Star EV BN72-14-AC-D Owner's And Service Manual
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Star EV BN72-14-AC-D Owner's And Service Manual

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Owner's Manual and Service Guide
Enclosed Bus:
BN72-14-AC-D and BN72-11-AC-D (Wheelchair Accessible)

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Summary of Contents for Star EV BN72-14-AC-D

  • Page 1 Owner’s Manual and Service Guide Enclosed Bus: BN72-14-AC-D and BN72-11-AC-D (Wheelchair Accessible)
  • Page 2 Thanks for buying the Star EV Enclosed Bus. This manual contains information you will need for proper operation, maintenance, and care of your Enclosed Bus. A thorough understanding of these simple instructions will help you to obtain maximum enjoyment from your new Star EV.

  • Page 3: Table Of Contents

    Table of Contents Vehicle Specifications Operation Important labels Functions Operational Process Safety Maintenance Battery maintenance Traction/motor maintenance Speed controller maintenance Brake system maintenance Lubrication General maintenance notes Periodic maintenance Storage Troubleshooting Electrical Diagrams...

  • Page 4: Vehicle Specifications

    1: Vehicle Specifications Enclosed Bus BN72-14-AC-D-M and BN72-11-AC-D-Wheelchair-M (Wheelchair Accessible model) 14 / Wheelchair: 11+ wheel- Fiberglass with steel frame Passengers Body Material chair and aluminum doors Twelve 6 V (72 V) batteries, Independent suspension, coil Battery System Front Suspension...

  • Page 5: Functions

    Functions Power key: Controls the power supply of the whole vehicle. When the key is inserted into it and turned clockwise, it will switch on the lights, horn, and the control sys- tem; when the key is turned back, the power will be switched off. Acceleration pedal: Controls the speed.

  • Page 6: Operational Process

    make sure that it is in the OFF position. Combination meter: This meter shows information including lights, speed, range, hand brake, and battery power. Operational Process Starting the vehicle Select F for Forward or R for Reverse from F/R Button. Switch on power with key.

  • Page 7: Safety

    • Explosive hydrogen gas is produced while battery is charged. Only charge the battery in well-ventilated areas. • Before using the charger, check if the battery charger you are using is cor- rectly rated for your local AC electricity network. •...

  • Page 8: Battery Maintenance

    3: Maintenance Battery Maintenance WARNING: Battery electrolyte is poisonous and dangerous, may cause severe burns, injury, etc.. Always wear protective clothing, gloves, and goggles when han- dling batteries, electrolyte, and charging your battery. KEEP OUT OF REACH OF CHILDREN. Cleaning •...
  • Page 9 • 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 two weeks. • When driving, the driver should always be aware of the drop level of the battery power from the battery power meter.
  • Page 10 Watering procedure Open the vent caps and look inside the fill wells. Check electrolyte level; the minimum level is at the top of the plates. If necessary add just enough water to cover the plates at this time. Put batteries on a complete charge before adding any additional water (refer to the Charging section).
  • Page 11 Check voltage level(s). Perform equalization charge. Refer to the Equalizing section for the proper procedure. Take 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: The battery is old and approaching the end of its life.

  • Page 12: Traction/Motor Maintenance

    State of charge as related to specific gravity and open circuit voltage Open circuit voltage Percentage of Specific Gravity Charge Corrected to 80° F 12 V 24 V 36 V 48 V 100% 1.277 6.37 8.49 12.73 25.46 38.20 50.93 1.258 6.31 8.41...

  • Page 13: Speed Controller Maintenance

    Symptoms Possible Causes All copper plates turn black The pressure of brush is incorrect. The commutator turns black in a Short circuit in the commutator or armature coil; poor welding or certain order and in groups disconnection between the commutators and the armature coil. The central line of the commutator deviates or its surface is not The commutator turns black round and smooth.

  • Page 14: Lubrication

    Lubrication Use 901 vehicle brake oil DOT3 as brake oil. Use 1L of 85W/90GL lubrication oil for gear box. Use 1L of 90GL hypoid gear oil for the rear axle. Lubrication points: steering gears, horizontal bars, steering ball joints, and bearings. General Maintenance Notes •...
  • Page 15 • Check if all the connections between the motor, the battery, and the con- troller are in good condition. Use the following cleaning procedure for routine maintenance: Turn the power key to OFF position. Remove power by disconnecting the battery. Discharge the capacitors in the controller by connecting a load (such as a contactor coil or a horn) across the controller’s B+ and B- terminals.
  • Page 16 Item Descriptions Daily Weekly Monthly Quarterly Annually Observe the charging status, check ☑ if the charger plug becomes hot. Charger Clean the surface of the charger. Do ☑ not get any water inside the charger. Check if all terminals are tightened properly.

  • Page 17: Storage

    4: Storage Follow the steps below when the vehicle is stored. 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. Turn the power key to OFF position, remove the key, and store the key in a safe place.
  • Page 18 2. Locking control when vehicle starts running, speed cannot be adjusted. Malfunction Possible Reason Troubleshooting Terminals of solenoid stick together Check or repair Vehicle runs at full speed Controller failure Change when it starts Potentiometer failure Repair or change Internal short of motor Repair or change Motor is assembled too tight or blocked Repair or change...
  • Page 19 4. Possible reason and troubleshooting for malfunctions of mechanic system. System Malfunction Possible Reason Troubleshooting Clearance of tension rod ball is too big Change Steering knuckle and master pin is not lubri- Steering heavy Add lube cated Steering shaft or its plastic cover is worn out Change Rack of redirector is worn out Change redirector...
  • Page 20 4. Possible reason and troubleshooting for malfunctions of mechanic system. System Malfunction Possible Reason Troubleshooting Brake pedal has no free travel Adjust Clearance between brake shoe and drum is too Adjust or change small or releasing spring is disabled Braking drag Piston of wheel cylinder is ineffective Check or change Piston of master cylinder is ineffective...

  • Page 21: Electrical Diagrams

    6: Electrical Diagrams...
  • Page 22 This manual tries to be as sound and elaborate as possible in literal and figurative description as well as technical description on the ba- sis of existing data. At the same time, JH Global reserves the right to alter the content of this manual and this manual is subject to change without prior notice;...
  • Page 24 STAR EV, a brand of JH Global Services, Inc. 378 Neely Ferry Road | Simpsonville, SC 29680 www.starev.com...

This manual is also suitable for:

Bn72-11-ac-d

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