StarEv AP48-04, AP48-06, AP48-06-D, AP48-04-D Owner's Manual And Service Manual

Owner’s Manual and Service Guide

4- and 6-passenger Bubble Cars: AP48-04, AP48-04-D, AP48-06, AP48-06-D

November 2014

Thanks for buying our Star EV Bubble Car. For better use, please read through this manual before

operating this vehicle to avoid any possible 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.

Important Information:

Important information is showed in following way in this manual:

WARNING: Failure to follow Warning instructions could result in severe 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.

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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

2

Vehicle Specifications

4-Passenger Bubble Car

6-Passenger Bubble Car

Passengers

4

6

Battery group

8 x 6V (48V), Trojan T-105 included

Motor

7 HP AC

Controller power

450A Curtis Controller

Maximum speed (mph)

19.5 (20-25 LSV)

Load capacity (lbs)

780

990

Dimensions (in)

122 x 59 x 77 (L x W x H)

153 x 59 x 77

Weight (lbs)

1760 (no doors), 1936 (doors)

1980 (no doors), 2244 (doors)

Ground Clearance (in)

5 5 Turing Radius (ft)

14.7

19.8

Wheelbase (in)

87.8

118

Body material

Reinforced fiberglass

Climbing capacity

(loaded)

20%

20% Front suspension

Independent, coil over shock

Rear suspension

Leaf spring and shock

Steering system

Rack and pinion

Brake system

4-wheel hydraulic drum brake

Tire size

155R12, 6-ply, DOT

Tire Pressure (psi)

55

Wheel type

12 inch aluminum

Chassis

Welded steel frame

Roof

Fiberglass

Drive Train

Direct rear drive

Windshield

AS1 DOT 430 automotive windshield

3

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

4

Power key: Controls the power supply of the whole vehicle. When the key is inserted 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. It should be depressed slowly. The vehicle speeds up with

gradual depression, 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, 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 forwards while depressing the lower part (R) makes the vehicle move in reverse, 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.

5

Emergency stop switch: Stops the power of the whole vehicle in case of emergency. 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 shift F/R button to

neutral position.

2| Engage the handbrake lever to park the vehicle.

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3| Release the service brake.

4| Switch off all lights.

5| 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-board) charger. Before you use the charger, read the charger operation

manual.

Explosive hydrogen gas is produced while battery is charged. Only charge the batteries 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 a long time.

Charging Procedure

Turn off the power of the vehicle before charging.

For a non-onboard 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.

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4| Turn off the charger when the batteries are fully charged. Disconnect the charger from AC

power first, and then disconnect the charger with AC receptacle.

For onboard (built-in) charger:

1| Connect the charger with AC power.

2| Turn on the charger.

3| Turn off the charger when the batteries are fully charged, disconnect the charger with AC

power.

Safety

The driver should have a good knowledge of the operation system of the vehicle and its features

while following rules for safe operation. This is a low speed electric vehicle, and should be used on

approved roads and meet the road regulations. 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 cannot be overloaded, or the motor will be damaged. An overloaded vehicle can

lose control.

• 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 road ahead.

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

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StarEv AP48-04, AP48-06, AP48-06-D, AP48-04-D Owner's Manual And Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual