Related Manuals for StarEv BN72-08-AC-Autodrive-M
Summary of Contents for StarEv BN72-08-AC-Autodrive-M
- Page 1 Owner’s Manual and Service Guide M-Series Shuttle Bus: BN72-08-AC-Autodrive-M, BN72-11-AC-Autodrive-M, BN72-14-AC-Autodrive-M, and BN72-23-AC-ADS-M...
- Page 2 Thanks for buying the Star EV M-Series Bus. This manual contains information you will need for proper operation, maintenance, and care of your M-Series Bus. A thorough understanding of these simple instructions will help you to obtain maximum enjoyment from your new Star EV.
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Page 3: Table Of Contents
Table of Contents Safety Information General safety For the user Vehicle Specifications Operation and Service Before initial use Controls Vehicle cleaning and care Periodic service schedule Periodic test for mechanical brake Lubrication Batteries and charging Troubleshooting Battery Terms Explained Electrical Diagrams... -
Page 4: Safety Information
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. - Page 5 General Operation Safety • Use the vehicle in a responsible manner and maintain the vehicle in safe operating condition. • Read and observe all warnings and operation instruction labels affixed to the vehicle. • Follow all safety rules established in the area where the vehicle is being operated.
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Page 6: For The User
manufacturer’s instructions. • Maintain the vehicle in an area away from exposed flame or persons who are smoking. • Be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated. • Test-drive the vehicle after any repairs or maintenance. - Page 7 • Ascend or descend grades slowly. • Under all travel conditions the vehicle 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. •...
- Page 8 ties may be on or off the premises. Maintenance and inspection of the vehicle should be performed in conformance with the manufacturer’s recommendations and the following practices. • A scheduled preventive maintenance, lubrication, and inspection system should be followed. • Only qualified and authorized personnel should be permitted to maintain, repair, adjust, and inspect vehicles.
- Page 9 This safety information is intended to provide the controlling party with basic safe- ty information and to encourage the controlling party to implement a vehicle safety program. Safety Survey The controlling party should perform a safety survey periodically, and as condi- tions warrant to their premises, to identify areas where the vehicle should not be operated and to identify possible hazards.
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Page 10: Vehicle Specifications
2: Vehicle Specifications Shuttle Bus BN72-08-AC-Autodrive-M, BN72-11-AC-Autodrive-M BN72-08-AC-Autodrive-M BN72-11-AC-Autodrive Passengers 8, all facing forward 11, 3 facing backward Twelve 6 V (72 V), Trojan T-105 Twelve 6 V (72 V), Trojan T-105 Battery System Motor Power 10 hp AC motor... - Page 11 Shuttle Bus BN72-11-AC-H, BN72-14-AC-Autodrive-M, BN72-23-AC-Autodrive-M BN72-11-AC-H (Wheelchair BN72-14-AC-Autodrive-M BN72-23-AC-Autodrive-M Accessible) 11, 3 facing backward + Passengers 14, 3 facing backward 23, 4 facing backward wheelchair Twelve 6 V (72 V), Trojan Twelve 6 V (72 V), Trojan Twelve 6 V (72 V), Trojan Battery System T-105, optional second T-105...
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Page 12: Before Initial Use
3: Operation and Service Information 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. - Page 13 Front light and turn signal switch Horn Steering wheel Key switch Windshield wiper switch CD player Light switch Forward/Reverse switch Charging receptacle 10. Parking brake handle 11. Accelerator pedal 12. Brake pedal WARNING: To prevent loss of control, do not move the Forward/Reverse switch while the vehicle is in motion.
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Page 14: Vehicle Cleaning And Care
turn key to ‘OFF’ position and remove key. • Make sure that the direction selector is in correct position before attempt- ing to start the vehicle. • Always bring the vehicle to a complete stop before shifting the direction selector. •... -
Page 15: Periodic Service Schedule
Periodic Service Schedule NOTE: Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions. Daily Before Use: • Check general operation of service brake • Check park brake function • Check warning device function in reverse •... -
Page 16: Periodic Test For Mechanical Brake
• Front Springs: Check for loose hardware, cracks at attachments • Front Wheel Alignment: Check for unusual tire wear, align if required • Parking Brake: Check for bent/binding linkage rod, check for damage or wear to latch arm or catch bracket, lubricate as required, use light oil. Do not lubricate cables or brake latch. -
Page 17: Lubrication
The Periodic Brake Performance Test should be performed regularly as an evalua- tion 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”... -
Page 18: Batteries And Charging
time. Excess grease may cause grease seals to fail or grease migration into areas that could damage components. 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 per- sonal injury or death, keep all smoking materials, open flame or sparks away from the batteries. - Page 19 Battery A battery is defined as two dissimilar metals immersed in an acid. If the acid is ab- sent 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.
- Page 20 • Check electrolyte level. (See Electrolyte Level and Water section.) • Tighten all vent caps before charging. • Do not overcharge or undercharge the batteries. • Do not charge a frozen battery. • 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.
- Page 21 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 • Examine the outside appearance of the battery. • Look for cracks in the container. •...
- Page 22 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 bat- teries with a solution of sodium bicarbonate (baking soda) and water.
- Page 23 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 petro- leum jelly (Vaseline) to prevent corrosion. Keep the area around batteries clean and dry. Electrolyte Level and Water Correct level of the electrolyte is 1"...
- Page 24 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.
- Page 25 Procedure: Open the vent caps and look inside the fill wells. Check electrolyte lev- el; the minimum level is at the top of the plates. If there is no electrolyte visible, add just enough distilled/deionized wa- ter to cover the plates. Replace and tighten all water vent caps.
- Page 26 battery terminal protectant. Insulate the metal container to prevent the metal can from contacting battery terminals which could result in an ex- plosion. • Use care to connect the battery wires as shown. Tighten the battery post hardware to 50 - 70 in. lbs. (6 - 8 Nm) torque. Protect the battery terminals and battery wire terminals with a commercially available protective coat- ing.
- Page 27 state of charge of a battery. • In winter conditions, the battery must be fully charged to prevent the pos- sibility 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.
- Page 28 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. 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.
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Page 29: Troubleshooting
NOTE: This system can also be configured using 12-volt batteries. It is not rec- ommended that you mix batteries of different voltages within the same sys- tem. 4: 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. - Page 30 Problem Possible Reason Processing Methods Brake compensator is loose Adjust brake draw-bar Poor braking condition Replace the brake shoe or brake Brake shoe is worn cable Check the control fuse: if it is broken, replace. Check jiggle switch on the charge socket for looseness. Fasten it to the connection cables.
- Page 31 ρ25°C = ρt +0.0007 (t-25) ρ25°C ——25°C electrolyte specific gravity ρt ——t°C 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/cm3. If any specific gravity readings register low, then follow the steps below: Check and record voltage level(s).
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Page 32: Battery Terms Explained
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 Open circuit voltage Specific Gravity (g/cm³) Percentage of Charge Corrected to 25° C 12 V 100% 1.28... - Page 33 plete 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.
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Page 34: Electrical Diagrams
6: Electrical Diagrams... - Page 36 JH Global has the final say on the interpretation of this manual. All rights reserved. STAR EV, a brand of JH Global Services, Inc. 378 Neely Ferry Road | Simpsonville, SC 29680 www.starev.com...
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