StarEv AP48-04 Owner's Manual And Service Manual

4- and 6-passenger bubble cars

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Owner's Manual and Service Guide
4- and 6-passenger Bubble Cars: AP48-04, AP48-04-D, AP48-06, AP48-06-D
November 2014

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Summary of Contents for StarEv 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 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.
  • Page 3: Table Of Contents

    Table of Contents Vehicle Specifications Important Labels Operation Functions Operational Process Charging Batteries Safety Battery Maintenance Cleaning Recharging Watering Specific Gravity Test Open-Circuit Voltage Test Gear Box Installation Traction/Motor Speed Controller Troubleshooting Brake System Lubrication General Maintenance Notes Periodical Maintenance Storage Troubleshooting Electrical wiring...
  • Page 4: Vehicle Specifications

    Vehicle Specifications 4-Passenger Bubble Car 6-Passenger Bubble Car Passengers Battery group 8 x 6V (48V), Trojan T-105 included 8 x 6V (48V), Trojan T-105 included Motor 7 HP AC 7 HP AC Controller power 450A Curtis Controller 450A Curtis Controller Maximum speed (mph) 19.5 (20-25 LSV) 19.5 (20-25 LSV)
  • Page 5: Functions

    Operation Please read the following labels carefully before operating the vehicle, and promptly replace any Important Labels labels which become unreadable or removed. Security Warning label under the dashboard Warning label under the dashboard • Warning label beside the parking brake handle •...
  • Page 6 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.
  • Page 7: Operational Process

    Emergency stop switch: Stops the power of the whole vehicle in case of emergency. Before you switch on the vehicle, always check the status of this switch to make sure that it is in the OFF NOTE: position. Digital display: This meter shows information including lights, speed, range, hand brake, and battery power.
  • Page 8: Charging Batteries

    Release the service brake. Switch off all lights. Switch off the power key and take out the key. Charging Batteries 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 CAUTION: manual.
  • Page 9: Safety

    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: Connect the charger with AC power. Turn on the charger. Turn off the charger when the batteries are fully charged, disconnect the charger with AC power.
  • Page 10: Cleaning

    Avoid starting and stopping suddenly. Avoid turning the vehicle too sharply at high speeds. • Always drive slowly up inclines and down declines. • Do not make any modification or addition which may affect the capacity or safety. • Children are not allowed to play in the vehicle. Children should be seated between adults •...
  • Page 11: Recharging

    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 batteries and do not connect the positive pole to the negative pole.
  • Page 12 plates. Keeping the water at the correct level after a full charge will prevent having to worry about the water level at a different state of charge. It is recommended that batteries be checked once a month until you get a feel for how often you must water your batteries.
  • Page 13: Specific Gravity Test

    Specific Gravity Test (Flooded batteries only) Do not add water at this time. Fill and drain the hydrometer 2 to 4 times before pulling out a sample. There should be enough sample electrolyte in the hydrometer to completely support the float.
  • Page 14: Open-Circuit Voltage Test

    A weak or bad cell is developing. Battery was watered excessively previous to testing. Batteries in conditions 1 - 4 should be taken to a specialist for further evaluation or retired from service. Open-Circuit Voltage Test For accurate voltage readings, batteries must remain idle (no charging, no discharging) for at least 6 hrs, preferably 24 hrs.
  • Page 15: Installation

    State of charge as related to specific gravity and open circuit voltage Open-Circuit Voltage Specific Gravity Percentage of Corrected to Charge 80° F 1.277 6.37 8.49 12.73 25.46 38.20 50.93 1.258 6.31 8.41 12.62 25.24 37.85 50.47 1.238 6.25 8.33 12.50 25.00 37.49...
  • Page 16: Traction/Motor

    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 17: Speed Controller

    Troubleshooting for Motor Only a qualified electrician should change and adjust the carbon brush. Warning: All copper plates turn Symptoms Possible Causes The pressure of brush is incorrect. black The commutator turns Short circuit in the commutator or armature coil; poor welding or black in a certain order disconnection between the commutators and the armature coil.
  • Page 18: Lubrication

    When the vehicle starts, the controller will inspect signals from the accelerator. If signal exceeds 20%, the HPD (protection unit in the controller) will prohibit the output of the controller. The controller will self-check when the vehicle is running. If any defect inspected, the controller will stop the vehicle to protect the operator and the vehicle.
  • Page 19: General Maintenance Notes

    General Maintenance Notes To avoid any damage on the brake shoe, the handbrake should be released to its bottom before staring the vehicle. • The lubricant for rear power assembly must be applied and changed as per user’s manual. The brake system must be adjusted once every 3 months. •...
  • Page 20 Discharge the capacitors in the controller by connecting a load (such as a contactor coil or a horn) across the controller’s B+ and B- terminals. Remove any dirt or corrosion from the connector areas. The controller should be wiped clean with moist rag. Dry it before reconnecting the battery. The controller should not be subjected to pressured water flow from either a standard hose or a power washer.
  • Page 21 Clean the surface of battery. Observe the charging status, check if the  charger plug becomes hot. Charger  Clean the surface of the charger. Do not get any water inside the charger.  Check if all terminals are tightened properly.
  • Page 22: Storage

    Adjust the toe-in of the front end. Clean the body and seat.   After above maintenance, drive the vehicle to check if the vehicle works properly. Storage Please follow the steps below when the vehicle is stored. Check the liquid level inside the battery; recharge it fully before storing the vehicle. Charge the battery once a month if your vehicle will be stored more than one month.
  • Page 23: Troubleshooting

    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 Connector(s) in circuit is loose or open Tighten or connect Malfunction Possible reason...
  • Page 24 Internal short of motor Repair or change Vehicle stops immediately Motor is assembled too tight or blocked Repair or change after it starts Controller failure Repair or change Accelerator failure Repair or change Normal power at low Controller failure Check or change speed, weak power at Motor failure Check or change...
  • Page 25 Gear inside transmission case Change is worn out Orientation pin is loose Change Pressure of front tire is Check the pressure and deficient inflate Screw plug of redirector is too Adjust tight Lack of lube in redirector Maintain/add lube Toe-in is abnormal Adjust Steering heavy Clearance of tension rod ball...
  • Page 26 Front suspension is loose Change Tire pressure is abnormal Inflate Toe-in is improper Adjust Drum bearing loose Change U type bolt of leaf spring is Tighten loose Abnormal tire fray Rim is distorted or frame is Tighten distorted Brake force of each wheel is Adjust different Overexerting accelerate or...
  • Page 27 Star EV has the final say on the interpretation of this manual. Please contact your local Star EV dealer with any questions or concerns, or visit www.starev.com to locate an authorized dealer in your area.

This manual is also suitable for:

Ap48-06Ap48-06-dAp48-04-d

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