Star View the User Manual

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Star View the User Manual | Manualzz

Owner’s Manual and Service Guide

Roadster-2+2, Roadster-4+2, Roadster-6+2

August 2014

Table of Contents

Specifications 2

Operation

Vehicle layout

3

Dashboard

3

Switches

4

Pedals

5

Charging

5

Cigarette lighter

5

User information 6

Driver information

6

Driving

Operation procedure

7

Safety

7

Driving on hilly terrain

7

Parking safety tips

8

Before initial use 8

Maintenance

Battery maintenance

9

Charging the battery group

11

Brake system maintenance

12

Steering system maintenance

12

Motor maintenance

12

Lubrication maintenance

12

Maintenance schedule

13

Troubleshooting 14

After-sale service 16

Monthly maintenance record 17

Electrical diagrams 18

1

Vehicle Specifications

Passengers

Battery group

Motor

Controller

Top speed (mph)

Load capacity (lbs)

Dimensions (in)

Weight including battery (lbs)

4

48 V, 8 x 6V, Trojan

T105

7HP, AC

Curtis 450A 1236

19.5 (20-25 LSV)

800

140 x 53 x 46

1205

2+2 Roadster

1580

4+2 Roadster

6

48 V, 8 x 6V, Trojan

T105

7HP, AC

Curtis 450A 1236

19.5 (20-25 LSV)

1080

156 x 53 x 50

6+2 Roadster

8

48 V, 8 x 6V, Trojan

T105

7HP, AC

Curtis 450A 1236

19.5 (20-25 LSV)

1800

187 x 56 x 50

1300

Ground Clearance (in) 5.9

Turing Radius (ft) 14

Wheelbase (in)

Climbing capacity

Front suspension

Steering system

Brake system

67

25%

Rack and pinion

Rear drum

5.9

17

95

25%

Leaf spring and shock Leaf spring and shock Leaf spring and shock

Rack and pinion

4-wheel hydraulic

5.9

19

125

25%

Rack and pinion

4-wheel hydraulic

Tire size

Tire pressure (psi)

Wheel type

225 / 55 / 12 DOT

30

12 inch aluminum

225 / 55 / 12 DOT

30

12 inch aluminum

225 / 55 / 12 DOT

30

12 inch aluminum

2

Operation

Vehicle Layout

1|

Dashboard

2|

Steering wheel

3|

Combination switches

4|

CD player (optional)

5|

Brake pedal

6|

Forward/reverse switch

7|

Accelerator pedal

8|

Key switch

9|

Cigarette lighter

10|

Speakers (optional)

11|

Charger socket

12|

Turn signal lever, horn and light switch

13|

Cup holders

Dashboard

1|

Speed gauge mounting point

2|

Speedometer

3|

Lights on indicator

4|

Left turn signal indicator

5|

Power display

6|

Right turn signal indicator

7|

Brake light

Notes:

• Low battery voltage alarm light: Red when battery voltage is low.

• Turn signal: The turn signal lever has a button on the end. Push in to sound horn; pull lever back to turn on lights.

• High beam: The indicator will light up yellow when high beams are on.

3

Switches

Key switch

Normal off position: key can only be removed in this position

All power systems are on when in this position.

WARNING:

Do not take out the key when the vehicle is running. Do not leave key in ignition to avoid theft or accidental operation by a child.

Forward/Reverse switch

The switch has three positions. The vehicle goes forward when FWD is pressed down and backward when REV is pressed down. When the switch is centered, vehicle is in the neutral position.

WARNING:

Do not shift between forward and reverse when vehicle is running or damage to the transmission and/or motor can occur.

Turn signal

Push lever up to illuminate right turn signal; push down to illuminate left turn signal.

Headlight switch

Pull turn signal lever into back position to turn lights on. Push back forward for lights to be in off position.

Horn

Press down the horn button on the end of the turn signal lever to engage horn.

4

Pedals

Parking brake

Accelerator

Brake pedal

Parking brake

The parking brake will click and lock in the down position to indicate that the parking brake is engaged. Lightly push on the accelerator pedal to release the parking brake.

Braking

Depress the brake pedal to brake.

Accelerating

Press the pedal and control speed by force applied to the pedal.

WARNING: Before leaving the cart, put the Forward/Reverse switch in the neutral. Before moving forward or reverse the parking brake should be released to prevent serious damage to the brake system and related parts.

Charging, Charger Socket

Plug the larger round plug end into the vehicle charge port. Plug the power cord end into a standard outlet (110 V) to begin the recharging cycle. See charging section (p. 11).

Cigarette lighter

Plug in any 12 V DC accessories into outlet. Ideal for use of MP3, phone chargers, mini fans and other accessories.

5

User Information

Read all vehicle specifications, and use vehicles according to manufacturer recommendations.

Do not modify the vehicles without manufacturer’s approval. Any modifications will affect the function, safety, and warranty of vehicles.

Any replacements of spare parts by an authorized STAR EV dealer (i.e., changing batteries, tires, seats, etc.) shouldn’t affect the safety requirements. Do not attempt to lift the suspension of this vehicle as serious injury could occur and the vehicle will no longer be warranted by the manufacturer.

This is a low speed electric vehicle, and should be used on approved roads and meet the road regulations. Carefully review the laws for golf car and low speed vehicle use in the city and state you are operating the vehicle in.

Driver Information

It is recommended that only persons with a valid motor vehicle driver’s license be allowed to operate the vehicle.

The driver should pay close attention to road conditions, pedestrians and other vehicles on the road.

Remind passengers to buckle seat belts and keep arms and legs inside the vehicle at all times when it is moving.

Report accidents to your insurance company.

The driver should not modify, add or remove any parts of the vehicle. Do not add or install any optional steering wheel unless they are designed to fit this vehicle. Please see authorized dealer in your area for help.

The driver should operate vehicles in approved areas.

6

Driving

Operation Procedure

1|

Insert the key and turn it to ON position.

2|

Press the green forward switch (or reverse).

3|

Release the parking brake by lightly pressing on the accelerator pedal. The speed will increase as pedal is pressed downward.

4|

When stopping the vehicle, release the accelerator pedal and depress the brake pedal slowly.

Then push down the parking pedal after stopping to engage the parking brake.

Safety

Release the parking pedal before driving to avoid any damage to the brake shoes or motor.

Do not depress the accelerator pedal too aggressively or frequently or it will shorten the life of the drive train and components.

Do not start, stop, or turn at high speeds.

Do not pass other vehicles traveling in the same direction at intersections, blind spots, or at other dangerous locations. Follow all traffic laws.

Avoid running over loose objects, potholes, and bumps to avoid damage to the vehicle and possible injury to passengers.

Please observe and obey all traffic regulations, including the passenger and weight capacity requirements, authorized speed limits, and other regulations.

Keep a clear view of the path of travel. Observe other traffic and pedestrians, and maintain a safe distance, based on speed of travel, from a vehicle ahead.

Driving on hilly terrain

Ascend or descend grades slowly.

Do not turn around when driving on a sharp incline or decline. Be careful when driving near to the edge of the slope.

7

Parking safety tips

Park the cart on flat and solid ground.

Depress the brake pedal. Keeping the direction switch in neutral position, turn off the ignition switch and take out the key. Make sure that the brake pedal is locked in park. You will hear a load click when the parking brake is engaged.

Keep the vehicle stored inside of a garage if possible. Don’t leave it outside in snow or rain, as water can get into the electrical system which will cause damage. Check with your local dealer about the advantages of a car cover if you cannot park the vehicle in a garage, car port, or similar covering.

Before Initial Use

Read, understand and follow the safety label on the instrument panel. Be sure you understand how to operate the vehicle, its equipment and how to use it safely. Maintaining good performance depends to a large extent on the proper operation of the vehicle.

New Vehicle Inspection

Before a new vehicle is put into operation, the items shown below must be performed.

1|

Check status of each spare part, especially the nut on the steering wheel and braking system.

2|

Check for any leakage problems with the steering system, turning system and transaxle.

3|

Check the water level of each battery. Maintain proper levels (see Trojan battery guide) and do

not overfill battery cells!

4|

Check if tire inflation is correct. Low pressure will lead to difficulty turning and bumpy riding.

Keep the normal air pressure for the tire to prevent premature wear. Recommended tire pressure is 30 PSI.

5|

Check for any worn items between the wiring and other locations where parts rub against each other.

8

Maintenance

Turn off the electricity, take out the key and push down on the parking brake.

When working underneath vehicles, please use jack and triangle wood to fix the front and rear wheels, in order to avoid accidents.

Keep the maintenance area clean and safe.

Please perform vehicle maintenance according to safety guidance. Refer to STAR EV preventative maintenance schedule or visit an authorized dealer.

Maintain the ventilation of working sites.

Check and maintain safe working conditions. Check and maintain the braking, steering, speed direction control system, emergency facilities, head/rear lights, controller, and safety equipment.

Check the battery cover caps to ensure they are snapped into place.

Battery Maintenance

The batteries for this vehicle have high current, high capacity, and a long lifetime. To keep the vehicle in good performance, it is very important to maintain it in the correct procedure.

The connectors on the batteries are the output connectors. Keep the area clean and dry, with no foreign matter or dust on it. Proper care will ensure batteries’ performance and longevity.

WARNING:

Do not use tap water when filling cells. Use distilled water only!

Check the height of the electrolyte periodically. Check it once per week in summer and once every two weeks the rest of the year. Standard height level is 10-15mm (½“) higher than the battery plate. If is too low, please add the recommended distilled water.

Keep the wiring well-connected. After using the vehicle initially for 2-3 days, the completed inspection for all connectors should be carried out. Inspect the vehicle once a week following. Any loose or rusty connectors should be fixed. Loose or rusty connectors can cause high temperature, damage, or possible sparking.

9

NOTE:

Don’t over-tighten terminals!

Charge the battery immediately after discharge, or it will affect the battery life. Charge the batteries that are in long storage or non-fully charged separately.

Keep the filling-water container clean, so no impurities will be put into the battery.

When the environment temperature is under -40° F, the density of the electrolyte after charging is

1.28 - 1.29 g/cm

3

. If it is more than 1.30 g/cm

3

, the battery can be damaged badly. Add water immediately to keep the electrolyte value to normal. If the battery discharges by 80% (the electrolyte is between the range 1.13 - 1.15 g/cm

3

), charge it immediately. At this range the vehicle can only last 2 - 3 mi. Don’t discharge any longer, or it will damage the battery.

Charge the battery fully before storage. Charge it at least once a month for 24 hours. Discharge the batteries and charge it once again before use.

See an authorized dealer for further help and maintenance.

Battery Replacement

Replace the batteries immediately when approaching the end of the battery’s life. The capacity of a battery at the end of its life will decrease quickly and won’t meet the standard range (miles on full charge). Consult with the supplier or dealer for a detailed battery replacement.

Remove battery tie-downs and cables. Lift out batteries with a commercially available lifting device.

If the batteries have been cleaned and any acid in the battery rack area has been neutralized as recommended, no corrosion to the battery racks or surrounding area should be present. Any corrosion found should be immediately removed with a putty knife and a wire brush. The area should be washed with a solution of sodium bicarbonate (baking soda) and water and thoroughly dried before priming and painting with a corrosion resistant paint.

The batteries should be placed into the battery racks and the battery tie-downs tightened to 45 - 55 in. lbs. (5 - 6 Nm) torque to prevent movement but not tight enough to cause distortion of the battery cases.

Inspect all wires and terminals. Clean any corrosion from the battery terminals or the wire terminals with a solution of sodium bicarbonate (baking soda) and clean with a wire brush.

10

WARNING:

To prevent battery explosion that could result in severe personal injury or death, extreme care must be used with aerosol containers of battery terminal protectant. Insulate the metal container to prevent the metal can from contacting battery terminals which could

result in an explosion.

Use care to connect the battery wires as shown. Tighten the battery post hardware to 50 - 70 in. lbs.

(6 -8 Nm) torque. Protect the battery terminals and battery wires with a commercially available protective coating.

Battery Connections

Charging the Battery group

In order to optimize battery life, please use the recommended charger to recharge the batteries.

Keep the key switch in OFF position during charging.

Keep the charger in a cool, dry location and avoid moisture.

Charging should be monitored.

NOTE:

When disconnecting the charger, be sure to unplug cord from AC power source first then unplug cord connected to vehicle.

11

Brake System Maintenance

Adjust the gap between the brake drum and brake shoes.

Dial up the adjusting ratchet wheel of the brake drum until the wheel cannot turn freely, then dial down the ratchet wheel 7 - 8 teeth.

Steering System Maintenance

Check if there is any damage to the dust cover of the tie-rod. A broken dust cover will let water in and damage the tie-rod, and the steering system will not be flexible. Replace a new one immediately once a worn one is found. Make sure the front wheel toe-in is between 3 - 5 mm (1/8 – 3/16”). If it exceeds this value, adjust the tie-rod screw stem.

Motor Maintenance

The drive motor is an AC motor. Keep the motor surface clean at all times. Clean the surface with a dry cloth. Avoid any water contact inside motor.

Lubrication Maintenance

Check the brakes once a month. Fill it full if brake fluid is low in master cylinder. The front hub, front wheel bearing, brake system, and steering system should be filled once every year with #3 general lithium based lubricant.

The gear oil should be changed once a year. User can choose gear oil according to the climate.

(

Summer: GL-4 90, Winter: GL-80W/90)

Replace the grease for the rear axle once a year, using recommended oil type GL-5 90 and GL-5

80W/90. Fill the level to 1.2 liters (40 oz). When changing, first twist down the oil plug to discharge the gear oil. Clean the oil plug and replace it, then inject the new gear oil.

12

Maintenance Schedule

Item

Check tire pressure

Check tires for abrasions

Check tightness of the bearing bolt and the tire nut

Tire rotation

Check braking and the parking function

Check brake tube for leakage

Check if brake shoes are worn

Check if steering wheel works freely

Check brake pump

Check tightness for the turning ball joint and rod

Check nut on the steering rack’s spindle

Check tightness of steering rack and bracket

Inspect and adjust front wheel’s toe-in

Checking tightness of front absorber and helix spring

Check height of electrolyte

Check density of electrolyte

Check if the battery’s pole is loose

Clean battery pole by water

Check light and relay performance

Clean and fix wiring connector

Check and adjust front tire’s bearing

Check or replace transaxle

Check performance of gearbox and bearing (after the first h f )

Clear and lubricate front wheel bearing

Checking motor bearing

Lubricate other parts (use general oil)

weekly monthly quarterly

13

Troubleshooting

The authorized qualification for repair, the requirement for application, safety and the maintenance requirement should be the same.

Problem Possible reason Processing methods

Operation procedure is wrong

Refer to user manual

Wiring connector is corroding

Cut off the power, remove the nut, clean the connector and replace the nut

Cart cannot move

Battery power is low

Direction switch is damaged

Charge the battery

Replace part

Accelerator is damaged Replace part

Direction contactor is damaged

Replace part

Repair or replace parts

Lighten the load of the vehicle to decrease the temperature

Vehicle moves slowly and/or stops when climbing

Releasing the accelerator pedal does not slow down the vehicle

Wiring is loose

Vehicle is overloaded resulting in the shutting off the controller when temperature reaches

167° F

The spring for the accelerator pedal is broken and the pedal cannot reposition

Shut off the ignition lock, step on the parking pedal ,then contact with the supplier

14

No indication (LEDs) on the dashboard

Bumpy riding

Turning is difficult

Turning excessively

Lack of power, slow response

Rear bearing is leaking oil

Parts are loose

Fuse is burned out

The tire pressure is unbalanced

The front and rear wheel are not aligned

Lock the inserted parts

Replace the fuse

Balance the air pressure

Correct the assembly of the wheels

Tire pressure is too low

Shaft is short of lubrication.

Tie-rod is damaged

Inflate tires

Add lubrication

The direction shaft pin or joints are damaged

Replace parts

Replace part

Adjust or replace Steering rack has not been adjusted well or abased

The direction shaft is loose

Tighten direction shaft

Low battery power

Damaged drive gear

Charge the battery

Replace

Maintain speed control system Speed control system is faulty

Axle of the tire or the washer is damaged

Too much oil

Replace parts

Reduce oil quantity

15

Abnormal noise

Drive gear or the bearing is damaged

Bearing of front or rear suspension is damaged

Wheel screw is loose

Replace part

Adjust or replace

Tighten

Motor’s bearing is damaged

Replace part

Brake drum is damaged

Replace part

Low braking power

Brake shoe is not clean Keep clean

These possible causes are just for your reference and do not include all causes that result in these listed issues.

After-Sale Service

Star EV has authorized local dealers that will provide the friendly service and technical support for end users. Be sure to visit www.starev.com

to find a dealer in your area.

Users can report faulty problems by telephone, fax and email. Keep Star EV dealers informed of the model number, VIN number, estimated delivery time, contract number and date as well as a detailed description or photos of the faulty parts and problems, and our team will handle it accordingly.

Do not disassemble.

16

Monthly Maintenance record

Record

Is tire pressure normal? Are wing nuts tightened?

Is the batteries’ water level normal?

Any batteries or controller motor wirings loose?

Is the controller system normal?

Is the fixed screw for the steering system normal?

Are the wiring connectors clean?

Are the body and the frame of the vehicle normal?

Are the front axle and rear axle normal?

VIN NO:

Normal

Date

Abnormal Remarks

17

18

19

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