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Problem

Possible Reason

Processing Methods

Poor braking condition

Brake compensator is loose

Adjust brake draw-bar

Brake shoe is worn

Replace the brake shoe or brake 

cable

Vehicle 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 

contact joint should be connected. 

If disconnected, replace.

Low voltage and controller protec-

tion

Charge battery as soon as possible

Running with too heavy a load for 

a long period that results in the 

controller over-heat protection.

After the temperature of the con-

troller 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.  Do not add water at this time.
2.  Wash hydrometer with deionized water.
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 com-

pletely support the float.

5.  Take a reading, record it, and return the electrolyte back to the cell.
6.  Check electrolyte specific gravity for each cell, testing one cell tempera-

ture 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.

30

Содержание BN72-08-AC-Autodrive-M

Страница 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...

Страница 2: ...e instructions will help you to obtain maximum enjoyment from your new Star EV If you have any questions about the operation or maintenance of your M Series Bus please consult your Star EV dealer Read...

Страница 3: ...on 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 Expla...

Страница 4: ...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 communi ties may...

Страница 5: ...e trained and qualified to do so Follow the manufacturer s maintenance procedures for the vehicle Be sure to disable the vehicle before performing any maintenance Disabling includes removing the key f...

Страница 6: ...Be aware of pedestrians at all times Do not drive the vehicle in a manner that would endanger anyone Riding on the vehicle by persons other than the operator is authorized only on personnel seat prov...

Страница 7: ...ectric Vehicles 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 fa...

Страница 8: ...zardous area operation should be inspected to ensure that maintenance preserves the original approved safe operating features Vehicles should be kept in a clean condition to minimize fire hazards and...

Страница 9: ...or 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 avoi...

Страница 10: ...s plastic Fiberglass plastic Front Suspension Independent suspension coil over shock Independent suspension coil over shock Rear Suspension Leaf spring and shock Leaf spring and shock Steering System...

Страница 11: ...and injected mold Front Suspension Independent suspension coil over shock Independent suspension coil over shock Independent suspension coil over shock Rear Suspension Leaf spring and shock Leaf spri...

Страница 12: ...ar 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 p...

Страница 13: ...onmental 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 designat...

Страница 14: ...damage to seals plastics seat material body finish or electrical system Do not use pressure in excess of 700 psi to wash exterior of vehicle Clean windshield with lots of water and a clean cloth Minor...

Страница 15: ...tteries Clean batteries and terminals check charge condition and all connections Wiring Check all wiring for loose connections and broken insulation Charger Receptacle Clean connections keep receptacl...

Страница 16: ...ease leakage Rack End Ball Joint Lubricate use wheel bearing grease Rear Axle Check for unusual noise and loose or missing mounting hard ware Annually Front Wheel Bearings Check and adjust as required...

Страница 17: ...t dry clean paved surface 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 br...

Страница 18: ...nstalling 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...

Страница 19: ...n 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 e...

Страница 20: ...eceptacle housing for dirt or debris Charge the batteries after each day s use Monthly Inspect all wiring for fraying loose terminations corrosion or deteriora tion of insulation Check that the electr...

Страница 21: ...smoke near batteries 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 a...

Страница 22: ...eparing Acid Neutralizing Solution 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 e...

Страница 23: ...the increase in volume of the electrolyte that results from the charging cycle CAUTION Do not overfill batteries The charging cycle will expel electro lyte and result in component damage A battery be...

Страница 24: ...tering 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 th...

Страница 25: ...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 Clea...

Страница 26: ...ger 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 ke...

Страница 27: ...important things to avoid Freezing Avoid locations where freezing temperature is expected Keeping a battery at a high state of charge will also prevent freezing See following table 31 Heat Avoid dire...

Страница 28: ...y 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 batte...

Страница 29: ...ording to require ments Turning parts are not lubricated Apply lubricant Abnormal abrasion on tire The toe in is not correct Adjust the toe in Tire pressure is not correct Inflate the tire according t...

Страница 30: ...rotection After the temperature of the con troller comes down the protection status should recover Specific Gravity Testing A cost effective way to identify a poorly performing battery is to use a hyd...

Страница 31: ...g conditions may exist The battery is old and approaching the end of its life The battery was left in a state of discharge too long Electrolyte was lost due to spillage or overflow A weak or bad cell...

Страница 32: ...aterials 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 batt...

Страница 33: ...nt DC power from a battery into 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 S...

Страница 34: ...34 6 Electrical Diagrams...

Страница 35: ...35...

Страница 36: ...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 th...

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