AERO-SERVICE EV4 QUAD User manual

VERSION 1.00
EV4 QUAD
AERO-SERVICE Jacek Skopiński
Dereniowa 4/69
02-776 Warsaw
POLAND
OWNERS
MANUAL

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2017-07-24 VERSION 1.00 Page 2of 25
Index
1. PRELIMINARY INFORMATION ..................................................................................................4
1.1. Content and addressees of this manual............................................................................................................................ 4
1.2. Symbols............................................................................................................................................................................ 4
1.3. Cooperation with the user of EV4.................................................................................................................................... 4
1.4. Compliance with safety requirements.............................................................................................................................. 5
2. Vehicle description............................................................................................................................6
2.1. Manufacturer contact details:.......................................................................................................................................... 6
2.2. General description ......................................................................................................................................................... 6
3. Proper use........................................................................................................................................11
4. Warnings for unauthorised use......................................................................................................11
5. Residual risk....................................................................................................................................12
6. Technical information ....................................................................................................................12
7. Putting to use...................................................................................................................................13
7.1. Minimal requirements for vehicle operation.................................................................................................................. 13
7.2. Before use ...................................................................................................................................................................... 13
8. Operator requirements....................................................................................................................13
9. Use of Personal Protective Equipment...........................................................................................14
10. Use ...................................................................................................................................................14
10.1. How to operate the EV4................................................................................................................................................. 14
10.2. Essential activities during use ....................................................................................................................................... 15
10.3. Display description........................................................................................................................................................ 16
10.4. Charging and fuse description....................................................................................................................................... 17
11. Setup ................................................................................................................................................19
11.1. Seat height ..................................................................................................................................................................... 19
11.2. Braking system............................................................................................................................................................... 19
11.3. Shock absorbers............................................................................................................................................................. 19
12. Maintenance....................................................................................................................................20
12.1. Wheels............................................................................................................................................................................ 21
12.2. Bolts and glued parts..................................................................................................................................................... 21
12.3. Vehicle transmission...................................................................................................................................................... 21
12.4. Lubrication .................................................................................................................................................................... 22
13. Fixing...............................................................................................................................................22
14. Moving EV4.....................................................................................................................................22
15. Part specification.............................................................................................................................22

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16. Noise ................................................................................................................................................23
17. Radiation .........................................................................................................................................23
18. Troubleshooting ..............................................................................................................................23
19. Declaration of conformity...............................................................................................................23
Warning! Please read this manual before first use and observe safety regulations first. To ensure proper operation of the
vehicle for a long time, follow the maintenance instructions carefully.
If you are left with any questions after reading this manual, AERO-SERVICE will gladly answer them.

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1. PRELIMINARY INFORMATION
1.1. Content and addressees of this manual
This technical publication is a manual for EV4 QUAD manufactured by AERO-SERVICE.
The manual refers to „main application of the device”, together with all the technical information about
exploitation, assembly and maintenance of the device. This manual is addressed to all users of the EV4 vehicle.
In case of loss or a case where it will no longer be usable it is recommended to order a copy of the manual from the
producer.
The manufacturer reserves the right to these materials and intellectual property rights and prohibits,
even in part, copying and/or disclosure of the content of the documentation without the
manufacturer's permission.
1.2. Symbols
To ensure safety of the users, and to avoid any interference in operation, safety instructions must be followed. These
symbols will help you achieve that:
SYMBOL
MEANING
DESCRIPTION
Danger
This symbol indicates situations of grave danger, neglect of which can
seriously jeopardize the risk of loss of health and safety of persons.
Danger
This symbol indicates serious electrical hazards which may negatively
impact health or even cause death.
Warning
This symbol indicates the need for warning or attention to key functions
or important information.
1.3. Cooperation with the user of EV4
The manual reflects the equipment and the technical condition of the machine at the time of commissioning. Any change
in this manual will result in the shipment of a copy of the manufacturer's new instruction to each customer and such
documentation should be stored with this manual.

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1.4. Compliance with safety requirements
AERO-SERVICE declares with all responsibility, that this product is compliant with following standards:
PN-EN ISO - 12100:2012 Safety of machines -- General design principles -- Risk assessment and risk
reduction.
EV4 QUAD meeets the requirements of the following European Directives:
The Directive 2006/42/EC of the European Parliament and of the Council of 17 May 2006 concerning
machinery and certain parts of machinery.
Directive 2014/30/EU of the European Parliament and of the Council of 26 February 2014 on the
harmonisation of the laws of the Member States relating to electromagnetic compatibility.
The devices have been CE marked and have been issued a declaration of conformity for them - due to the
requirements set out in the above directives.
Nameplate attached to the device:

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2. Vehicle description
2.1. Manufacturer contact details:
AERO-SERVICE Jacek Skopiński
Dereniowa 4/69
02-776 Warsaw, Poland
Tel. [phone]
e-mail. [e-mail]
2.2. General description
The vehicle has an adaptive suspension that adapts to the shape or inclination of the terrain and allows the vehicle to
tilt in the bend so as to eliminate the effect of the centrifugal force. The vehicle is used to transport people.
Diag. 1 EV4 QUAD

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Diag. 2 MAIN PARTS
Diag. 3 MAIN PARTS
BRAKE
CALIPER
BRAKE
CALIPER
FOOTREST
BRAKE
DISC
REAR
SWINGARM
FRAME
TRANSMISSION
BELT
FOOTREST
FRAME
SWINGARMS
BRAKE
PIPES
LINKS AND PUSHERS
OF STEERING
CONTROL
FRONT WHEELS
BRAKE
DISK
BRAKE
CALIPER
SUSPENSION
LINK

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Diag. 4 MAIN PARTS
Diag. 5 MAIN PARTS
STEERING COLUMN
REAR
SWINGARM
MOTOR
FOOTREST
FRONT SWINGARMS
FRAME
IGNITION KEY
SUSPENSION
LINK
REAR SWINGARM
MOTOR
REAR WHEEL
TRANSMISION BELT
TRANSMISION GEARS

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Diag. 6 MAIN PARTS
Diag. 7 MAIN PARTS
BRAKE DISC
REAR WHEEL
MOUNTING UNIT
TRANSMISION
BELT
REAR SWINGARM
BRAKE CALIPER
STEERING
KNUCKLE
BRAKE CALIPER
BRAKE DISC
LINKS AND PUSHERS OF
STEERING CONTROL

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Diag. 8 MAIN PARTS
HANDLEBAR
FRONT
WHEELS
FOOTREST
FRAME
IGNITION
SEAT
TRANSMISION
BELTS
REAR WHEELS

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3. Proper use
The vehicle can only be used to transport people over 18 years of age. The weight of the person and the
baggage must not exceed 100 kg.
WARNING! It is forbidden to use the vehicle contrary to its purpose.
Use for other purposes is not allowed. Proper use also includes all activities related to the correct and safe
operation and maintenance of the EV4. Accordingly, the user is obliged to:
read the manual and adhere to its recommendations and warnings;
understand how the machine operates and maintain safety;
avoid accidents.
4. Warnings for unauthorised use
WARNING! The manufacturer is not responsible for the consequences of improper use.
EV4 QUAD does not meet the requirements for vehicles intended for use in traffic.
Incorrect use of EV4 may cause personal injury. Use protective clothing such as suitable footwear, gloves, helmet,
knee pads, elbow pads, safety goggles, etc.
Do not use the product on: unhardened, wet, slippery and uneven surfaces.
It is forbidden to drive under the influence of alcohol, intoxicants, narcotics, and drugs which don’t allow driving
vehicles.
EV4 is an electric vehicle, so it is not allowed to use it in the rain or in humid conditions. The vehicle cannot be
driven into puddles.
It is prohibited to: pour water onto EV4, keeping and using it in rain, washing and cleaning under running water.
Removing dirt is possible using a damp cloth.
This product is only for users over the age of 18.
Persons using the vehicle must have the ability to maintain balance while driving as they would on a two-wheeled
vehicle such as a bicycle, scooter or motorbike. They should also have the appropriate height so that when using the
vehicle they can support their foot during the stop. They must be people who have good eyesight, reflexes, and are
able to make quick decisions.
The vehicle owner is fully responsible for any damages resulting from the use of the EV4

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EV4 is not designed for extreme driving. It is forbidden to perform jumps and other dangerous evolutions. You
cannot speed it up and stop too fast.
Speed must be adapted to field conditions. Longer braking distances should be considered for slippery surfaces.
Overload: do not overload the vehicle's power package and overload the vehicle itself. The weight of the driver along
with the luggage must not exceed 100kg. Overload and excessive load can damage the vehicle and the power unit.
Driving at the same time is only permitted by one person. Driving in two or more is prohibited.
Before each use of the vehicle, the driver is obliged to inspect the technical condition of the vehicle. Make sure all
components are in place, no screws and nuts missing. Check the front and rear brakes.
5. Residual risk
Residual risk is risk that still remains after all precautions have been taken.
When observing such recommendations as:
read the manual carefully;
do not place hands in between moving parts ;
do not make any modification or repairs to the electrical parts of the vehicle;
do not operate the vehicle without reading the manual first,
secure the EV4 from persons unauthorized to operate it,
Residual risk can be eliminated without endangering people and the environment. There is a residual risk in case of
non-compliance with the specified recommendations and guidelines.
6. Technical information
Main technical information is shown in the table below.
TECHNICAL INFORMATION
INPUT VOLTAGE
230 V
OUTPUT VOLTAGE
37 V
FREQUENCY
50-60 Hz
MAXIMUM POWER OUTPUT
2000 W
WEIGHT
53 kg

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7. Putting to use
7.1. Minimal requirements for vehicle operation
EV4 is an electric vehicle so it is not allowed to use it in the rain or in high humidity conditions. The vehicle cannot
be driven into puddles.
It is prohibited to pour water onto it, keep and use it in rain, wash and clean under running water. Storage and use
temperatures must be between +1 and +40 degrees Celsius.
7.2. Before use
Take special care when starting up the machine; check all safety and security functions. Remember to read this
manual carefully and first observe safety regulations.
Check before use:
Tire pressure,
Shock absorber pressure.
Battery charge.
Transmission belt tension
Check for suspension malfunctions.
Check for steering control malfunctions.
Check for brake system malfunctions.
8. Operator requirements
The person selected and authorized to operate and maintain EV4 must have the appropriate knowledge. Service work may
only be performed by persons who have manual skills and are familiar with the operating instructions. To properly handle EV4
the user must:
Know how to use and seek information in this document;
Know how the EV4 functions;
Have a medical condition consistent with the certificate given by a physician,
Have at least 18 years of age;
Be mentally and physically fit;

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The person selected and authorized to operate and maintain EV 4 must have the appropriate knowledge.
The weight of the driver with the luggage must not exceed 100 kg. Overloading can damage the vehicle and drive
train.
Recognize abnormalities in functioning and, if necessary, take necessary measures to remove them.
Persons using the vehicle must have the ability to maintain balance while driving as they would on a two-wheeled
vehicle such as a bicycle, scooter or motorbike. They should also have the appropriate height so that when using the
vehicle they can support their foot during the stop. They must be people who have good eyesight, reflexes, and can
make quick decisions.
9. Use of Personal Protective Equipment
To avoid injury when using EV4, wear protective equipment. Equipment includes bicycle helmet, knee and elbow
pads. Protective gloves are recommended during repairs and maintenance.
10. Use
10.1. How to operate the EV4
When using the EV4, sit on a seat, hold hands on the steering wheel, feet while on the ground and while driving on
footrests. Keep your hands and feet away from all the mechanical components of the vehicle such as steering suspension or
drive system. Do not touch: vehicle mechanisms drive system and vehicle suspension during operation. When you move the
vehicle, the feet of the vehicle must be moved directly onto the footrests. Leaving your feet on the ground can result in your
foot being caught under rear wheel. Before using the quad for the first time, charge the battery to 100%.
The throttle is on the right hand side of the steering wheel. It is used to start and to adjust the speed of the vehicle.
Increasing the speed is done by rotating the handle in a clockwise direction (looking at the lever from the left side of the
vehicle). When opening the throttle one should always be sitting on the vehicle. Hands must be on the steering wheel. One foot
should be on the footrest, the other leg should be used to slightly push away from the ground while opening more throttle. One
should take great care not to let the leg get under the rear wheel. When moving, both legs should be on the footrests.
The rider should be sitting on the seat. If necessary it is allowed to be moving while standing on the footrests. This
allows for a greater range of body balancing in rough terrain. However, bear in mind that when standing one is moving the
centre of mass higher and consequently lowering the stability of the vehicle. Stand steady on the footrests and distribute weight
on both feet equally. Standing with uneven weight distribution is forbidden and can result in loss of balance and tipping. The
equilibrium should be kept in the same way as in two-wheeled vehicles. Turning is done by simultaneous body balance and
steering turn. The vehicle is stopped when the lever is closed and the right and left brake levers are pressed simultaneously,
ensuring that the wheels are not locked. This may cause loss of steer ability, balance and tipping. Stopping in the final phase,
one should support with foot.
The maximum tilting of the vehicle while riding is 30 degrees. Increasing the tilting of the vehicle beyond 30 degrees
may cause the suspension to fall against the limiter and consequently vehicle damage and imbalance.

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Diag. 9 THE HANDLEBAR
10.2. Essential activities during use
1. Put the vehicle in vertical position (do
not sit on the vehicle when in fully
tilted position)
2. Sit on the seat and place one foot on
the footrest. When moving put both
feet on the footrests
3. Put the key into the ignitron and turn
fully to the right.
THROTTLE
COMPUTER
REAR BRAKE
LEVER
FRONT BRAKE
LEVER
BELL
IGNITION

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4. The vehicle is ready to run when the
computer is turned on.
5. To move forward open the throttle.
6. When moving put both feet on the
footrests to avoid are caught under the
rear wheels.
7. The speed of the vehicle is adjusted
with the throttle.
8. If you do not start driving within one
minute of turning on the ignition, the
engine controller will shut down
automatically. This protects the battery
from unnecessary discharge. In this
case, the vehicle's computer remains on
but in order to restart the engine
controller, switch the ignition switch
on and off again. The controller will
switch off automatically after the end
of the drive, for example, if one forgets
to switch off the ignition switch (after
about 1 minute).
9. After driving, turn off the vehicle with
a key and secure it against unwanted
use, children, etc. Leave the vehicle in
a tilted position and prevent it from
rolling downhill.
10.3. Display description
Diag. 10 COMPUTER DISPLAY 1
DAYLY
DISTANCE
ESTIMATED DISTANCE
TO RECHARGE
BATTERY CHARGE
SPEED
POWER
CONSUMPTIO
N

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Diag. 11 COMPUTER DISPLAY 2
10.4. Charging and fuse description
EV4 QUAD is supplied with a Li-Ion 37 V, 52 Ah battery. In order to properly charge the battery, use the charger
supplied with the vehicle. You will need a special 37 V charger for Li-Ion batteries. It is forbidden to use a charger other than
the original charger. Using a charger other than the original charger may result in electrical damage, short circuit, fire and
personal injury. It may also cause permanent damage to the battery and the vehicle's electrical system.
The charger must first be connected to the vehicle then to the network. The charging socket is at the top of the frame
under the seat. Take the lid off the socket and then plug in the charger plug. The charger must be disconnected from the vehicle
when the vehicle is fully charged (charge will not occur after 100%). It is indicated with a green lamp on the charger. Secure
the vehicle's charging socket when charging is complete. After the charge is complete, one can start the vehicle with the key.
Disconnect the charger before starting the vehicle. Do not connect any equipment or short connectors to the charger socket.
The charger for the EV4 does not charge other batteries.
EV4 vehicles have fuses for electrical wiring. Fuses are located on the battery casing. If the vehicle cannot be started
or the battery won’t recharge check whether the fuse has been blown. For this purpose dismantle the frame cover with the
screws and check the fuse in the battery. Locating the cover and fuse holder bolts is shown in the photographs.
If the vehicle cannot be started and the fuse is working, contact the manufacturer / service. Do not perform repairs on
your own. EV4 Quad has a main fuse with a current of 50 A, a charging circuit of 10 A and computer circuit of 2-5 A. When it
is necessary to replace the fuse, it is necessary to use a new one with the same current.
It is forbidden to use a fuse of other parameters. This may cause damage to the electrical system and fire.
CURRENT FROM
BATTERY
POWER
BATTERY
VOLTAGE
SPEED
TOTAL DISTANCE
TRAVELED

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Diag. 12 BATTERY COVER BOLTS
Diag. 13 FUSES
COVER
BOLTS
COMPUTER FUSE
CHARGING FUSE
MAIN FUSE

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Diag. 14 CHARGING SOCKET
11. Setup
11.1. Seat height
The seat has 3 position height adjustments. Adjust the seat height according to the height of the driver. To do this,
unscrew and remove the 6 M5 bolts at the bottom of the seat tube. After selecting the appropriate height, fit and fasten the 6
bolts.
11.2. Braking system
The brake system has two independent front and rear brake circuits. The front wheels stop using the right lever and
the rear wheels stop using the left lever. The braking system is very effective, so excessive use of the brake lever can cause the
wheel to block and consequently you may fall into a slippage and lose balance. Operate the brake lever with your index finger
and middle finger instead of your whole hand. Front wheel locking may cause lack of front steering and cause the vehicle to tip
over. Before going full speed, one must practice using the brakes to properly control the vehicle, If squeaking occurs during
braking, it has become uneven in individual wheels, brakes have become ineffective, or other disturbing braking problems are
observed immediately replace the brake pads.
11.3. Shock absorbers
The hardness of the shock absorbers should be adjusted to the weight of the driver. Excessive deflection of the shock
absorber can cause damage to the vehicle and damper and cause discomfort to the driver. The shock absorber must be set as
follows: The person who will drive the vehicle must sit on the vehicle with both feet on the ground. The second person at the
same time should check the damper's initial deflection, which should be about half of total stroke. For DT SWISS shock
absorbers with a length of 190 mm the total deflection is 50 mm and the initial deflection (when the driver sits on the vehicle)
in the front and rear shock absorbers should be 25 mm. Adjustment of hardness is done by pumping the shock absorber with a
pump and dropping pressure is done by venting the valve. Approximate pressure in the front shock absorber is 2-3 bars while
in the rear 4-6 bar. Maximum pressure cannot exceed 18 bars. Exceeding this pressure can damage the shock absorber.
Damper adjustment should be unscrewed towards the softest damping. The shock absorber should be set to: unlocked.
CHARGING
SOCKET

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Diag. 15 SHOCK ABSORBER CONFIGURATION
Diag. 16 SHOCK ABSORBER CONFIGURATION
12. Maintenance
Please observe the following maintenance recommendations:
The maintenance and servicing times given in this manual must be strictly observed.
Any changes have to be approved by the manufacturer.
To prevent premature wear of EV4, diligently clean and maintain them at regular intervals.
SOFT
DAMPING
REGULATOR
STIFF
DAMPING LOCKED
DAMPING UNLOCKED
PUMPUNG VALVE
SHOCK ABSORBER