Star EV AP48-04 Manuel utilisateur

Owner’s Manual and Service Guide

AP Series:

AP48-04, AP48-04-D, AP48-06, AP48-06-D

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 aer

reading for future reference.

If you have 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: Failure to follow Warning instructions could result in se-

vere injury or death to the vehicle occupants, bystanders or persons

inspecting or repairing the vehicle.

CAUTION: Failure to follow Caution instructions could cause damage

to the vehicle.

Note: Remove the seat and backrest wrapping film to prevent seat vi-

nyl fading. If you have to stock the vehicle for long time, also remove

the seat and backrest wrapping film.

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

Table of Contents

1: Vehicle Specifications

AP-Series 4-Passenger AP48-04, AP48-04-D

Passengers 4Body Material Fiberglass

Battery System Eight 6 V (48 V) batteries,

Trojan T-105 Front Suspension Independent, coil over shock

Motor Power 7 hp AC motor Rear Suspension Leaf spring and shock

Controller Power 450 A Curtis AC controller Steering System Rack and pinion

Top Speed 19.5 mph (20-25 mph if street

legal) Brake System Four-wheel hydraulic drum

brake

Load Capacity 780 lbs Tire Size 23x8.5-12 All-terrain tire

Dimensions 122” x 59” x 77” (L x W x H) Tire Pressure 14 psi

Weight w/ Batteries 1780 lbs no doors, 1885 lbs

with doors Wheel Type 12” aluminum

Ground Clearance 5” Roof Aluminum frame with fiber-

glass

Turning Radius 14.7  Windshield AS1, DOT automotive wind-

shield

Wheel Base 88” Drive Train Direct rear drive

Top Climbing Grade 20% Voltage Reducer 30 A, 48 V to 12 V reducer

included

Warranty Two year bumper-to-bumper warranty (less wear items)

AP-Series 6-Passenger AP48-06, AP48-06-D

Passengers 6Body Material Fiberglass

Battery System Eight 6 V (48 V) batteries,

Trojan T-105 Front Suspension Independent, coil over shock

Motor Power 7 hp AC motor Rear Suspension Leaf spring and shock

Controller Power 450 A Curtis AC controller Steering System Rack and pinion

Top Speed 19.5 mph (20-25 mph if street

legal) Brake System Four-wheel hydraulic drum

brake

Load Capacity 990 lbs Tire Size 23x8.5-12 All-terrain tire

Dimensions 153” x 59” x 77” (L x W x H) Tire Pressure 14 psi

Weight w/ Batteries 1905 lbs no doors, 2244 lbs

with doors Wheel Type 12” aluminum

Ground Clearance 5” Roof Aluminum frame with fiber-

glass

Turning Radius 19.8  Windshield AS1, DOT automotive wind-

shield

Wheel Base 118” Drive Train Direct rear drive

Top Climbing Grade 20% Voltage Reducer 30 A, 48 V to 12 V reducer

included

Warranty Two year bumper-to-bumper warranty (less wear items)

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

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 o.

Acceleration pedal: Controls the speed. It should be depressed slowly. The vehicle

speeds up with the gradual stepping-down, and reaches the full speed when the

pedal is stepped to the bottom. The vehicle slows down when the pedal is released

gradually. When the pedal is fully released, 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 forwards while depressing the lower part (R) makes the

vehicle move backwards, and the middle is neutral. NOTE: The buzzer will sound

when the lower part of this button is depressed to give warning to the people

around your electric vehicle.

Hand-brake lever: Parks and brakes the vehicle.

Steering wheel: Controls the driving direction.

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. NOTE: Before you switch on the vehicle, always check the status of this switch

to make sure that it is in the OFF position.

Digital display: This meter shows information including lights, speed, range, hand

brake, and battery power.

Operational Process

Starting the vehicle

1. Select F for Forward or R for Reverse from F/R button.

2. Switch on power with key.

3. Release the handbrake lever.

4. Depress the acceleration pedal smoothly.

WARNING: If you switch on power key first before selecting Forward or Reverse on

F/R Button, the vehicle will not run.

Stopping the vehicle

1. Step brake pedal to decelerate the vehicle until it stops completely and

shi F/R button to neutral position.

2. Engage the handbrake lever to park the vehicle.

3. Release the service brake.

4. Switch o all lights.

5. Switch o the power key and take out the key.

Charging Batteries

• CAUTION: There are two dierent kinds of chargers for this vehicle. One

is an exterior charger and the other is a built-in (on-body) charger. Before

you use the charger, read the charger operation manual.

• Explosive hydrogen gas is produced while battery is charged. Only charge

the battery in well-ventilated areas.

• Before using the charger, check if the battery charger you are using is

correctly rated for your local AC electricity network.

• Do not disconnect the DC output cord from the battery receptacle when the

charger is ON, otherwise an arc could occur which may cause an explosion.

• Do not open the housing of the charger. Only a qualified electrician should

open the housing of the charger.

• The charger should be stored in safe and dry room with good ventilation.

The charger should be packed properly if not used for long time.

Charging Procedure

Turn o the power of the vehicle before charging.

For a exterior charger with one set of batteries:

1. Connect charger to DC receptacle on the vehicle.

2. Connect the charger to AC power.

3. Turn on the charger.

4. Turn o the charger when the batteries are fully charged. Disconnect the

charger from AC power first, and then disconnect the charger with AC

receptacle.

For on-board (built-in) charger:

1. Connect the charger with AC power.

2. Turn on the charger.

3. Turn o the charger when the batteries are fully charged, disconnect the

charger with AC power.

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 o streets unless it is allowed.

• The vehicle cannot be overloaded, or the motor will be damaged. An

overloaded vehicle can lose control and its life will be shortened.

• Unqualified persons are prohibited to drive the vehicle.

• Make sure this vehicle runs in its rated climbing ability.

• Don’t overtake other vehicles at crossroads, in blind areas or in other

dangerous zones.

• Keep your entire body inside the vehicle, keep seated and holding on while

the vehicle is moving.

• Do not start the vehicle until all occupants are securely seated.

• Keep your hands on the steering wheel and your eyes on the path ahead.

• Always back out the vehicle slowly and watch the back carefully.

• Avoid starting and stopping suddenly.

• Avoid turning the vehicle too sharply at high speeds.

• Always drive slowly up and down slopes.

• Do not make any modification or addition which may aect the capacity

or safety.

• Do not allow children to play in the vehicle. Children should be seated

between adults and protected while the vehicle is moving.

4: Maintenance

WARNING: Battery electrolyte is poisonous and dangerous, may cause severe

burns, injury, etc. Always wear protective clothing, gloves, and goggles when

handling batteries, electrolyte, and charging your battery.

KEEP OUT OF REACH OF CHILDREN.

Battery Maintenance

Cleaning

The exterior of the battery, the connection wires and bolts should always be kept

clean and dry. When cleaning, make sure all vent caps are tightly in place. Clean

the battery top with a cloth or brush and solution of baking soda and water. When

cleaning, do not allow any cleaning solution or other foreign matter to get inside

the battery. This should be done every week.

Clean battery terminals and the inside of cable clamps using a post and clamp

cleaner. Clean terminals will have a bright metallic shine. This should be done

whenever necessary.

Reconnect the clamps to the terminals and thinly coat them with petroleum jelly

(Vaseline) to prevent corrosion.

WARNING: Before you disconnect any battery cable from any terminal on the

battery, always remove the power by disconnecting the main battery cable from

the controller.

Checking the terminals and nuts: The connection of the battery should always be

kept in good condition. Check every week on whether any battery cable terminal

or nut has become loose in order to prevent any damage to terminals. Check the

status of the battery cable weekly. A damaged battery cable should be replaced

immediately.

Foreign matter: Do not place any objects on the battery and do not connect the

positive pole to the negative pole. This may cause a short circuit and sparking.

Recharging

• As long as you use the vehicle, regardless of how long you have used it,

the battery should be recharged fully on the same day. Any delay in re-

charging will negatively aect the battery. The lead-acid battery does not

develop a memory, so need not be fully discharged before recharging.

• If the vehicle is going to be kept unused for a long time, the battery should

be fully recharged first. Aer that, the battery should be fully recharged

every two weeks.

• When driving, the driver should always be aware of the drop level of the

battery power from the battery power meter. Any drop means the battery

power is diminishing. The driver can estimate the distance needed to be

taken, and recharge the battery at a proper time in case the vehicle cannot

get back to the recharging station in time for recharging.

WARNING: Make sure the battery is recharged before the battery power meter

shows 20% power is le inside the battery. An over-discharged battery will have a

very short service life and will make recharging diicult.

WARNING: During recharge, the vehicle should be parked in a well-ventilated area

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