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Summary of Contents for Star EV AP48-04
- Page 1 Owner’s Manual and Service Guide AP Series: AP48-04, AP48-04-D, AP48-06, AP48-06-D...
- Page 2 Thanks for buying the Star EV AP-Series. For better use, please read through this manual before operating this vehicle to avoid any possi- ble damage due to improper operation. Keep the manual handy after reading for future reference. If you have any questions about the operation or maintenance of your vehicle, please consult your Star EV dealer.
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Page 3: Table Of Contents
Table of Contents Vehicle Specifications Operation Important Labels Functions Operational Process Charging Batteries Safety Maintenance Battery Cleaning Recharging Watering Specific Gravity Test Open-Circuit Voltage Test Installation Gear Box Traction/Motor Troubleshooting Speed Controller Brake System Lubrication General Maintenance Notes Periodical Maintenance Storage Troubleshooting Electric Wiring... -
Page 4: Vehicle Specifications
1: Vehicle Specifications AP-Series 4-Passenger AP48-04, AP48-04-D Passengers Body Material Fiberglass Eight 6 V (48 V) batteries, Battery System Front Suspension Independent, coil over shock Trojan T-105 Motor Power 7 hp AC motor Rear Suspension Leaf spring and shock Controller Power... -
Page 5: Important Labels
2: 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 Functions... - Page 6 Power key: Controls the power supply of the whole vehicle. When the key is insert- ed 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 off. Acceleration pedal: Controls the speed.
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Page 7: Operational Process
Hand-brake lever: Parks and brakes the vehicle. Steering wheel: Controls the driving direction. Headlight switch: Controls the headlight. Direction light switch: Controls the turning signal. Wiper and horn switch: Controls the wiper and horn. Emergency stop switch: Stops the power of the whole vehicle in case of emergen- cy. -
Page 8: Charging Batteries
Engage the handbrake lever to park the vehicle. Release the service brake. Switch off all lights. Switch off the power key and take out the key. Charging Batteries • CAUTION: There are two different kinds of chargers for this vehicle. One is an exterior charger and the other is a built-in (on-body) charger. -
Page 9: Safety
3: 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 off 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. -
Page 10: Recharging
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. -
Page 11: Watering
with the fill caps tightly secured. Keep far away from any flame and sparks to avoid any explosion or fire that could cause physical injury or damage to the property. During recharge, if the vehicle had doors, keep the doors open. Lift the seat bottom to keep the battery compartment open to the air. -
Page 12: Specific Gravity Test
Testing: Visual inspection alone is not sufficient to determine the overall health of the battery. Both open-circuit voltage and specific gravity readings can give a good indication of the battery’s charge level, age, and health. Routine voltage and gravity checks will not only show the state of charge but also help spot signs of improper maintenance, such as undercharging and over-watering, and possibly even locate a bad or weak battery. -
Page 13: Open-Circuit Voltage Test
Open-Circuit Voltage Test For accurate voltage readings, batteries must remain idle (no charging, no discharging) for at least 6 hrs, preferably 24 hrs. Disconnect all loads from the batteries. Measure the voltage using a DC voltmeter. Check the state of charge with the table below. Charge the battery if it registers 0% to 70% charged. -
Page 14: Gear Box
Gear Box Maintenance • The clearance for the clutch should be kept at 2 – 3 mm. • The friction plate should be changed periodically; the friction value on one side should not exceed 2 mm. • Adjust the flatness of the platen spring plate (feeling manually). First, tighten the screws diagonally, using your hand to check the flatness of the spring plate. -
Page 15: Speed Controller
Speed Controller Maintenance • The speed controller of the vehicle is wholly imported, which adopts high frequency MOS technology to realize the control of speed, torque and brake with smoothness, silence, and high energy efficiency. • When the vehicle starts, the controller will inspect signals from the accelerator. -
Page 16: Periodical Maintenance
the contactor should be checked. Any defective parts should be replaced immediately. Dust should be cleaned with low pressure air. • The electric contactors easily become hot if their mutual contact is not in good condition, so special attention should be paid regularly to the electric contactors. - Page 17 Periodical Maintenance Chart Regular maintenance is required for the best performance and safe operation of the vehicle. WARNING: Make sure to turn off the power key and apply the park brake when you do the maintenance unless specified. If the owner is not familiar with the maintenance of this vehicle, the dealer should do the work.
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Page 18: Storage
Periodical Maintenance Chart, continued Item Description Daily Weekly Monthly Quarterly Yearly Check if the brake drum and the ☑ brake shoe should be replaced. Check if the hand brake func- ☑ tions. Check if the hose and tube for the ☑... -
Page 19: Troubleshooting
6: Troubleshooting There is no settled mode to diagnose and eliminate malfunctions. During maintaining and checking, we suggest you first listen, then look and feel. Below is the diagnoses and maintenance of some common malfunctions. The vehicle doesn’t move Malfunction Possible Reason Troubleshooting Connector(s) in circuit is loose or open... - Page 20 Possible reason and troubleshooting for other malfunctions System Malfunction Possible Reason Troubleshooting Clearance of rear axle decelerating gear is Adjust, change too big, or the decelerating gear is broken Transmission cross shaft is worn out Change Gear of transmission is worn out or Abnormal sound when Change damaged...
- Page 21 System Malfunction Possible Reason Troubleshooting Master cylinder and/or wheel cylinder is Check, eliminate, damaged or leaking oil change Brake fluid is insufficient or empty Add fluid Air enters into oil pipe Bleed air Brake fail Free travel of brake pedal is too long or Adjust the clearance of arrester is too big Brake drum is worn out or distorted...
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Page 22: Electric Wiring
7: Wiring Diagram... - Page 23 This manual tries to be as sound and elaborate as possible in literal and figurative description as well as technical description on the basis of existing data. At the same time, JH Global reserves the right to alter the content of this manual and this manual is subject to change without prior notice;...
- Page 24 STAR EV, a brand of JH Global Services, Inc. 378 Neely Ferry Road | Simpsonville, SC 29680 www.starev.com...
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