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StarEv AP48-04, Owner'S Manual And Service Manual

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StarEv AP48-04 Owner'S Manual And Service Manual Download Page 3

2 

 

Table of Contents 

Vehicle Specifications   

 

 

 

3 

Operation 

 

Important Labels  

 

 

 

 

4

 

 

Functions   

 

 

 

 

 

4

 

 

Operational Process   

 

 

 

6

 

 

Charging Batteries 

 

 

 

 

7

 

 
Safety   

 

 

 

 

 

 

 

8 

Maintenance 

 

 

 

 

 

 

 

 

Battery   

 

 

 

 

 

 

9

 

 

 

Cleaning 

 

 

 

 

 

 

9

 

 

 

Recharging

   

 

 

 

 

10 

 

 

Watering 

 

 

 

 

 

10 

 

 

Specific Gravity Test   

 

 

12 

 

 

Open-Circuit Voltage Test

   

 

13 

 

 

Installation 

 

 

 

 

 

14

 

 

Gear Box 

 

 

 

 

 

 

14 

 

Traction/Motor   

 

 

 

 

15

 

 

 

Troubleshooting

   

 

 

 

16 

 

Speed Controller   

 

 

 

 

16 

 

Brake System

 

 

 

 

 

 

17 

 

Lubrication 

 

 

 

 

 

 

17 

 

General Maintenance Notes

 

 

 

18 

 

Periodical Maintenance

   

 

 

18 

Storage  

 

 

 

 

 

 

 

21 

Troubleshooting 

 

 

 

 

 

22 

Electrical wiring  

 

 

 

 

 

27 

 

Summary of Contents for AP48-04

Page 1: ...Owner s Manual and Service Guide 4 and 6 passenger Bubble Cars AP48 04 AP48 04 D AP48 06 AP48 06 D November 2014...

Page 2: ...ave any questions about the operation or maintenance of your vehicle please consult your Star EV dealer Important Information Important information is showed in following way in this manual WARNING Fa...

Page 3: ...8 Maintenance Battery 9 Cleaning 9 Recharging 10 Watering 10 Specific Gravity Test 12 Open Circuit Voltage Test 13 Installation 14 Gear Box 14 Traction Motor 15 Troubleshooting 16 Speed Controller 16...

Page 4: ...7 19 8 Wheelbase in 87 8 118 Body material Reinforced fiberglass Reinforced fiberglass Climbing capacity loaded 20 20 Front suspension Independent coil over shock Independent coil over shock Rear susp...

Page 5: ...wing 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 Warni...

Page 6: ...ly When the pedal is fully released the electric brake works Brake pedal Decelerates the vehicle F R switch This switch is a three position button Depressing the upper part F makes the vehicle move fo...

Page 7: ...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 smoothl...

Page 8: ...ou 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 cau...

Page 9: ...ions Carefully review the laws for golf car and low speed vehicle use in the city and state you are operating the vehicle in WARNING Drive the vehicle off streets unless it is permitted The vehicle ca...

Page 10: ...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 oth...

Page 11: ...te the distance needed to be taken and recharge the batteries at a proper time in case the vehicle cannot get back to the recharging station in time for recharging WARNING Make sure the batteries are...

Page 12: ...e top of the plates 3 If necessary add just enough water to cover the plates at this time 4 Put batteries on a complete charge before adding any additional water refer to the Charging section 5 Once c...

Page 13: ...adings for every 10 above 80 F b Subtract 004 for every 10 below 80 F 9 Compare the readings 10 Check the state of charge using the table below The readings should be at or above the factory specifica...

Page 14: ...o discharging for at least 6 hrs preferably 24 hrs 1 Disconnect all loads from the batteries 2 Measure the voltage using a DC voltmeter 3 Check the state of charge with the table below 4 Charge the ba...

Page 15: ...8 5 98 7 97 11 96 23 92 35 87 47 83 30 1 124 5 91 7 88 11 81 23 63 35 44 47 26 20 1 098 5 83 7 77 11 66 23 32 34 97 46 63 10 1 073 5 75 7 67 11 51 23 02 34 52 46 03 Battery Installation Tighten the ba...

Page 16: ...iodically For a new vehicle change the oil after one month or accumulated running distance exceeding 750 miles change the oil again two months later then change the oil every six months The oil type i...

Page 17: ...the clearance between the brush and commutators is too big the brush is made by wrong materials the brush is the wrong type Sparks The motor is overloaded the commutators are not clean round or smoot...

Page 18: ...The pedal travel shouldn t exceed 2 3 of the full free pedal travel The clearance for the brake plate is self adjusted Under a force of around 45 lbs the parking brake handle should be fixed in one ge...

Page 19: ...e make sure that the new fuse is right in rated current Disconnect the positive pole from the battery when maintenance is done Never step the accelerator hard and frequently which may shorten the life...

Page 20: ...harging for a few minutes more don t wash the electrical parts with water You can remove dust with a brush or high pressure air Periodic Maintenance Chart Regular maintenance is required for the best...

Page 21: ...should be replaced Check if the accelerator pedal works well and if it can be released freely and automatically Chassis and body Check if the brake drum and the brake shoe should be replaced Check if...

Page 22: ...th if your vehicle will be stored more than one month 2 Turn the power key to OFF position remove the key and store the key in a safe place 3 Engage the handbrake 4 Check the tire pressure to make sur...

Page 23: ...hten or change Power key is broken Change voltmeter is broken Change Battery terminals connect improperly Adjust Display on instrument panel when vehicle is on but vehicle doesn t move Improper operat...

Page 24: ...only run in one direction F R switch failure Change Controller Failure Change 4 Possible reason and troubleshooting for other malfunctions System Malfunction Possible reason Troubleshooting Transmiss...

Page 25: ...shaft or its plastic cover is worn out Change Unstable wheels Rack of redirector is worn out Change redirector Screw plug of redirector is too tight Adjust Toe in is adjusted improperly Adjust Bearin...

Page 26: ...rake fail Master cylinder and or wheel cylinder is damaged or leaking oil Check eliminate change Brake fluid is insufficient or empty Add fluid Air enters into oil pipe Bleed air Free travel of brake...

Page 27: ...aking noise Shoes distort Change Brake facing wear out Change Brake drum breach scraped to uneven Change This manual tries to be as sound and elaborate as possible in literal and figurative descriptio...

Page 28: ...27...

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