcs x 6V 6pcs x 6V 8pcs x 6V 6pcs x 6V 8pcs x 6V Dimensions mm 2670 1180 1890 2870 1180 1890 2680 1180 1800 LxWxH Range km based on flat road at gt 100 AC a speed of system 20km h Maximum Speed 32 for 4KW DC motor 32 for 4KW DC motor 32 for 4KW DC motor km h for 21 32 for 38KW AC motor 21 32 for 3KW AC motor 21 32 for 3KW AC motor Gear Ratio 40 for 5KW AC motor 4
25. r cell repeat the 3 steps above 6 Check all cells in the battery 7 Replace the vent caps and wipe off any electrolyte that might have been spilled 8 Correct the readings to 80 F Add 004 to readings for every 10 above 80 F Subtract 004 for every 10 below 80 F 9 Compare the readings 10 Check the state of charge using Table 1 emperature Hydrometer Reading F yy us Trojan 43 40 37 de 254 1 552 1 258 1 259 1 262 1 256 putin Laval uel ibis 1 266 1 253 1 270 1 250 a A EMAA AMI a l i Laer 1 276 1 244 En 1282 1 241 En 1 386 1 238 E 1 290 1 233 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 1 Check and record voltage level s 2 Put battery s on a complete charge 3 ake specific gravity readings again If any specific gravity readings still register low then follow the steps below 1 Check voltage level s 2 Perform equalization charge Refer to the Equalizing section for the proper procedure 3 ake specific gravity readings again 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 lo
26. st 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 II Open Circuit Voltage Test For accurate voltage readings batteries must remain idle no charging no discharging for at least 6 hours preferably 24 hours 25 1 Remove all connections from the batteries 2 Measure the voltage with a DC voltmeter 3 Check the state of charge with Table 1 4 Charge the battery if it registers 0 to 70 charged lf the battery value is lower than that in Table 1 the following conditions may exist 1 The battery was left in a state of discharge too long 2 The battery has a bad cell Batteries in these conditions should be taken to a specialist for further evaluation or retired from service TABLE 1 State of charge as related to specific gravity and open circuit voltage Specific Gravity Open Circuit Voltage Percentage of Corrected to 80 F 12V 24V Charge C2 12 73 25 46 1 258 12 62 20 24 1 238 12 50 25 00 1 217 12 37 24 74 1 195 f 12 24 24 48 1 172 12 10 24 20 1 148 11 96 23 92 1 124 E 11 81 23 63 1 098 11 66 23 32 1 073 i 11 51 23 02 7 Battery installation WARNING When working with batteries DO NOT put wrenches or any other metal objects across the battery terminals Otherwise an arc can oc
27. stratification a condition where acid concentration is greater at the bottom of the battery than at the top Equalizing also helps to remove sulfate crystals that might have built up on the plates If left unchecked this build up which 27 is called sulfation will reduce the overall capacity of the battery Equalizing is recommended when low or wide ranging specific gravity 015 is detected after fully charging a battery The Operation and Maintenance of the Charger Note As standard configuration the charger is built onboard the vehicle in some cases it may not be built onboard the vehicle Using the onboard charger 1 Connect the cord to the receptacle on the vehicle 2 Connect the cord from the receptacle to an outlet of the household grid 3 After the charger cord is connected the red indicator on the charger will flash The charger will start the procedure of self inspection After self inspection a green indicator flashes and the charger will begin to charge the batteries When battery capacity is less than 80 the green indicator flashes slowly When battery Capacity is more than 80 the green indicator flashes fast When the battery is fully charged the green indicator will stop flashing and the charger will stop charging automatically Note This charger has the function of over discharging protection to keep the battery from over discharging When the battery is close to the charging point it will reduce the
28. terminals and nuts The connection of the batteries should be kept in good condition Check the battery cable terminals and nuts weekly in order to prevent sparking or damage to terminals A damaged battery cable should be replaced immediately 3 Battery compartment 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 or dangerous sparking This can cause damage to the battery or injury to the user 4 Recharging a Regardless of how long you have used the vehicle the battery should be recharged fully on the same day Any delay on the re charging will reduce the life of the battery Note the lead acid battery does not develop a memory so it need not be fully discharged before recharging b If the vehicle is going to be kept unused for a long time the battery should be fully recharged first After that the battery should be fully recharged every 2 weeks c When driving the driver should be aware of the drop level of the battery power from the battery power meter The driver should estimate the distance needed to be taken and recharge the battery at a proper time to ensure that the vehicle can get back to the charging location in time for recharging WARNING Make sure the battery is recharged before the battery power meter shows 20 Is left An over discharged battery will have a very short service life WARNING During recharging the vehicle should be parke
29. the power key to OFF remove the key and store the key in a safe place 3 Move the tow switch into TOW position on the controller cover 4 Check the tire pressure to make sure its pressure is set to the recommended amount 5 Clean the exterior of the vehicle and apply rust inhibitor 6 Cover the vehicle with a breathable cover and store it in a dry safe and well ventilated place 7 If the vehicle is planned to store for a long time check the liquid level inside the battery once a month and recharge the battery 12 Wiring Diagram 1 Wiring diagram for vehicle 36V with Curtis Controller 1243 FIG 1 2 Wiring diagram for vehicle 48V with Curtis Controller 1266 FIG 2 3 Wiring diagram for vehicle 48V with Curtis Controller 1268 FIG 3 4 Wiring diagram for vehicle 48V with Curtis Controller 1234 1236 FIG 4 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 interpretation right of this manual All rights reserved 35 36
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