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1. BN72 23 Passengers 23 Battery 72V 12 x 6 V Trojan batteries two sets optional Motor 12 HP AC Controller Curtis AC 550A 72V Charger Full automatic charger 72V 12A UL listed Top speed mph 18 Load capacity Ibs 3850 Dimensions in 221 x 83 x 89 Weight Ibs 3080 Ground clearance in 5 9 Turning radius ft 26 Wheel base in 135 Climbing ability loaded 15 Front suspension Independent coil over shock Rear suspension Leaf spring and shock Steering system Rack and pinion power steering Brake System 4 wheel hydraulic drum Tire size 195 70 R 15C Tire pressure psi 44 Wheel type Steel 6JJ 15 Differential Whole style steel rear axle reduction ratio 12 49 1 Charger 20 A 72 V full automatic high frequency charger Brake range ft 15 Chassis Steel 13 Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Thank you for purchasing this vehicle Before driving the vehicle we ask you to spend some time reading this Owner s Manual and Service Guide This guide contains the information that will assist you in maintaining this highly reliable vehicle This vehicle has been designed and manufactured as a World Vehicle Some countries have individual requirements to comply with their specifications therefore some sections may not apply in your country Most of the s
2. state of charge will also prevent freezing See following table 31 Heat Avoid direct exposure to heat sources such as radiators or space heaters Temperatures above 80 F accelerate the battery s self discharge characteristics Storage Procedure 1 Completely charge the battery before storing 2 Store the battery in a cool dry location protected from the elements 3 During storage monitor the specific gravity flooded or voltage Batteries in storage should be given a boost charge when they show a 70 charge or less See Table 1 in the Testing Section 4 Completely charge the battery before re activating 5 For optimum performance equalize the batteries flooded before putting them back into service Refer to the Equalizing section for this procedure Electrolyte Freezing Point at Various States of Charge Specific Gravity g cm State of Charge Freezing Temperature 1 28 100 68 9 1 265 92 57 4 1 25 85 52 2 1 2 62 26 7 1 15 40 15 1 1 20 7 2 How to Increase System Power Two or more batteries can be easily connected to boost your system s voltage and or capacity There are three methods to obtain additional voltage and or capacity as described below To increase voltage connect batteries in series 32 Battery System 12 Volt 225 AH using Two Trojan T105 Deep Cycle Batteries 6 Volts 225 AH To increase amp hour capacity connect batteries in parallel Battery System
3. Electric Vehicles Owner s Manual and Service Guide Star EV M Series 8 11 14 and 23 Passenger Buses May 2014 Table of Contents Safety Information General safety For the user Vehicle Specifications 8 passenger bus 11 passenger bus 14 passenger bus 23 passenger bus Operation and Service Information Before initial use Controls and indicators Vehicle cleaning and care Periodic service schedule Tire inspection Periodic brake test for mechanical brake Lubrication Battery and charging Safety Battery Battery charging Battery maintenance Battery cleaning Electrolyte level and water Watering Replacement Prolonged storage How to increase system power Troubleshooting Battery terms explained Assembly Electrical diagrams 10 11 12 13 14 15 17 18 20 20 21 22 23 23 24 25 27 28 30 31 32 34 38 40 48 This manual has been designed to assist in maintaining the vehicle in accordance with procedures developed by the manufacturer Adherence to these procedures and troubleshooting tips will ensure the best possible service from the product To reduce the chance of personal injury or property damage the following must be carefully observed General Safety Good common sense and prudent driving practices do more to prevent accidents and injury than all of the warnings and instructions combined The manufacturer strongly suggests that all users and maintenance personnel read this entir
4. This safety information is intended to provide the controlling party with basic safety information and to encourage the controlling party to implement a vehicle safety program It is suggested and recommended this section be reprinted in the vehicle manufacturer s operation and service manuals to encourage safe operations and practices at the controlling party s facility Safety Survey The controlling party should perform a safety survey periodically and as conditions warrant to their premises to identify areas where the vehicle should not be operated and to identify possible hazards Wet and Loose Terrain Wet grassy areas and loose terrain may cause a vehicle to lose traction and may affect stability Wet areas and loose terrain should be chained or roped off to prevent vehicle operations or be identified by a suitable warning not to operate the vehicle in this area due to wet and loose terrain Sharp Turns Blind Corners Bridge Approaches Sharp turns blind spots bridge approaches and other potentially hazardous areas should be either chained or roped off to prevent vehicle operations or identified with a suitable warning to the operator of the nature of the hazard and stating the proper precautions to be taken to avoid the hazard Vehicle Pedestrian Interference Areas Areas where pedestrians and the vehicle interfere should be avoided whenever possible by rerouting the vehicle traffic or the pedestrian traffic to
5. C 25C electrolyte specific gravity pt tC electrolyte specific gravity 10 Check the state of charge using Table on the next page The readings should be at or above the specification of 1 280 0 01 g cm If any specific gravity readings register low then follow the steps below 1 Check and record voltage level s 2 Put battery on a complete charge 3 Take specific gravity readings again If any specific gravity readings still register low then follow the steps below 1 Check voltage level s 2 Perform charging Refer to the charging section for the proper procedure 3 Take specific gravity readings again If any specific gravity reading still registers lower than the specification of 1 280 0 01 g cm then one or more of the following conditions may exist 36 e The battery is old and approaching the end of its life e The battery was left in a state of discharge too long e Electrolyte was lost due to spillage or overflow e A weak or bad cell is developing e Battery was watered excessively previous to testing Batteries in these conditions should be taken to a specialist for further evaluation or retired from service NOTE Electrolyte specific gravity is 1 10 g cm under full charge Open Circuit Voltage Test For accurate voltage readings batteries must remain idle no charging no discharging for at least 6 hours preferably 24 hours 1 Disconnect all loads from the batteries 2 Meas
6. Roun MAINCONTACTOR ENCODER KEY p sl SWITCH amp Visa Charge SWITCH FU2 BATTERY 48 b FU3 104A iy L 72V flasher VA B black 0 orange R red P purple R W red white S6 winds l lwiper te switch R Gr red grey R Bl red blue G Gr Green grey Y Gr Yellow grey Y G yellow green W Br White Brown Br Y Brown yel low ji P left right left left right rear rear rear front rear Y R 4 yel low red breaking Braking tuming tuming tuming BI B b lue black light lights light light light right left right left right hom a motor front rear rear front front player for turning light light light light windsheild light wiper 49
7. The user should not perform any modification or addition which affects capacity or safe operation of the vehicle or make any change not in accordance with the owner s manual without the manufacturer s prior written authorization Where authorized modifications have been made the user should ensure that capacity operation warning and maintenance instruction plates tags or decals are changed accordingly Changing and Charging Storage Batteries for Electric Personnel and Burden Carriers The user should require battery changing and charging facilities and procedures to be in accordance with appropriate paragraphs of ANSI NFPA 505 The user should periodically inspect facilities and review procedures to be certain that appropriate paragraphs of ANSI NFPA 505 are strictly complied with and should familiarize carrier operators with it General Safety Rule and Practices Safeguard pedestrians at all times Do not drive cart in a manner that would endanger anyone Riding on the cart by persons other than the operator is authorized only on personnel seat provided by the manufacturer When a cart is to be left unattended stop it apply the parking brake stop the engine or turn off power turn off the control or ignition circuit and remove the key if provided Block the wheels if machine is on an incline Use only approved carts in hazardous locations as defined in the appropriate safety standards Operators should not add to or
8. eliminate the interference If elimination of the interference is not possible or is highly impractical signs should be erected warning pedestrians of the vehicle traffic and vehicle operators of the pedestrian traffic and to drive slowly and use extreme caution Preventative Maintenance The vehicle may become hazardous if maintenance is neglected or improperly performed Therefore maintenance facilities trained personnel and procedures in accordance with the manufacturer s recommendations should be provided by the controlling party A regularly scheduled inspection and preventive maintenance program in accordance with the manufacturer s recommendations should be established Such a program will be a valuable tool in providing the golfing patron with a safe properly operating the vehicle and thereby help to avoid accidents Only qualified trained and authorized personnel should be permitted to inspect adjust and maintain resort vehicle Only manufacturer s recommended replacement parts and materials should be used Maintenance Safety Procedures All maintenance should be performed in accordance with the manufacturer s recommended safety procedures as outlined in the manufacturer s operation and service manuals The following list of recommended safety procedures are general in nature and in no way supersede the manufacturer s specific instructions Follow manufacturer s instructions for immobilizing the vehicle
9. just enough distilled de ionized water to cover the plates 3 Replace and tighten all water vent caps 4 Put batteries on a complete charge before adding any additional water refer to the Charging section 5 Once charging is completed remove the vent caps and check the electrolyte level 6 Add water until the electrolyte level is 1 8 below the bottom of the fill well 29 7 Clean replace andtighten all vent caps WARNING Never add acid to a battery Battery Replacement Remove battery and hold down 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 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 hold 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 brush clean if required WARNING To prevent bat
10. modify the cart Traveling Observe all traffic regulations including authorized speed limits Under normal traffic conditions keep to the right Maintain a safe distance based on speed of travel from a vehicle ahead and keep the Cart under control at all times Do not pass another vehicle traveling in the same direction at intersections blind spots or at other dangerous locations Keep a clear view of the path of travel observe other traffic and personnel and maintain a safe clearance Slow down or stop as conditions dictate and activate the sound producing warning device at cross aisles and when visibility is obstructed at other locations Ascend or descend grades slowly Under all travel conditions the cart should be operated at a speed that will permit it to be brought to a stop in a safe manner Do not indulge in dangerous activities such as stunt driving or horseplay Avoid running over loose objects potholes and bumps To negotiate turns reduce speed to improve stability then turn hand steering wheel or tiller in a smooth sweeping motion Loading At the beginning of each shift during which the cart will be used the operator should check the cart condition and inspect the tires warning devices lights battery speed and directional controllers brakes and steering mechanism If the cart is found to be in need of repair or in any way unsafe the matter should be reported immediately to the designate
11. not function Automatic chargers will determine the correct duration of charge to the battery set and will shut off when the battery set is fully charged Always refer to the instructions of the specific charger used Charging batteries properly requires administering the right amount of current at the right voltage Most charging equipment automatically regulates these values Some chargers allow the user to set these values For proper charging refer to the instructions that came with your charging equipment Before charging the following should be observed e Be familiar with and follow the instructions issued by the charger manufacturer e Batteries should be charged after each period of use e Lead acid batteries need not be fully discharged before recharging e Charge only in well ventilated area Keep sparks or flames away from a charging battery e Verify charger voltage settings are correct e Check electrolyte level See Electrolyte Level and Water section e Tighten all vent caps before charging e Do not overcharge or undercharge the batteries 23 e Do not charge a frozen battery e Avoid charging at temperatures above 48 C Battery Maintenance WARNING To reduce the possibility of fire never attach a battery charger to a vehicle that is to be unattended beyond the normal charging cycle Overcharging could cause damage to the vehicle batteries and result in extreme overheating The charger should be checked
12. the battery due to gassing and the increase in volume of the electrolyte that results from the charging cycle CAUTION Do not overfill batteries The charging cycle will expel electrolyte and result in component damage A battery being charged will gas with the majority of the gassing taking place at the end of the charging cycle This gas is hydrogen which is lighter than air Water and sulfuric acid droplets 27 will be carried out of the battery vents by the hydrogen gas however this loss is minimal If the battery electrolyte level is too high the electrolyte will block the vent tube and the gas will force it out of the vent tube and battery cap The water will evaporate but the sulfuric acid will remain where it can damage vehicle components and the storage facility floor Sulfuric acid loss will weaken the concentration of acid within the electrolyte and reduce the life of the battery Over the life of the battery a considerable amount of water is consumed It is important that the water used be pure and free of contaminants that could reduce the life of the battery by reducing the chemical reaction The water must be distilled or purified by an efficient filtration system Water that is not distilled should be analyzed and if required filtration installed to permit the water to meet the requirements of the water purity table Impurity Parts per Million Color Clear Suspended Trace Total Solids 100 Calcium and Magn
13. vehicle Clean windshield with lots of water and a clean cloth Minor scratches may be removed using a commercial plastic polish Normal cleaning of vinyl seats and plastic or rubber trim requires the use of a mild soap solution applied with a sponge or soft brush and wipe with a damp cloth The painted surfaces of the vehicle provide attractive appearance and durable protection Frequent washing with lukewarm or cold water and mild detergent is required to preserve the painted surface Occasional cleaning and waxing with non abrasive products designed for clear coat automotive finishes will enhance the appearance and durability of the painted surfaces Corrosive materials used as fertilizers can collect on the underbody of the vehicle These materials will cause corrosion of underbody parts unless flushed occasionally with plain water Thoroughly clean any areas where mud or other debris can collect Sediment packed in closed areas should be loosened to ease removal taking care not to chip or otherwise damage paint 17 Periodic Service Schedule NOTE Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions Daily Before Use e Check general operation of service brake e Check park brake function e Check warning device function in reverse e Check tire condition e Check overall vehicle condition After Use e Recharge batteries to full state of charge after each
14. 12 Volt 450 AH using Four Trojan T105 Deep Cycle Batteries 6 Volts 225 AH 33 NOTE This system can also be configured using 12 volt batteries It is not recommended that you mix batteries of different voltages within the same system Troubleshooting In general troubleshooting will be done for two distinct reasons First a battery that performs poorly and is outside of the manufacturer s specification should be identified in order to replace it under the terms of the manufacturer s warranty Different manufacturers have different requirements Consult the battery manufacturer or a manufacturer representative for specific requirements The second reason is to determine why a particular vehicle does not perform adequately Performance problems may result in a vehicle that runs slowly or in a vehicle that is unable to operate for the time required Problem Possible reason Processing methods Tire air pressure is too low According to the tire requirements inflate the tire Under Turning part is not Sine Daub lubricant lubricated The toe in is not correct Adjust the toe in Abnormal abrasion on Tire air pressure is not According to the tire requirements adjust the tire pressure correct tire Overexert when braking Adjust the stroke of brake pedal Check the voltage of single battery If it is less than 1V the Battery voltage is low or battery is aging replace it It is advised to chec
15. Front suspension Independent coil over shock Rear suspension Leaf spring and shock Steering system Rack and pinion power steering Brake System 4 wheel hydraulic drum Tire size 165 70 R 13 DOT Tire pressure psi 44 Wheel type 13 inch polished aluminum Differential Whole style steel rear axle reduction ratio 18 125 1 Charger 20 A 72 V full automatic high frequency charger Brake range ft 17 Chassis Steel 11 14 Passenger Bus BN72 14 ADS AC Passengers 14 Battery 72V 12 x 6 V Trojan T105 Motor 7 5 KW 10 HP AC Controller 550A Curtis controller Charger Full automatic charger 72V 12A UL listed Top speed mph 18 Load capacity Ibs 2640 Dimensions in 186 x 60x81 Weight Ibs 1900 Ground clearance in 5 9 Turning radius ft 19 Wheel base in 105 Climbing ability loaded 20 Front suspension Independent coil over shock Rear suspension Leaf spring and shock Steering system Rack and pinion power steering Brake System 4 wheel hydraulic drum Tire size 165 70 R13 DOT Tire pressure psi 44 Wheel type 13 inch polished aluminum Differential Whole style steel rear axle reduction ratio 18 125 1 Charger 20 A 72 V full automatic high frequency charger Brake range ft 18 Chassis Steel 12 23 Passenger Bus
16. after 24 hours and unplugged after the charge cycle is complete Before charging the batteries inspect the plug of the battery charger and vehicle receptacle housing for dirt or debris Charge the batteries after each day s use Monthly e Inspect all wiring for fraying loose terminations corrosion or deterioration of insulation e Check that the electrolyte level is correct and add suitable water as required e Clean the batteries and wire terminations Our experience shows that the key to achieving optimum performance and long life is a solid battery maintenance program using the simple procedures outline here Equipment We recommend the following equipment for use in battery care and maintenance e Wrench e Distilled Water e Voltmeter e Hydrometer e Thermometer e Post Cleaner e Baking Soda e Vaseline e Goggles amp Gloves CAUTION Always wear protective clothing gloves and goggles when handling batteries electrolyte and charging your battery 000 Batteries should be carefully inspected on a regular basis in order to detect and correct potential problems before they can do harm It is a great idea to start this routine when the batteries are first received Inspection Guideline 1 Examine the outside appearance of the battery e Look for cracks in the container e The top of the battery posts and connections should be clean free of dirt fluids and corrosion e Repair or replace any dam
17. aged batteries 2 Any fluids on or around the battery may be an indication that electrolyte spilling leaching or leaking out e Leaking batteries must be repaired or replaced 3 Check all battery cables and their connections e Look closely for loose or damaged parts e Battery cables should be intact broken or frayed cables can be extremely hazardous e Replace any cable that looks suspicious 4 Tighten all wiring connections to the proper specification Make certain there is good contact with the terminals WARNING e Do not smoke near batteries e Do not over tighten terminals Doing so can cause post breakage post meltdown or fire Battery Cleaning CAUTION To prevent battery damage be sure that all battery caps if equipped are tightly installed To reduce the possibility of damage to vehicle or floor neutralize acid before rinsing battery To reduce the possibility of damage to electrical components while cleaning do not use a pressure washer 25 Cleaning should take place per the Periodic Service Schedule Ref Fig 16 When cleaning the outside of batteries and terminals first spray with a solution of sodium bicarbonate baking soda and water to neutralize any acid deposits before rinsing with clear water Use of a water hose without first neutralizing any acid will move acid from the top of batteries to another area of the vehicle or storage facility where it will attack the metal structure o
18. and the battery is allowed to sit unused it will become partially discharged When it reaches 1 240 which it will do in less than twenty days it should be recharged If a battery is left in a discharged state sulfating takes place on and within the plates This condition is not reversible and will cause permanent damage to the battery In order to prevent damage the battery should be recharged A hydrometer can be used to determine the specific gravity and therefore the state of charge of a battery In winter conditions the battery must be fully charged to prevent the possibility of freezing A fully charged battery will not freeze in temperatures above 75 F 60 C Although the chemical reaction is slowed in cold temperatures the battery must be stored fully charged and disconnected from any circuit that could discharge the battery For portable chargers disconnect the charging plug from the vehicle receptacle The batteries must be cleaned and all deposits neutralized and removed from the battery case to prevent self discharge The batteries should be tested or recharged at thirty day minimum intervals Periods of inactivity can be extremely harmful to lead acid batteries When placing a battery into storage follow the recommendations below to insure that the battery remains healthy and ready for use The most important things to avoid Freezing Avoid locations where freezing temperature is expected Keeping a battery at a high
19. before beginning any maintenance Block chassis before working underneath the vehicle Maintenance and storage areas should be properly ventilated to avoid fire hazards in accordance with applicable fire codes and ordinances Before performing any maintenance on an electric vehicle disable the electrical system in accordance with the manufacturer s instructions Use only properly insulated tools when working on electrically powered vehicle or around batteries The controlling party should not perform any modification or addition which affects capacity or safe operation or make any change not in accordance with owner s manual without the manufacturer s prior written authorization Where authorized modifications have been made the controlling party should ensure that capacity operation warning and maintenance instruction plates tags or decals are changed accordingly Operating Safety Rules and Practices Only authorized persons should be allowed to operate the vehicle It is recommended that no persons be allowed to operate the vehicle except those persons who possess a valid motor vehicle driver s license The controlling party should display the operation and safety instructions as recommended by the vehicle manufacturers and the safety rules in a conspicuous place near the vehicle rental area or vehicle pick up area It is also recommended as with all motor vehicles that the warning Do not operate vehicle when u
20. d authority and the cart should not be operated until it has been restored to proper operating condition Do not make repairs or adjustments unless specifically authorized to do so Do not operate a cart with a leak in the battery Do not use open flames for checking electrolyte level in storage battery Maintenance Procedures Carriers may become hazardous if maintenance is neglected Therefore maintenance facilities trained personnel and procedures should be providing such facilities may be on or off the premises Maintenance and inspection of all carts should be performed in conformance with the manufacturer s recommendations and the following practices e A scheduled preventive maintenance lubrication and inspection system should be followed e Only qualified and authorized personnel should be permitted to maintain repair adjust and inspect carriers e Block chassis before working underneath it e Operations to check performance of the cart should be conducted in an authorized area where Safe clearance exists e Before commencing operation of the cart follow the manufacturer s instructions and recommended procedures e Avoid fire hazards and have fire protection equipment present in the work area Do not use an open flame to check level or leakage of battery electrolyte e Properly ventilate the work area e Brakes steering mechanisms speed and directional control mechanisms warning devices light
21. day s use e Inspect charger connector and receptacle at each charge Weekly Tires Examine for cuts excessive wear and pressure See Vehicle Specifications Wheels Check for bent rims missing or loose lug nuts Monthly 20 hours Batteries e Clean batteries and terminals See Battery Cleaning e Check charge condition and all connections Wiring Check all wiring for loose connections and broken insulation Charger Receptacle Clean connections keep receptacles free of dirt and foreign matter Accelerator Check for smooth movement Service Brake Mechanical Brakes Conduct brake performance test Park Brake Check brake performance and adjust if required Direction Selector Check attachment tighten if required 18 Steering Assembly Check for abnormal play tightness of all hardware Tie Rod Linkages Check for excessive play bent components or loose connections Rear Axle Check for leakage add lubricant level as required Quarterly 50 hours Front Axle Check for damage to axle and loose or missing hardware Front Shock Absorbers Check for oil leakage and loose fasteners Front Springs Check for loose hardware cracks at attachments Front Wheel Alignment Check for unusual tire wear align if required Park Brake e Check for bent binding linkage rod e Check for damage or wear to latch arm or catch bracket e Lubricate as required use light oil Do not lubricate cables or brake latch Rear Shock Absorbers Check
22. e manual paying particular attention to the CAUTIONS and WARNINGS contained therein Star EV reserves the right to make design changes without obligation to make these changes on units previously sold and the information contained in this manual is subject to change without notice Star EV is not liable for errors in this manual or for incidental or consequential or consequential damages that result from the use of the material in this manual These vehicles are designed and manufactured for off road use Some communities may permit these vehicles to be operated on their streets on a limited basis and in accordance with local ordinances With electric powered vehicles be sure that all electrical accessories are grounded directly to the battery post Never use the chassis or body as a ground connection Refer to Vehicle Specifications for vehicle seating capacity Never modify the vehicle in any way that will alter the weight distribution of the vehicle decrease its stability or increase the speed beyond the factory specification Such modifications can cause serious personal injury or death Vehicles that are capable of higher speeds must limit their speed to no more than the speed of other vehicles Additionally speed should be further moderated by the environmental conditions terrain and common sense General Operation Always e Use the vehicle in a responsible manner and maintain the vehicle in safe operating condit
23. eld wiper switch 6 CD player optional part 7 Light switch 8 Forward reverse switch 9 Charging receptacle 10 Parking brake handle 11 Accelerator pedal 12 Brake pedal WARNING To prevent loss of control do not move direction selector while the vehicle is in motion Moving the selector will result in a sudden slowing of the vehicle and the beeping of a warning device Unintentional movement of the accelerator pedal will release the park brake and may cause the vehicle to move which could result in severe injury or death To reduce the possibility of severe injury or death resulting from loss of vehicle control the following warnings must be observed 15 When driving vehicle consider the terrain traffic conditions and the environmental factors which affect the terrain and the ability to control the vehicle Use extra care and reduced speed when driving on poor surfaces such as loose dirt wet grass gravel etc Stay in designated areas and avoid extremely rough terrain Maintain a safe speed when driving downhill Use service brake to control speed when traveling down an incline A sudden stop or change of direction may result in loss of control Slow down before and during turns All turns should be made at reduced speed WARNING To reduce the possibility of severe injury or death resulting from improper vehicle operation the following warnings must be observed Refer to Vehicle Specifications for seating ca
24. ervice procedures in this guide can be accomplished using common automotive hand tools 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 Vehicle batteries must be fully charged before initial use Check for correct tire inflation See Vehicle Specifications Determine and record braking distance required to stop vehicle for future brake performance tests Remove the protective clear plastic that protect the seat bottom and back rest during shipping before placing the vehicle in service WARNING To prevent overheating that may cause serious damage to the charger and create the potential for fire do not block or obstruct the airways Portable chargers must be mounted on a platform above the ground or in such a manner as to permit the maximum airflow underneath and around the charger Portable chargers are shipped with the vehicle Prior to vehicle or charger operation chargers must be removed and mounted on a platform or wall above the ground to permit maximum airflow around and underneath the charger If the charger is operated in an outdoor location rain and sun protection must be provided 14 Controls and Indicators 1 Front light and turning light switch 2 Horn 3 Steering wheel 4 Keyswitch 5 Windshi
25. esium Oxides 40 Iron 5 Ammonia 8 Organic and Volatile Matter 50 Nitrites 5 Nitrates 10 Chloride 5 NOTE Even if the water is colorless odorless tasteless and fit for drinking the water should be analyzed to see that it does not exceed the impurity levels specified in the table Watering Flooded batteries only Flooded batteries need water More importantly watering must be done at the right time and in the right amount or else the battery s performance and longevity suffers Water should always be added after fully charging the battery Prior to charging there should be enough water to cover the plates If the battery is discharged partially or fully the water level should also be higher than the plates 28 Keeping the water at the correct level after a full charge will prevent having to worry about the water level at a different state of charge e Donotletthe plates get exposed to air e Do not fill the water all the way up to the cap e Do not use water with a high mineral content e Use distilled or de ionized water only CAUTION The electrolyte is a solution of acid and water so skin contact should be avoided Electrolyte 1 8 Below Bottom of Fill Well NANA l WA TW I SUINI Procedure 1 Open the vent caps and look inside the fill wells Check electrolyte level the minimum level is at the top of the plates 2 Ifthere is no electrolyte visible add
26. fically recommended by the manufacturer will not compromise the safety of personnel nor jeopardize the safe operation of the vehicle e Support the vehicle using wheel chocks and jack stands Never get under a vehicle that is supported by a jack Lift the vehicle in accordance with the manufacturer s instructions e Maintain the vehicle in an area away from exposed flame or persons who are smoking e Be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated e Test drive the vehicle after any repairs or maintenance All tests must be conducted in a safe area that is free of both vehicular and pedestrian traffic e Replace damaged or missing warning caution or information labels e Keep complete records of the maintenance history of the vehicle e Use extreme caution and if unsure as to the potential for injury refer the repair or maintenance to a qualified mechanic For the User General Safety Practices Like other machines this vehicle can cause injury if improperly used or maintained This section contains broad safety practices applicable to vehicle operations Before operation the user should establish such additional specific safety practices as may reasonably be required for safe operation Nameplates Markings Capacity and Modifications The user should maintain in a legible condition all nameplates warnings and instructions which are supplied by the manufacturer
27. for oil leakage loose mounting hardware Charger Plug Clean auxiliary contact see Battery Charger Maintenance Hardware and Fasteners e Check for loose or missing hardware and components e Tighten or replace missing hardware Semi Annual 125 hours Direction Selector Check for wear and smooth movement lubricate shaft with light oil if required King Pins Check for excessive play and tightness of retaining nuts Steering Assembly Check bellows and pinion seal for damage or grease leakage Rack End Ball Joint Lubricate use wheel bearing grease Rear Axle Check for unusual noise and loose or missing mounting hardware 19 Annual 250 300 hours Front Wheel Bearings Check and adjust as required see Technician s Repair and Service Manual Rear Axle Check lubricant add lubricant level as required Service Brakes e Clean and adjust e Check brake shoe linings Tire Inspection Tire condition should be inspected per the Periodic Service Schedule Inflation pressures should be checked when the tires are cool Be sure to install the valve dust cap after checking or inflating Periodic Brake Test for Mechanical Brake WARNING To reduce the possibility of severe injury or death always evaluate pedal travel before operating a vehicle to verify some braking function is present All driving brake tests must be done in a safe location with regard for the safety of all personnel NOTE Over time a subtle loss of pe
28. ich could result in an explosion Wrap wrenches with vinyl tape to prevent the possibility of a dropped wrench from shorting out a battery which could result in an explosion and severe injury or death 22 Battery A battery is defined as two dissimilar metals immersed in an acid If the acid is absent or if the metals are not dissimilar a battery has not been created The batteries most commonly used in these vehicles are lead acid A battery does not store electricity but is able to produce electricity as the result of a chemical reaction which releases stored chemical energy in the form of electrical energy The chemical reaction takes place faster in warm conditions and slower in cold conditions Temperature is important when conducting tests on a battery and test results must be corrected to compensate for temperature differences As a battery ages it still performs adequately except that its capacity is diminished Capacity describes the time that a battery can continue to provide its design amperes from a full charge A battery has a maximum life therefore good maintenance is designed to maximize the available life and reduce the factors that can reduce the life of the battery Battery Charging The battery charger is designed to fully charge the battery set If the batteries are severely deep cycled some automatic battery chargers contain an electronic module that may not activate and the battery charger will
29. indshield frame at the back to avoid the windshield from falling and to keep the points aligned 40 Frame B assembly Frame B is the frame stand beside the driver and co pilot seat When you affix the windshield stand the frame B to support it as well Frame B is two pieces one is the driver s side the other is the co pilot s side Frame B bottom bolt assembly Frame B top bolt assembly 41 First row armrest assembly Affix the backrest first then screw into the seat frame 42 Frame C assembly C frame left side C frame right side Take care to distinguish the right and left side 43 The Canopy Insert the canopy tube into the front windshield frame and connect them Make sure the windshield fits with the canopy frame tightly and affix the screws After connecting apply the sealant to prevent water damage 44 Canopy Tail Assembly Insert the canopy tube into the windshield frame Connect them tightly and apply sealant 45 Backrest Assembly Apply the screw from the backrest to the seat itself Side Mirror Assembly 46 Brake Hose Assembly Insert the brake hose in the correct position and fix them stable then screw it safely 47 0 5K THROTTLEPOT PEDAL SWITCH MOTOR TEMPERATURE SENSOR THROTTLEPOTWIPER THROTTLEPOTLOW GROUND 1238 CONTROLLER COIL RETURN DRIVER 5V PHASEA phases
30. ion e Read and observe all warnings and operation instruction labels affixed to the vehicle e Follow all safety rules established in the area where the vehicle is being operated e Reduce speed to compensate for poor terrain or conditions e Apply service brake to control speed on steep grades e Maintain adequate distance between vehicles e Reduce speed in wet areas e Use extreme caution when approaching sharp or blind turns e Use extreme caution when driving over loose terrain e Use extreme caution in areas where pedestrians are present Maintenance Always e Maintain the vehicle in accordance with the manufacturer s periodic service schedule e Ensure that repairs are performed by those that are trained and qualified to do so e Follow the manufacturer s maintenance procedures for the vehicle Be sure to disable the vehicle before performing any maintenance Disabling includes removing the key from the key switch and removal of a battery wire e Insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by shorting the battery terminals or associated wiring Remove the batteries or cover exposed terminals with an insulating material e Check the polarity of each battery terminal and be sure to rewire the batteries correctly e Use specified replacement parts Never use replacement parts of lesser quality e Use recommended tools e Determine that tools and procedures not speci
31. ity Capacity Rating The time in minutes that a new fully charged battery will deliver 25 amperes or 75 amperes at 800F and maintain a terminal voltage equal to or greater than 1 75 volts per cell Cell The basic current producing unit in a battery It consists of a set of positive plates negative plates electrolyte separators and casing A cell s nominal voltage is 2 volts Example A 12 volt battery has 6 cells Circuit The path followed by a flow of electrons A closed or short circuit is a complete path An open circuit has a broken path Cycle One discharge of a battery plus one recharge Depth of Discharge DOD The percentage of capacity actually removed from a battery compared to the total rated capacity Electrolyte In a deep cycle battery it is a dilute solution of sulfuric acid and water Hydrometer A tool used to measure the specific gravity of the electrolyte solution 38 Equalization An overcharge performed on flooded lead acid batteries after they have been fully charged This maintenance step helps eliminate stratification and sulfation Ohm A unit of measurement for electrical resistance within a circuit Open Circuit Voltage The voltage of a battery when there is no load attached not receiving or delivering energy This measurement is best taken when the battery has been at rest for at least 6 hours Power Inverter An electronic device that converts direct current DC power from a battery int
32. k the electrolyte battery is aging level which should be greater than 15 20 mm If issue is not Running solved replace the battery speed is slow The running speed is low when depressing the accelerate pedal If the accelerator pedal is loose fasten the screws on the pedal Measure the output voltage while accelerating The normal range is 0 5 V If it is out of this range replace the accelerator 34 Connection joint of master circuit is loose Check each connection joint If there is an issue please pull the inserted part out and adjust the inserted spring of rubber rind then insert the terminal again Arrester fault resulting from cart running with load Adjust the arrester Poor braking condition Brake compensator is loose Adjust brake draw bar Brake shoe is worn Replace the brake shoe or brake cable Cart cannot move Without control power Check the control fuse if it is broken replace Check jiggle switch on the charge socket for looseness Fasten it to the connection cables Turn on the key lock switch and if the input and output cables cannot be connected replace a with new key lock switch If the battery does not have a normal working voltage charge it as soon as possible Operation panel is disabled Check the connection cables on the operation panel for looseness if loose fasten it When using the direction selector the control contac
33. l of the items required for complete battery cleaning and watering electric vehicles only are contained in the Battery Maintenance Kit Batteries seem to attract dust dirt and grime Keeping them clean will help one spot trouble signs if they appear and avoid problems associated with grime Check that all vent caps are tightly in place Clean the battery top with a cloth or brush and a solution of baking soda and water When cleaning do not allow any cleaning solution or other foreign matter to get inside the battery Clean battery terminals and the inside of cable clamps using a post and clamp cleaner Clean terminals will have a bright metallic shine Reconnect the clamps to the terminals and thinly coat them with petroleum jelly Vaseline to prevent corrosion Keep the area around batteries clean and dry Electrolyte Level and Water Correct level of the electrolyte is 1 25 mm above the plates in each cell Expansion _ Vent Cap Space j A TT _ Gas Vent a 3 4 eo 19 5 mm i _ Vent 1 25mm Electrolyte level should be atleast 1 25 mm above the plates and 3 4 19 5 Plates mm below bottom of vent This level will leave approximately 34 19 5 mm of space between the electrolyte and the vent tube The electrolyte level is important since any portion of the plates exposed to air will be ruined beyond repair Likewise too much water will result in electrolyte being forced out of
34. m the point at which the brakes were latched The vehicle should stop within the normal range of stopping distances If the vehicle stops more than 4 ft 3 0m beyond the acceptable stopping distance or pulls to one side the vehicle has failed the test and should be tested again If the vehicle fails the second test it should immediately be removed from service The vehicle must be inspected by a qualified mechanic who should refer to the Troubleshooting section in the Technician s Repair and Service Manual Lubrication Checking the Lubricant Level Clean the area around the check fill plug and remove plug The correct lubricant level is just below the bottom of the threaded hole If lubricant is low add lubricant as required Add lubricant slowly until lubricant starts to seep from the hole Install the check fill plug In the event that the lubricant is to be replaced the vehicle must be elevated and the oil pan removed or the oil siphoned through the check fill hole CAUTION Do not use more than of grease in any grease fitting at any one time Excess grease may cause grease seals to fail or grease migration into areas that could damage components 21 Batteries and Charging Safety NOTE Always observe the following warnings when working on or near batteries WARNING To prevent battery explosion that could result in severe personal injury or death keep all smoking materials open flame or sparks away fr
35. nder the influence of alcohol or drugs Be posted in a conspicuous location Vehicle Specifications 8 Passenger Bus BN48 08 AC ADS Passengers 8 Battery 72V 12 x 6 V Trojan T105 Motor 7 5 KW 10 HP AC Controller 550A Curtis controller 72V Charger Full automatic charger 72V 12A UL listed Top speed mph 18 Load capacity Ibs 1400 Dimensions in 146x57x77 Weight lbs 1500 Ground clearance in 6 Turning radius ft 18 Wheel base in 83 Climbing ability loaded 20 Front suspension Independent coil over shock Rear suspension Leaf spring and shock Steering system Rack and pinion power steering Brake System 4 wheel hydraulic drum Tire size 165 70 R13 DOT Tire pressure psi 44 Wheel type 13 inch polished aluminum Differential Whole style steel rear axle reduction ratio 14 67 1 Charger 20 A 72 V full automatic high frequency charger Brake range ft 16 Chassis Steel 10 11 Passenger Bus BN72 11 ADS AC Passengers 11 Battery 72V 12 x 6 V Trojan T105 Motor 7 5 KW 10 HP AC Controller 550A Curtis controller Charger Full automatic charger 72V 12A UL listed Top speed mph 18 Load capacity Ibs 2645 Dimensions in 180x61x79 Weight lbs 1650 Ground clearance in 5 5 Turning radius ft 22 Wheel base in 106 Climbing ability loaded 20
36. o standard alternating current AC house power Primary Battery An energy storage device that can deliver energy but cannot be recharged i e disposable flashlight battery Secondary Battery An energy storage device than can deliver energy and can be recharged i e automotive or deep cycle battery Separator A divider made of porous material that is placed between the positive and negative plates in a battery cell and allows current to flow through it while preventing direct contact between the plates which would cause a short circuit Specific Gravity S G A measurement of the strength of battery electrolyte by comparing its density to that of pure water Stratification A condition where the concentration of acid is greater at the bottom of the battery that at the top Sulfation The formation of lead sulfate on the positive and negative electrodes Volt V A unit of measurement for electrical potential within a circuit Watt W A unit of measurement for electrical power Watt Hour Wh A unit of measurement for electrical power for a certain period of time 39 Assembly Front Windshield Assembly Please take out all the spare parts in the container and assemble them according to the following steps 1 Put the windshield up on the front body with the holes aligned 2 After adjusting the windshield and front body so that they are aligned insert screws When you affix the screws take care to support the w
37. om the batteries Hydrogen gas is formed when charging batteries Do not charge batteries without adequate ventilation A 4 concentration of hydrogen gas is explosive Be sure that the key switch is off and all electrical accessories are turned off before starting work on vehicle Never disconnect a circuit under load at a battery terminal Batteries are heavy Use proper lifting techniques when moving them Always lift the battery with a commercially available battery lifting device Use care not to tip batteries when removing or installing them spilled electrolyte can cause burns and damage The electrolyte in a storage battery is an acid solution which can cause severe burns to the skin and eyes Treat all electrolyte spills to the body and eyes with extended flushing with clear water Contact a physician immediately Always wear a safety shield or approved safety goggles when adding water or charging batteries Any electrolyte spills should be neutralized with a solution of 1 4 cup 60 mL sodium bicarbonate baking soda dissolved in 1 gallons 6 liters of water and flushed with water Overfilling batteries may result in electrolyte being expelled from the battery during the charge cycle Expelled electrolyte may cause damage to the vehicle and storage facility Aerosol containers of battery terminal protectant must be used with extreme care Insulate metal container to prevent can from contacting battery terminals wh
38. pacity Depressing accelerator pedal will release foot operated park brake and may cause inadvertent vehicle movement Turn the key to the OFF position whenever the vehicle is parked To prevent inadvertent movement when the vehicle is to be left unattended engage the park brake move direction selector to forward position turn key to OFF position and remove key Make sure that the direction selector is in correct position before attempting to start the vehicle Always bring the vehicle to a complete stop before shifting the direction selector Do not take vehicle out of gear while in motion coast Check the area behind the vehicle before operating in reverse All occupants must be seated Keep entire body inside vehicle and hold on while vehicle is in motion 16 Vehicle Cleaning and Care WARNING To reduce the possibility of severe injury or vehicle damage read and understand all instructions supplied by manufacturer of pressure washer CAUTION When pressure washing exterior of vehicle do not use pressure in excess of 700 psi To reduce the possibility of cosmetic damage do not use any abrasive or reactive solvents It is important that proper techniques and cleaning materials be used Using excessive water pressure may cause severe injury to operator or bystander damage to seals plastics seat material body finish or electrical system Do not use pressure in excess of 700 psi to wash exterior of
39. r the concrete asphalt floor Additionally conductive residue will remain on the batteries and contribute to their discharge WARNING To reduce the possibility of battery explosion that could result in severe injury or death do not use metallic spray wand to clean battery and keep all smoking materials open flame and sparks away from the battery The correct cleaning technique is to spray the top and sides of the batteries with a solution of sodium bicarbonate baking soda and water This solution is best applied with a garden type sprayer equipped with a non metallic spray wand or plastic spray bottle The solution should consist of the ingredients shown in the illustration Ref Fig 18 In addition special attention should be paid to metal components adjacent to the batteries which should also be sprayed with the solution 1 1 2 gallons DI 6 liters Z 1 quart C Clear Water 1 liter Clear Water 1 4 Cup 60 ml 3 Sodium Bicarbonate Sx 2 e Baking Soda Sodium Bicarbonate 6 n gt Baking Sod ini y Baking Soda Metallic Wand a A Plastic 2 Gallon Spray 7 5 liter Bottle Garden Sprayer Ref Pns 1 Preparing Acid Neutralizing Solution 26 Allow the solution to sit for at least three minutes Use a soft bristle brush or cloth to wipe the tops of the batteries to remove any conductive residue Rinse the entire area with low pressure clear water Do not use a pressure washer Al
40. rformance may take place Therefore it is important to establish the standard with a new vehicle The Periodic Brake Performance Test should be performed regularly Ref Fig 16 as an evaluation of braking system performance It is useful as a method of identifying subtle loss of performance over time The purpose of this test is to compare the braking performance of vehicle to the braking performance of new or known to be good vehicle or to an established acceptable stopping distance Actual stopping distances will be influenced by weather conditions terrain road surface condition actual vehicle weight accessories installed and vehicle speed The test is conducted by latching the parking brake to eliminate different pedal pressures and to include the effects of errors in linkage adjustment 20 Establish the acceptable stopping distance by testing a new or know to be good vehicle and recording the stopping location or stopping distance For fleets of vehicles several vehicles should be tested when new and the range of stopping locations or distances recorded Drive the vehicle at maximum speed on a flat dry clean paved surface Ref Fig 10 Quickly depress the brake pedal to latch the parking brake at the line or marker in the test area and remove foot from pedal The vehicle should stop aggressively The wheel brakes may or may not lock Observe the vehicle stopping location or measure the vehicle stopping distance fro
41. s guards and safety devices should be inspected regularly and maintained in a safe operating condition e Special cart or devices designed and approved for hazardous area operation should be inspected to ensure that maintenance preserves the original approved safe operating features e Carriers should be kept in a clean condition to minimize fire hazards and facilitate detection of loose or defective parts e Modification and additions which affect capacity and safe machine operation should not be performed by the customer or user without manufacturer s prior written authorization where authorized modifications have been made the user should ensure that capacity operation warning and maintenance instruction plates tags or decals are changed accordingly e Care should be taken to ensure that all replacement parts are interchangeable with the original parts and of a quality at least equal to that provided in the original equipment Maintenance Operations Like other machines this vehicle can cause injury if improperly used or maintained This section contains broad safety practices recommended for safe vehicle operations Before operation the controlling party should establish such additional specific safety practices as may be reasonably required for safe operations Experience has shown that vehicles which comply with the provisions stated are safe when properly operated in accordance with the safety and operation
42. t joint should be connected If disconnected replace Low voltage and controller protection Running with too heavy a load for a long period that results in the controller over heat protection Charge battery as soon as possible After the temperature of the controller comes down the protection status should recover Specific Gravity Testing A cost effective way to identify a poorly performing battery is to use a hydrometer to identify a battery in a set with a lower than normal specific gravity Once the particular cell or cells that are the problem are identified the suspect battery can be removed and replaced At this point there is nothing that can be done to salvage the battery however the individual battery should be replaced with a good battery of the same brand type and approximate age 1 Donotadd water at this time 2 Wash hydrometer with de ionized water 35 3 Fill and drain the hydrometer 2 to 4 times before pulling out a sample 4 There should be enough sampled electrolyte in the hydrometer to completely support the float 5 Takea reading record it and return the electrolyte back to the cell 6 Check electrolyte specific gravity for each cell testing one cell temperature by thermometer 7 Check all cells in the battery repeating the steps above 8 Replace the vent caps and wipe off any electrolyte that might have been spilled 9 025 C pt 0 0007 t 25 p 25
43. tery 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 Ibs 6 8 Nm torque Protect the battery terminals and battery wire terminals with a commercially available protective coating front of vehicle t Battery Connections 30 A new battery must mature before it will develop its maximum capacity Maturing may take up to 100 charge discharge cycles After the maturing phase the older a battery gets the lower the capacity The only way to determine the capacity of a battery is to perform a load test using a discharge machine following manufacturer s recommendations Prolonged Storage CAUTION Battery charger controller and other electronic devices need to be disconnected since they will contribute to the premature discharge of batteries During periods of storage the batteries will need attention to keep them maintained and prevent discharge In high temperatures the chemical reaction is faster while low temperatures cause the chemical reaction to slow down A vehicle that is stored at 90 F 32 C will lose 002 of specific gravity each day If a fully charged battery has a specific gravity of 1 275
44. ure the voltage using a DC voltmeter 3 Check the state of charge with the following table 4 Charge the battery if it registers 0 to 70 charged If battery registers below the Table 1 values the following conditions may exist e The battery was left in a state of discharge too long e The battery has a bad cell Batteries in these conditions should be taken to a specialist for further evaluation or retired from service State of charge as related to specific gravity and open circuit voltage Perea o CGE Specific Gravity g cm Open circuit voltage Corrected to 25 C 6V 8V 12V 100 1 28 6 37 8 49 12 73 90 1 26 6 31 8 41 12 73 80 1 24 6 25 8 33 12 50 70 1 22 6 19 8 25 12 37 37 60 1 2 6 12 8 16 12 24 50 1 18 6 05 8 07 12 1 40 1 15 5 98 7 97 11 96 30 1 13 5 91 7 88 11 81 20 1 1 5 83 7 77 11 66 10 1 07 5 75 7 67 11 51 Battery Terms Explained Active Material In the positive plates the active material is lead dioxide In the negative it s metallic sponge lead When a circuit is created these materials react with sulfuric acid during charging and discharging Ampere Amp A unit of measurement for the electron flow or current through a circuit Ampere Hour Amp Hr AH A unit of measure for a battery s electrical storage capacity calculated by multiplying the current in amperes by the time in hours Example A battery which delivers 5 amps for 20 hours provides 5 amps x20 hours 100 AH of capac

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