Star EV BN72-14-AC-D, BN72-11-AC-D Owner's And Service Manual
Owner’s Manual and Service Guide
Enclosed Bus:
BN72-14-AC-D and BN72-11-AC-D (Wheelchair Accessible)
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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.
If you have any questions about the operation or maintenance of
your Enclosed 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 Enclosed
Bus and should remain with the vehicle when lending or resold.
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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
Table of Contents
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5
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7
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12
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21
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1: Vehicle Specifications
1: Operation
Important Labels
Please read the following labels carefully before operating the vehicle, and promptly replace any labels which become unreadable or removed.
• Security Warning label under the dashboard
• Warning label under the dashboard
• Warning label beside the parking brake handle
Enclosed Bus BN72-14-AC-D-M and BN72-11-AC-D-Wheelchair-M (Wheelchair Accessible
model)
Passengers
14 / Wheelchair: 11+ wheelchair
Body Material
Fiberglass with steel frame
and aluminum doors
Battery System
Twelve 6 V (72 V) batteries,
Trojan T-105
Front Suspension
Independent suspension, coil
over shocks
Motor Power 9.5 hp AC motor Rear Suspension
Integral rear axle, coil spring
non-independent suspension,
hydraulic shock absorber
Controller Power 550 A Curtis AC controller Steering System
Rack and pinion power
steering
Top Speed 19 mph Brake System
Front and rear drum, hydraulic
brake, mechanical parking
brake
Load Capacity 2200 lbs / Wheelchair: 1900 lbs Tire Size 155 R 12 DOT tire
Dimensions
203” x 61” x 82” (L x W x H)
Wheelchair: 207” x 61” x 82” (L
x W x H)
Tire Pressure 65 psi
Weight w/ Batteries 3100 lbs Wheel Type 12” aluminum
Ground Clearance 5.5” Roof Fiberglass
Turning Radius 20 Windshield
AS1, DOT automotive windshield
Wheel Base 108” / Wheelchair: 104” Drive Train Automatic drive system
Top Climbing Grade 20% Voltage Reducer
30 A, 72 V to 12 V reducer
included
Warranty
One year bumper-to-bumper warranty, less wear items; two year Trojan battery warranty, based on date code
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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 system; when the key is turned back, the power will be switched o.
Acceleration pedal: Controls the speed. It should be depressed slowly. The vehicle
speeds up with the gradual stepping-down, and reaches the full speed when the
pedal is stepped to the bottom. The 4
vehicle slows down when the pedal is released gradually. When the pedal is fully
released, electric brake works.
Service brake pedal: Decelerate the vehicle.
F/R switch: This switch is a three-position button. Depressing the upper part (F)
makes the vehicle move forwards while depressing the lower part (R) makes the
vehicle move backwards, and the middle is neutral. NOTE: The buzzer will sound
when the lower part of this button is depressed to give warning to the people
around your electric vehicle.
Hand-brake lever: Parks and brakes the vehicle.
Steering wheel: Controls the driving direction.
Light switch: Controls light system, including turning signals and headlight (in-
cludes high beam and lower beam).
Wiper and horn switch: Controls the wiper and horn.
Emergency stop switch: Stops the power of the whole vehicle in case of emergency.
NOTE: Before you switch on the vehicle, always check the status of this switch to
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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
1. Select F for Forward or R for Reverse from F/R Button.
2. Switch on power with key.
3. Release the handbrake lever.
4. Depress the acceleration pedal smoothly.
WARNING: If you switch on Power Key first before selecting Forward or Reverse on
F/R Button, the vehicle will not run.
Stopping the vehicle
1. Step Service Brake Pedal to decelerate the vehicle until it stops completely
and shi F/R button to Neutral position.
2. Engage the handbrake lever to park the vehicle.
3. Release the service brake.
4. Switch o all lights.
5. Switch o the power key and take out the key.
Charging
CAUTION: There are two dierent kinds of chargers for this vehicle. One is an exteri-
or charger and the other is a built-in (on-body) charger. Before you use the charger,
read the charger operation manual.
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• 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 correctly rated for your local AC electricity network.
• Do not disconnect the DC output cord from the battery receptacle when
the charger is ON, otherwise an arc could occur which may cause an explosion.
• Do not open the housing of the charger. Only a qualified electrician should
open the housing of the charger.
• The charger should be stored in safe and dry room with good ventilation.
The charger should be packed properly if not used for long time.
2: Safety
The driver should have a good knowledge of the operation system of the vehicle
and its features while following rules for safe operation. WARNING: Drive the vehicle o streets unless it is allowed.
• The vehicle cannot be overloaded, or the motor will be damaged. An overloaded vehicle can lose control and its life will be shortened.
• Unqualified persons are prohibited to drive the vehicle.
• Make sure this vehicle runs in its rated climbing ability.
• Don’t overtake other vehicles at crossroads, in blind areas or in other dangerous zones.
• Keep your entire body inside the vehicle, keep seated and holding on while
the vehicle is moving.
• Do not start the vehicle until all occupants are securely seated.
• Keep your hands on the steering wheel and your eyes on the path ahead.
• Always back out the vehicle slowly and watch the back carefully.
• Avoid starting and stopping suddenly.
• Avoid turning the vehicle too sharply at high speeds.
• Always drive slowly up and down slopes.
• Do not make any modification or addition which may aect the capacity
or safety.
• Do not allow children to play in the vehicle. Children should be seated between adults and protected while the vehicle is moving.
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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 handling batteries, electrolyte, and charging your battery.
KEEP OUT OF REACH OF CHILDREN.
Cleaning
• The exterior of the battery, the connection wires and bolts should always
be kept clean and dry. When cleaning, make sure all vent caps are tightly
in place. Clean the battery top with a cloth or brush and solution of baking soda and water. When cleaning, do not allow any cleaning solution or
other foreign matter to get inside the battery. This should be done every
week.
• Clean battery terminals and the inside of cable clamps using a post and
clamp cleaner. Clean terminals will have a bright metallic shine. This
should be done whenever necessary.
• Reconnect the clamps to the terminals and thinly coat them with petroleum jelly (Vaseline) to prevent corrosion.
• WARNING: Before you disconnect any battery cable from any terminal on
the battery, always remove the power by disconnecting the main battery
cable from the controller.
• Checking the terminals and nuts: The connection of the battery should always be kept in good condition. Check every week on whether any battery
cable terminal or nut has become loose in order to prevent any damage to
terminals. Check the status of the battery cable weekly. A damaged battery cable should be replaced immediately.
• Foreign matter: Do not place any objects on the battery and do not connect the positive pole to the negative pole. This may cause a short circuit
and sparking.
Recharging
• As long as you use the vehicle, regardless of how long you have used it,
the battery should be recharged fully on the same day. Any delay in recharging will negatively aect the battery. The lead-acid battery does not
develop a memory, so need not be fully discharged before recharging.
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