Karsan STAR Euro 5 User manual

1
GENERAL INFORMATION

1
GENERAL INFORMATION
Dear New Karsan STAR Euro 5 Owner,
You did the best choice with KARSAN STAR. You
owned a new minibus of which every details are
designed for your comfort and commercial success.
Now you have a modern, powerful, strong business
partner.
It is important to read this manual carefully in order to
understand and know your vehicle well. In order to use
your vehicle in most secure and efcient way please
follow up the descriptions and warnings in this manual.
Congratulations for your new commercial source and get
plenty of earnings.
Karsan Otomotiv Sanayii ve Tic. A.Ş.
PREFACE

2
GENERAL INFORMATION
PREFACE .......................................................................................................................................................................................................1
CONTENT ......................................................................................................................................................................................................2
Purpose of this Manual .............................................................................................................................................................................9
Purpose of this Vehicle .............................................................................................................................................................................9
Driver Properties......................................................................................................................................................................................9
Passenger and Vehicle Safety....................................................................................................................................................................9
Symbols ...................................................................................................................................................................................................... 10
Prior to Use ................................................................................................................................................................................................. 11
Technical Information ................................................................................................................................................................................... 12
Dimensions.................................................................................................................................................................................................. 13
Instrument & Control Panel........................................................................................................................................................................... 14
Side Control Panel........................................................................................................................................................................................ 15
Emergency Stop Button.......................................................................................................................................................................... 15
Engine Compartment Fire Extinguisher .................................................................................................................................................... 15
Button Group......................................................................................................................................................................................... 16
Left Control Panel......................................................................................................................................................................................... 18
Button Group......................................................................................................................................................................................... 18
Audio System............................................................................................................................................................................................... 19
Radio- CD- Mp3 Player (Optional)............................................................................................................................................................ 19
Tacograph (Optional).................................................................................................................................................................................... 20
Gauges........................................................................................................................................................................................................ 21
Instrument Panel ................................................................................................................................................................................... 21
Rev Counter .......................................................................................................................................................................................... 22
Speedometer ......................................................................................................................................................................................... 22
Engine Coolant Temperature Indicator..................................................................................................................................................... 22
CONTENT

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GENERAL INFORMATION
Fuel Indicator ...................................................................................................................................................................................23
Warnings During Driving ..........................................................................................................................................................................24
Display.............................................................................................................................................................................................27
Main Screen......................................................................................................................................................................................27
Warnings During Driving ..........................................................................................................................................................................28
Main Menu .......................................................................................................................................................................................28
Reseting Trip Informaiton ..................................................................................................................................................................28
Brake Linings....................................................................................................................................................................................28
Messages .........................................................................................................................................................................................29
Settings............................................................................................................................................................................................29
Languages........................................................................................................................................................................................29
Parking Lamps, Low Beam Headlights.......................................................................................................................................................30
Left Control Arm ...............................................................................................................................................................................30
Parking Lamps ..................................................................................................................................................................................30
Low Beam Headlights........................................................................................................................................................................30
High Beam Headlights, Direction Signals, Horn ..........................................................................................................................................31
High Beam Headlights .......................................................................................................................................................................31
Horn ................................................................................................................................................................................................31
Right Signal......................................................................................................................................................................................31
Left Control Arm......................................................................................................................................................................................32
Left Signal ........................................................................................................................................................................................32
Windshield Wiper ..............................................................................................................................................................................32
Windshield Washer............................................................................................................................................................................32
Right Control Panel..................................................................................................................................................................................33
ZF 6 S 1010 Manuel Transmission .....................................................................................................................................................33
CONTENT

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GENERAL INFORMATION
ZF 6 AS 1010 Robotic Transmission ......................................................................................................................................................... 33
Right Control Panel Buttons........................................................................................................................................................................... 34
A/C Unit Control Panel.................................................................................................................................................................................. 38
Defroster Unit Control Panel.......................................................................................................................................................................... 39
Doors .......................................................................................................................................................................................................... 40
Lower Control Panel ..................................................................................................................................................................................... 41
Parking Brake ........................................................................................................................................................................................ 41
Auxiliary Brake....................................................................................................................................................................................... 41
Vehicle Information ...................................................................................................................................................................................... 42
Passenger Seats..................................................................................................................................................................................... 42
Sun Visor............................................................................................................................................................................................... 42
Interior Rear View Mirror ........................................................................................................................................................................ 42
Digital Display........................................................................................................................................................................................ 43
Escape Hatch......................................................................................................................................................................................... 43
Rear View Camera.................................................................................................................................................................................. 43
LCD Monitor (Optional)........................................................................................................................................................................... 44
Assistant’s Seat...................................................................................................................................................................................... 44
Assistant Control Panel ................................................................................................................................................................................. 45
Entertainment Panel............................................................................................................................................................................... 45
Passenger Entertainment Panels.................................................................................................................................................................... 46
Back of Each Seat ................................................................................................................................................................................. 46
Passenger Heaters........................................................................................................................................................................................ 47
Interior Lights .............................................................................................................................................................................................. 48
Driver’s Reading Lamp............................................................................................................................................................................ 48
Ceiling Illumination Lamps...................................................................................................................................................................... 48
CONTENT

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GENERAL INFORMATION
Ceiling Night lamps ...........................................................................................................................................................................49
Passenger Night Lamps .....................................................................................................................................................................49
Corridor Illumination Lamps...............................................................................................................................................................49
Passenger Control Panels .........................................................................................................................................................................50
Exterior Lights.........................................................................................................................................................................................51
Parking Lamps ..................................................................................................................................................................................51
Low Beam Headlights........................................................................................................................................................................52
High Beam Headlights .......................................................................................................................................................................53
Signals .............................................................................................................................................................................................54
Flashers ...........................................................................................................................................................................................55
Front Fog Lamps...............................................................................................................................................................................56
Rear Fog Lamps................................................................................................................................................................................57
First Use of the Vehicle ............................................................................................................................................................................58
Running -in.......................................................................................................................................................................................58
Economic Drive.................................................................................................................................................................................58
Checking the Leaks ...........................................................................................................................................................................59
Checking Engine Oil .........................................................................................................................................................................59
Checking Engine Coolant ...................................................................................................................................................................60
Checking Windshield Wiper Water .....................................................................................................................................................60
Checking A/C Condense Water Plugs ..................................................................................................................................................60
Checking Tyres..................................................................................................................................................................................61
Checking Rims ..................................................................................................................................................................................61
Checking Emergency Equipments.......................................................................................................................................................61
Checking Headlamps .........................................................................................................................................................................62
Checking Fuel Level...........................................................................................................................................................................62
CONTENT

6
GENERAL INFORMATION
Checking AdBlue Level............................................................................................................................................................................ 62
Rear View Mirror Sight Test .................................................................................................................................................................... 63
Checking Steering Wheel Position............................................................................................................................................................ 63
Checking the Doors and Hatches............................................................................................................................................................. 63
Driving Safety & Comfort ............................................................................................................................................................................. 64
Seat Belt Adjustment.............................................................................................................................................................................. 64
Starting the Engine....................................................................................................................................................................................... 66
Ignition Key ........................................................................................................................................................................................... 66
Starting................................................................................................................................................................................................. 66
Moving Forward ........................................................................................................................................................................................... 67
Manuel Transmission .............................................................................................................................................................................. 67
Robotic Transmission (Optional) .............................................................................................................................................................. 68
Start Engine .......................................................................................................................................................................................... 70
Setting Off, Forwards.............................................................................................................................................................................. 70
Setting Off in Reverse............................................................................................................................................................................. 71
Rear View Camera (Optional).................................................................................................................................................................. 71
Park Sensor (Optional) ........................................................................................................................................................................... 71
Changing Operating Mode ...................................................................................................................................................................... 72
Change in Direction of Travel .................................................................................................................................................................. 72
Stopping................................................................................................................................................................................................ 72
Clutch Protection.................................................................................................................................................................................... 73
Decelerating & Stopping ............................................................................................................................................................................... 74
Service Brake ........................................................................................................................................................................................ 74
Retarder (Optional) ................................................................................................................................................................................ 74
Decelerating & Stopping ............................................................................................................................................................................... 75
Park Brake ............................................................................................................................................................................................ 75
CONTENT

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GENERAL INFORMATION
Parking.............................................................................................................................................................................................75
Refueling ................................................................................................................................................................................................76
Refuel Hatch.....................................................................................................................................................................................76
Diesel ..............................................................................................................................................................................................76
Tyre Specications...................................................................................................................................................................................77
Choosing the Proper Tyre...................................................................................................................................................................77
Technical Specications .....................................................................................................................................................................77
Tyre Pressures ..................................................................................................................................................................................77
Winter / Snow Tyre .................................................................................................................................................................................79
Obligation.........................................................................................................................................................................................79
Snow Chain ......................................................................................................................................................................................79
Storage / Seasonal Replacement ........................................................................................................................................................79
Tyre Replacement....................................................................................................................................................................................79
Preventive Rules ...............................................................................................................................................................................79
Mounting the Tyres ...........................................................................................................................................................................80
Emergency .............................................................................................................................................................................................81
Emergency Hammers ........................................................................................................................................................................81
Emergency Exit Valves.............................................................................................................................................................................82
Locking the Door From Outside..........................................................................................................................................................82
Opening the Doors from Inside ..........................................................................................................................................................83
Firs Aid Kit..............................................................................................................................................................................................84
Fire Extinguisher .....................................................................................................................................................................................85
Towing ...................................................................................................................................................................................................86
Shut Off the Electric Circuit In Case of Emergency.....................................................................................................................................87
Shut Off ...........................................................................................................................................................................................87
Jump Start........................................................................................................................................................................................87
CONTENT

8
GENERAL INFORMATION
Engine Oil Control ........................................................................................................................................................................................ 88
Oil Level Control Stick............................................................................................................................................................................. 88
Engine Oil Task ...................................................................................................................................................................................... 88
Viscosity................................................................................................................................................................................................ 88
Defected Engine Oil................................................................................................................................................................................ 88
Air Filter ...................................................................................................................................................................................................... 89
Engine Cooling Water ................................................................................................................................................................................... 90
Antifreeze.................................................................................................................................................................................................... 91
Other Fluids................................................................................................................................................................................................. 92
Steering Wheel Hydraulic Fluid................................................................................................................................................................ 92
AdBlue Tank .......................................................................................................................................................................................... 92
Checking AdBlue Level............................................................................................................................................................................ 92
Cleaning of the Vehicle ................................................................................................................................................................................. 93
External Cleaning................................................................................................................................................................................... 93
Internal Cleaning ................................................................................................................................................................................... 93
Corrosion Protection............................................................................................................................................................................... 93
Corrosion Protection ..................................................................................................................................................................................... 94
Cleaning of New Vehicles .............................................................................................................................................................................. 95
Seasonal Maintenance .................................................................................................................................................................................. 96
Preparation for Winter Conditions............................................................................................................................................................ 96
Paint Maintenance.................................................................................................................................................................................. 96
Surface Protection.................................................................................................................................................................................. 96
Protection Against Salt ........................................................................................................................................................................... 96
Cleaning by pressurized water................................................................................................................................................................. 96
Polishing................................................................................................................................................................................................ 96
Periodic Maintenance Table ........................................................................................................................................................................... 97
CONTENT

9
GENERAL INFORMATION
This user’s guide is prepared for you to use
your vehicle in a manner of safe and effective
way.
These safety informations are to protect you
and your passengers.
Therefore prior to run your vehicle please read
this manual carefully.
In case of injuries due to not to obey the safety
rules in this manual will be the responsibility of
the vehicle owner and the driver.
User manual should be in the vehicle during
the sales of the vehicle. In addition to these
informations,all national regulations are valid.
This manual is designed for common use in all
KARSAN STAR models, therefore some
specications can be different than in this
manual.
Purpose of this Manual Purpose of this Vehicle Driver Properties
Passenger and Vehicle Safety
Karsan STAR
This vehicle is manufactured to carry
passengers.
Passenger capacity is shown in the capacity
label.
This vehicle cannot be used for another
purpose.
Improper use of this vehicle will be
responsibility of the owner and the driver.
The driver stated in this handbook must meet
the properties below for their own countries.
• Minimum legal age
• Physical and mental compatibility
• Proper training
In order to keep you and your passengers
safe, some hardwares are used in the vehicle.
Also some equipments and materials are
recommended for the safety issues.
This equipments,hardwares and materials
should be used in their capacity and necessary
physical conditions should be kept to get the
efcient result.
INFORMATION
The technical informations, design
specications and technical drawings are
valid on the issue date and are not binding.
KARSAN has the rights to change the
specications without any prior declaration.

10
GENERAL INFORMATION
Meaning of Symbols
To explain some informations clearly, some
symbols are used in this manual.
INFORMATION
This symbol is used to give an important
information about the subject.
WARNING
This symbol is used to warn the user against
possible injuries and damages.
REFER TO DOCUMENT
This symbol is used to remind the user that
for more and detailed information original
handbook of the component must be
examined.
ENVIRONMENT
This symbol is used to warn the user to
protect the environment during processes.
OPTION
This symbol is used to inform the user about
the optional properties and functions.
Service and Maintenance
Symbols
To obtain an economical,efcient and strong
working condition, periodical maintenance
should be done.
Ensure the periodical maintenance and service
work is performed by user and authorized
services according to the user manual,warranty
and service manuals given with the vehicle.

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GENERAL INFORMATION
For the vehicle safety,use only genuine
KARSAN spare parts which are tested and
approved by KARSAN.
In case of injuries and damages caused by
non-genuine parts, KARSAN will not accept
any responsibility.
Use of non-genuine parts and changes done by
unauthorized person can cause safety problems
on the vehicle.
These safety problems can cause damages and
injuries of passengers. And also driver can face
undesirable troubles.
To make the service and maintenance work
at KARSAN service stations will ensure the
comfortable driving experience and also
low fuel consumption. Therefore the clean
environment can be achieved.
When you provide your vehicle to KARSAN
service station,it becomes one of the members
of KARSAN environment system.
At all of KARSAN service stations,
environment protection regulations are applied
completely to avoid pollution.
Mobile phones can cause driver carelessness.
Therefore the use of mobile devices are not
recommended during the journey.
And also the national regulations related with
the electromagnetic radiation are obligatory.
Prior to mount audio devices, ensure that
your authorized vendor applied the related
regulations.
Use of Genuine Parts and Accessories KARSAN Services and Environment Using Mobile Phones and Other Accessories
Prior to Use

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VEHICLE INFORMATION
ENGINE
PERFORMANCE
Type FPT NEF4 Diesel, Direct Injection with High Pressure Common Rail
Power (kW) 110 (150 HP)
Emission Euro V - EEV
Number of Cylinder 4
Cylinder Volume (cm3) 3900
Max. Gradeability (%) 30
Turning Radius (mm) 7000
Max. Torque (Nm) 600
Max. Speed (km/hour) 100
TRANSMISSION Type ZF 6S 1010 BO Manual, 6 Forward ZF 6AS 1010 BO Robotic, 6 Forward
CLUTCH Type Hydraulic Drive
PASSENGER CAPACITY
(Seated + Standing + Wheel Chaired +
Foldable Seat + Driver)
CLASS III : 31+1+1 / 29+1+1/ 27+1+1
TYRES Size 225 / 75 R 17.5
FUEL TANK Capacity (lt.) 140
AdBlue TANK Capacity (lt.) 35
LUGGAGE Capacity (m3) 4.25
INTERNAL HEIGHT Height (mm) 1950
SUSPENSION SYSTEM Front Axle Independent Suspension & Air Bellow
Rear Axle Rigid Axle + Panhard & Air Bellow
BRAKE SYSTEM Front & Rear Electro-Pneumatic Brake System
ELECTRICAL SYSTEM Battery : 2 x 12V - 125 Ah Alternators : 2 x 90 A - 28 V
Technical Information

13
VEHICLE INFORMATION
19554580
8150
1615
3237 (with A/C)
2998 (without A/C)
2436
Dimensions

14
VEHICLE INFORMATION
Instrument & Control Panel
• Side Control Panel
• Left Control Panel
• Instrument Panel
• Screen
• Warning Panel
• Right Control Panel
• Right Control Arm
• Lower Control Panel
Right Control PanelLower Control Panel Right Control Arm
Left Control Panel Instrument Panel ScreenSide Control Panel Warning Panel

15
VEHICLE INFORMATION
Side Control Panel
Press button to close all functions and shut
of battery power. Flashers start to blink and
internal illumination lamps lights up when the
button is pressed.
• Press and hold the button for 5 seconds to
activate the re extinguisher
1. Manual operating button ;
2. Warning LED’s
3. Power On switch.
Side control panel is located at the lower left
side of the steering wheel.
Emergency Stop Button Engine Compartment Fire ExtinguisherAccess
GÜÇ

16
VEHICLE INFORMATION
Button Group
LCD Monitor Button
Driver’s Side Window Button
5
6
Escape Hatch Button
Escape Hatch Button
3
4
Driver’s Sun-visor Button
Assistant’s Sun-visor Button
1
2
1 43 62 5
Side Control Panel

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VEHICLE INFORMATION
Driver’s Side Window Button
Opens and closes the window
on the left side of the driver.
LCD Monitor Button
Activates the foldable LCD
monitor. Press button to open,
press again to close it.
Escape Hatch (Front Side)
Button
Press button to open the front
side of the escape hatch.
Press again to close it.
Escape Hatch (Rear Side)
Button
Press button to open the rear
side of the escape hatch.
Press again to close it.
Side Control Panel
Assistant’s Side Sun-visor
Button
Press upper side of the button
to raise the windshield, press
lower side of the button to
lower the windshield.
Driver’s Side Sun-visor Button
Press upper side of the button
to raise the windshield, press
lower side of the button to
lower the windshield.
INFORMATION
Both side of the escape hatch (front and
rear) can be opened at the same time.

18
VEHICLE INFORMATION
Left Control Panel
Left control panel is located at the left side of
the steering wheel.
Access Button Group
Windshield Defrost Button
Rear View Mirror Defrost Button
Rear Fog Lamps Button
Front Fog Lamps Button
1
2
3
4
1 2 43
Windshield Defrost Button
Press button to defrost the
front windshield.
Rear View Mirror Defrost
Button
Press button to defrost the
rear view mirror.
Rear Fog Lamps Button
Press button to activate the
rear fog lamps. To activate the
fog lamps, park lamps must
be activated formerly.
Front Fog Lamps Button
Press button to activate the
front fog lamps. To activate
the fog lamps, park lamps
must be activated formerly.