StarEv BN72-08-AC-Autodrive-M, BN72-23-AC-ADS-M, BN72-11-AC-Autodrive-M, BN72-14-AC-Autodrive-M Owner's Manual And Service Manual
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
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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.
If you have any questions about the operation or maintenance of
your M-Series Bus, please consult your Star EV dealer.
Read and understand this manual completely before operating your
Star EV.
This manual should be considered a permanent part of your M-Series
Bus and should remain with the car when lending or resold.
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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
Table of Contents
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6
10
12
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14
15
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17
18
29
32
34
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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.
1: Safety Information
General Safety
STAR EV strongly suggests that all users and maintenance personnel read this
entire 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 o-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.
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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 aixed to
the vehicle.
• Follow all safety rules established in the area where the vehicle is being
operated.
• Reduce speed to compensate for poor terrain or conditions.
• Apply service brake to control speed on steep grades.
• Maintain adequate distance between vehicles.
• Reduce speed in wet areas.
• Use extreme caution when approaching sharp or blind turns.
• Use extreme caution when driving over loose terrain.
• Use extreme caution in areas where pedestrians are present.
General Maintenance Safety
• Maintain the vehicle in accordance with the manufacturer’s periodic service schedule.
• Ensure that repairs are performed by those that are 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 from the key switch and removal of a battery
wire.
• 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.
• Check the polarity of each battery terminal and be sure to rewire the batteries correctly.
• Use specified replacement parts. Never use replacement parts of lesser
quality.
• Use recommended tools.
• Determine that tools and procedures not specifically recommended by the
manufacturer will not compromise the safety of personnel nor jeopardize
the safe operation of the vehicle.
• Support the vehicle using wheel chocks and jack stands. Never get under a
vehicle that is supported by a jack. Li the vehicle in accordance with the
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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 aer any repairs or maintenance. All tests must be
conducted in a safe area that is free of both vehicular and pedestrian traffic.
• Replace damaged or missing warning, caution or information labels.
• Keep complete records of the maintenance history of the vehicle.
• 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.
• 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 provided by the manufacturer.
• When the vehicle is to be le unattended, stop, apply the parking brake,
stop the engine or turn o power, turn o the control or ignition circuit,
and remove the key. Block the wheels if machine is on an incline.
• Use only approved vehicles in hazardous locations, as defined in the appropriate safety standards.
• Operators should not add to, or modify, the vehicle.
• Observe all traic regulations, including authorized speed limits. Under
normal traic conditions, keep to the right. Maintain a safe distance, based
on speed of travel, from a vehicle ahead.
• 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 traic and personnel,
and maintain a safe clearance.
• Slow down or stop, as conditions dictate, and activate the sound-producing warning device at intersections and when visibility is obstructed at
other locations.
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• 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.
• Avoid running over loose objects, potholes, and bumps.
• To negotiate turns, reduce speed to improve stability, then turn steering
wheel in a smooth, sweeping motion.
Nameplates, Markings, Capacity, and Modifications
The user should maintain in a legible condition all nameplates, warnings and instructions which are supplied by the manufacturer.
The user should not perform any modification or addition which aects 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 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 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.
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At the beginning of each shi during which the vehicle 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 vehicle is found to be in need of repair or in any way unsafe, the matter should be
reported immediately to the designated authority and the vehicle 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 vehicle 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 facili-
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ties may be on or o 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.
• Block chassis before working underneath it.
• Operations to check performance of the vehicle should be conducted in an
authorized area where safe clearance exists.
• Before commencing operation of the vehicle, follow the manufacturer’s
instructions and recommended procedures.
• 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.
• Properly ventilate the work area.
• Brakes, steering mechanisms, speed and directional control mechanisms,
warning devices, lights, guards, and safety devices should be inspected
regularly and maintained in a safe operating condition.
• Special vehicles designed and approved for hazardous 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
facilitate detection of loose or defective parts.
• Modification and additions which aect 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.
• 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.
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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.
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 o 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, Bridges
Sharp turns, blind spots, bridges and other potentially hazardous areas should be
either chained or roped o 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 traic or the pedestrian traic to eliminate the
interference. If elimination of the interference is not possible or is highly impractical, signs should be erected warning pedestrians of the vehicle traic and vehicle
operators of the pedestrian traic 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. Only
qualified, trained and authorized personnel should be permitted to inspect, adjust
and maintain the vehicle.
Only STAR EV replacement parts and materials should be used.
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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
Battery System Twelve 6 V (72 V), Trojan T-105 Twelve 6 V (72 V), Trojan T-105
Motor Power 10 hp AC motor 10 hp AC motor
Top Speed 18 mph 18 mph
Load Capacity 1400 lbs 2640 lbs
Weight w/ Batteries 2130 lbs 2600 lbs
Ground Clearance 5.5" 5.5"
Turning Radius 18 18
Wheel Base 83" 83"
Top Climbing Grade 20% 20%
Body Material Fiberglass, 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 Rack and pinion power steering Rack and pinion power steering
Tire Size 167/70-R13, DOT tire 167/70-R13, DOT tire
Tire Pressure 44 psi 44 psi
Wheel Type 13" aluminum 13" aluminum
Roof Fiberglass Fiberglass
Windshield
AS1, DOT automotive windshield with
wiper
AS1, DOT automotive windshield with
wiper
Drive Train Autodrive Autodrive
Voltage Reducer 20 A, 72 V to 12 V included 20 A, 72 V to 12 V included
Warranty
One year bumper-to-bumper warranty, less wear items
Two year Trojan battery warranty, based on date code
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Shuttle Bus BN72-11-AC-H, BN72-14-AC-Autodrive-M, BN72-23-AC-Autodrive-M
BN72-11-AC-H (Wheelchair
Accessible)
BN72-14-AC-Autodrive-M BN72-23-AC-Autodrive-M
Passengers
11, 3 facing backward +
wheelchair
14, 3 facing backward 23, 4 facing backward
Battery System
Twelve 6 V (72 V), Trojan
T-105
Twelve 6 V (72 V), Trojan
T-105
Twelve 6 V (72 V), Trojan
T-105, optional second
bank (24 total)
Motor Power 10 hp AC motor 10 hp AC motor 12 hp AC motor
Top Speed 18 mph 18 mph 18 mph
Load Capacity 2640 lbs 2640 lbs 3850 lbs
Weight w/ Batteries 2640 lbs 2800 lbs 3080 lbs
Ground Clearance 5.5" 5.5" 5.5"
Turning Radius 21 21 26
Wheel Base 83" 83" 135"
Top Climbing Grade 20% 20% 15%
Body Material Fiberglass, plastic Fiberglass, plastic
Fiberglass 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 spring and shock Leaf spring and shock
Steering System
Rack and pinion power
steering
Rack and pinion power
steering
Rack and pinion power
steering
Tire Size 167/70-R13, DOT tire 167/70-R13, DOT tire 195/70R 15C, DOT tire
Tire Pressure 44 psi 44 psi 44 psi
Wheel Type 13" aluminum 13" aluminum Steel 6JJ-15
Roof Fiberglass Fiberglass Fiberglass
Windshield
AS1, DOT automotive
windshield with wiper
AS1, DOT automotive
windshield with wiper
AS1, DOT automotive
windshield with wiper
Drive Train Autodrive Autodrive Autodrive
Voltage Reducer 20 A, 72 V to 12 V included 20 A, 72 V to 12 V included 30 A, 72 V to 12 V included
Warranty
One year bumper-to-bumper warranty, less wear items
Two year Trojan battery warranty, based on date code
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