Star EV BN72-08-AC-Autodrive-M User 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
4
6
10
12
12
14
15
16
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 con-
tained 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 communi-
ties 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 connec-
tion.
Refer to Vehicle Specifications for vehicle seating capacity.
Never modify the vehicle in any way that will alter the weight distribution of the ve-
hicle, 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 aixed 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 ser-
vice 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 associat-
ed wiring. Remove the batteries or cover exposed terminals with an insu-
lating material.
• Check the polarity of each battery terminal and be sure to rewire the bat-
teries 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 aer any repairs or maintenance. All tests must be
conducted in a safe area that is free of both vehicular and pedestrian traf-
fic.
• 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. Be-
fore 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 ap-
propriate safety standards.
• Operators should not add to, or modify, the vehicle.
• Observe all traic regulations, including authorized speed limits. Under
normal traic 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 intersec-
tions, blind spots, or at other dangerous locations.
• Keep a clear view of the path of travel, observe other traic and personnel,
and maintain a safe clearance.
• Slow down or stop, as conditions dictate, and activate the sound-produc-
ing 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 in-
structions which are supplied by the manufacturer.
The user should not perform any modification or addition which aects 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 car-
rier operators with it.
Loading
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, bat-
tery, speed and directional controllers, brakes, and steering mechanism. If the ve-
hicle 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, mainte-
nance 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 elec-
trolyte.
• 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 aect capacity and safe machine oper-
ation should not be performed by the customer or user without manufac-
turer’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 interchange-
able 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 opera-
tions. Before operation, the controlling party should establish such additional spe-
cific 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 safe-
ty 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 condi-
tions 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 af-
fect 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 suit-
able 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 traic or the pedestrian traic to eliminate the
interference. If elimination of the interference is not possible or is highly impracti-
cal, signs should be erected warning pedestrians of the vehicle traic and vehicle
operators of the pedestrian traic 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 accor-
dance 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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3: Operation and Service Information
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 operator.
Vehicle batteries must be fully charged before initial use. Check for correct tire in-
flation. See Vehicle Specifications. Determine and record braking distance required
to stop vehicle for future brake performance tests.
Remove the protective clear 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 potential for fire, do not block or obstruct the airways. Portable
chargers must be mounted on a platform above the ground or in such a manner as
to permit the maximum airflow underneath and around the charger.
Portable chargers are shipped with the vehicle. Prior to vehicle or charger oper-
ation, chargers must be removed and mounted on a platform or wall above the
ground to permit maximum airflow around and underneath the charger. If the char-
ger is operated in an outdoor location, rain and sun protection must be provided.
Controls

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1. Front light and turn signal switch
2. Horn
3. Steering wheel
4. Key switch
5. Windshield wiper switch
6. CD player
7. Light switch
8. Forward/Reverse switch
9. Charging receptacle
10. Parking brake handle
11. Accelerator pedal
12. Brake pedal
WARNING: To prevent loss of control, do not move the Forward/Reverse switch
while the vehicle is in motion. Moving the selector will result in a sudden slowing of
the vehicle and the beeping of a warning device.
Unintentional movement of the accelerator pedal will release the park brake and
may cause the vehicle to move which could result in severe injury or death. To re-
duce the possibility of severe injury or death resulting from loss of vehicle control,
the following warnings must be observed:
• When driving vehicle, consider the terrain, traic conditions and the en-
vironmental factors which aect 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 designated areas and avoid extremely rough terrain.
• Maintain a safe speed when driving downhill. Use service brake to control
speed when traveling down an incline. A sudden stop or change of direc-
tion may result in loss of control.
• Slow down before and during turns. All turns should be made at reduced
speed.
• WARNING: To reduce the possibility of severe injury or death resulting from
improper vehicle operation, the following warnings must be observed:
• Refer to Vehicle Specifications for seating capacity.
• Depressing accelerator pedal will release foot operated park brake and
may cause inadvertent vehicle movement. Turn the key to the ‘OFF’ posi-
tion whenever the vehicle is parked.
• To prevent inadvertent movement when the vehicle is to be le unattend-
ed, engage the park brake, move direction selector to forward position,

14
turn key to ‘OFF’ position and remove key.
• Make sure that the direction selector is in correct position before attempt-
ing to start the vehicle.
• Always bring the vehicle to a complete stop before shiing the direction
selector.
• Do not take vehicle out of ‘gear’ while in motion (coast).
• Check the area behind the vehicle before operating in reverse.
• All occupants must be seated. Keep entire body inside vehicle and hold on
while vehicle is in motion.
Vehicle Cleaning and Care
WARNING: To reduce the possibility of severe injury or vehicle damage, read and
understand all instructions supplied by manufacturer of pressure washer.
CAUTION: When pressure washing exterior of vehicle, do not use pressure in excess
of 700 psi. To reduce the possibility of cosmetic damage, do not use any abrasive
or reactive solvents.
• It is important that proper techniques and cleaning materials be used. Us-
ing excessive water pressure may cause severe injury to operator or by-
stander, 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 scratches may
be removed using a commercial plastic polish.
• Normal cleaning of vinyl seats and plastic or rubber trim requires the use
of a mild soap solution applied with a sponge or so brush and wipe with
a damp cloth.
• The painted surfaces of the vehicle provide attractive appearance and du-
rable protection. Frequent washing with lukewarm or cold water and mild
detergent is required to preserve the painted surface.
• Occasional cleaning and waxing with non-abrasive products designed for
‘clear coat’ automotive finishes will enhance the appearance and durabil-
ity of the painted surfaces.
• Corrosive materials used as fertilizers can collect on the underbody of the
vehicle. These materials will cause corrosion of underbody parts unless
flushed occasionally with water. Thoroughly clean any areas where mud or
other debris can collect. Sediment packed in closed areas should be loos-
ened to ease removal, taking care not to chip or otherwise damage paint.

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Periodic Service Schedule
NOTE: Some maintenance items must be serviced more frequently on vehicles
used under severe driving conditions.
Daily
Before Use:
• Check general operation of service brake
• Check park brake function
• Check warning device function in reverse
• Check tire condition
• Check overall vehicle condition
Aer Use:
• Recharge batteries to full state of charge aer each day’s use
• Inspect charger connector and receptacle at each charge
Weekly
• Tires: Examine for cuts, excessive wear and pressure (See Vehicle Specifi-
cations)
• Wheels: Check for bent rims, missing or loose lug nuts
Monthly
• Batteries: 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 receptacles free of dirt and
foreign matter
• Accelerator: Check for smooth movement
• Service Brake (Mechanical Brakes): Conduct brake performance test
• Park Brake: Check brake performance and adjust if required
• Direction Selector: Check attachment, tighten if required
• Steering Assembly: Check for abnormal play, tightness of all hardware
• Tie Rod / Linkages: Check for excessive play, bent components, or loose
connections
• Rear Axle: Check for leakage, add lubricant level as required
Quarterly
• Front Axle: Check for damage to axle and loose or missing hardware
• Front Shock Absorbers: Check for oil leakage and loose fasteners

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• Front Springs: Check for loose hardware, cracks at attachments
• Front Wheel Alignment: Check for unusual tire wear, align if required
• Parking Brake: Check for bent/binding linkage rod, check for damage or
wear to latch arm or catch bracket, lubricate as required, use light oil. Do
not lubricate cables or brake latch.
• Rear Shock Absorbers: Check for oil leakage, loose mounting hardware
• Charger Plug: Clean auxiliary contact (see Battery Charger Maintenance)
• Hardware and Fasteners: Check for loose or missing hardware and compo-
nents, tighten or replace missing hardware
Semi-Annually
• Direction Selector: Check for wear and smooth movement (lubricate sha
with light oil if required)
• King Pins: Check for excessive play and tightness of retaining nuts
• Steering Assembly: Check bellows and pinion seal for damage or grease
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, see Technician’s Re-
pair and Service Manual
• Rear Axle: Check lubricant, add lubricant level as required
• Service Brakes: Clean and adjust, check brake shoe linings
Tire Inspection: Tire condition should be inspected per the Periodic Service Sched-
ule. Inflation pressures should be checked when the tires are cool. Be sure to install
the valve dust cap aer checking or inflating.
Periodic Test for Mechanical Brake
WARNING: To reduce the possibility of severe injury or death, always evaluate ped-
al travel before operating a vehicle to verify some braking function is present. All
driving brake tests must be done in a safe location with regard for the safety of all
personnel.
NOTE: Over time, a subtle loss of performance may take place. Therefore, it is im-
portant to establish the standard with a new vehicle.

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The Periodic Brake Performance Test should be performed regularly as an evalua-
tion of braking system performance. It is useful as a method of identifying subtle
loss of performance over time.
The purpose of this test is to compare the braking performance of vehicle to the
braking performance of new or “known to be good” vehicle or to an established ac-
ceptable stopping distance. Actual stopping distances will be influenced by weath-
er conditions, terrain, road surface condition, actual vehicle weight (accessories
installed) and vehicle speed. The test is conducted by latching the parking brake
to eliminate dierent pedal pressures and to include the eects of errors in linkage
adjustment.
Establish the acceptable stopping distance by testing a new or “know to be good”
vehicle and recording the stopping location or stopping distance. For fleets of ve-
hicles, several vehicles should be tested when new and the range of stopping loca-
tions or distances recorded.
Drive the vehicle at maximum speed on a flat, 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 brakes may or may not lock. Observe the vehicle stopping location or
measure the vehicle stopping distance from the point at which the brakes were
latched. The vehicle should stop within the ‘normal’ range of stopping distances. If
the vehicle stops more than 4 . (3.0m) beyond the acceptable stopping distance or
pulls to one side, the vehicle has failed the test and should be tested again.
If the vehicle fails the second test, it should immediately be removed from service.
Lubrication
Checking the Lubricant Level
To Clean the area around the check/fill plug and remove plug. The correct lubricant
level is just below the bottom of the threaded hole. If lubricant is low, add lubricant
as required. Add lubricant slowly until lubricant starts to seep from the hole. Install
the check/fill plug. In the event that the lubricant is to be replaced, the vehicle must
be elevated and the oil pan removed or the oil siphoned through the check/fill hole.
CAUTION: Do not use more than ½ - ¾ of grease in any grease fitting at any one

18
time. Excess grease may cause grease seals to fail or grease migration into areas
that could damage components.
Batteries and Charging
Safety
• NOTE: Always observe the following warnings when working on or near
batteries.
• WARNING: To prevent battery explosion that could result in severe per-
sonal injury or death, keep all smoking materials, open flame or sparks
away from the batteries.
• Hydrogen gas is formed when charging batteries. Do not charge batteries
without adequate ventilation. A 4% concentration of hydrogen gas is ex-
plosive.
• Be sure that the key switch is o and all electrical accessories are turned
o before starting work on vehicle.
• Never disconnect a circuit under load at a battery terminal.
• Batteries are heavy. Use proper liing techniques when moving them. Al-
ways li the battery with a commercially available battery liing device.
Use care not to tip batteries when removing or installing 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 the body
and eyes with extended flushing with clear water. Contact a physician im-
mediately.
• Always wear a safety shield or approved safety goggles when adding water
or charging batteries.
• Any electrolyte spills should be neutralized with a solution of 1/4 cup (60
mL) sodium bicarbonate (baking soda) dissolved in 1½ gallons (6 liters) of
water and flushed with water.
• Overfilling batteries may result in electrolyte being expelled from the bat-
tery during the charge cycle. Expelled electrolyte may cause damage to
the vehicle and storage facility.
• Aerosol containers of battery terminal protectant must be used with ex-
treme care. Insulate metal container to prevent can from contacting bat-
tery terminals which could result in an explosion.
• Wrap wrenches with vinyl tape to prevent the possibility of a dropped
wrench from ‘shorting out’ a battery, which could result in an explosion
and severe injury or death.

19
Battery
A battery is defined as two dissimilar metals immersed in an acid. If the acid is ab-
sent or if the metals are not dissimilar, a battery has not been created. The batteries
most commonly used in these vehicles are lead acid.
A battery does not store electricity, but is able to produce electricity as the result of
a chemical reaction which releases stored chemical energy in the form of electrical
energy. The chemical reaction takes place faster in warm conditions and slower in
cold conditions. Temperature is important when conducting tests on a battery and
test results must be corrected to compensate for temperature dierences.
As a battery ages, it still performs adequately except that its capacity is diminished.
Capacity describes the time that a battery can continue to provide its design am-
peres from a full charge.
A battery has a maximum life, therefore good maintenance is designed to maximize
the available life and reduce the factors that can 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 electronic mod-
ule that may not activate and the battery charger will not function. Automatic char-
gers will determine the correct duration of charge to the battery set and will shut o
when the battery set is fully charged. Always refer to the instructions of the specific
charger used.
Charging batteries properly requires administering the right amount of current at
the right voltage. Most charging equipment automatically regulates these values.
Some chargers allow the user to set these values. For proper charging, refer to the
instructions that came with your charging equipment.
Before charging, the following should be observed:
• Be familiar with and follow the instructions issued by the charger manu-
facturer.
• Batteries should be charged aer each period of use.
• Lead acid batteries need not be fully discharged before recharging.
• Charge only in well-ventilated area. Keep sparks or flames away from a
charging battery.
• Verify charger voltage settings are correct.

20
• Check electrolyte level. (See Electrolyte Level and Water section.)
• Tighten all vent caps before charging.
• Do not overcharge or undercharge the batteries.
• Do not charge a frozen battery.
• Avoid charging at temperatures above 48°C.
Battery Maintenance
WARNING: To reduce the possibility of fire, never attach a battery charger to a
vehicle that is to be unattended beyond the normal charging cycle. Overcharging
could cause damage to the vehicle batteries and result in extreme overheating. The
charger should be checked aer 24 hours and unplugged aer the charge cycle is
complete.
Before charging the batteries, inspect the plug of the battery charger and vehicle
receptacle housing for dirt or debris. Charge the batteries aer each day’s use.
Monthly:
• Inspect all wiring for fraying, loose terminations, corrosion or deteriora-
tion of insulation.
• Check that the electrolyte level is correct and add suitable water as re-
quired.
• Clean the batteries and wire terminations.
Our experience shows that the key to achieving optimum performance and long life
is a solid battery maintenance program using the simple procedures outline here.
Equipment: We recommend the following equipment for use in battery care and
maintenance:
• Wrench
• Distilled Water
• Voltmeter
• Hydrometer
• Thermometer
• Post Cleaner
• Baking Soda
• Vaseline
• Goggles & Gloves (CAUTION: Always wear protective clothing, gloves, and
goggles when handling batteries, electrolyte, and charging your battery.)
Batteries should be carefully inspected on a regular basis in order to detect and