Star EV AP48-04 User 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

1
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.

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

3
Vehicle Specifications
4-Passenger Bubble Car
6-Passenger Bubble Car
Passengers
4
6
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)
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
Reinforced fiberglass
Climbing capacity
(loaded)
20%
20%
Front suspension
Independent, coil over shock
Independent, coil over shock
Rear suspension
Leaf spring and shock
Leaf spring and shock
Steering system
Rack and pinion
Rack and pinion
Brake system
4-wheel hydraulic drum brake
4-wheel hydraulic drum brake
Tire size
155R12, 6-ply, DOT
155R12, 6-ply, DOT
Tire Pressure (psi)
55
55
Wheel type
12 inch aluminum
12 inch aluminum
Chassis
Welded steel frame
Welded steel frame
Roof
Fiberglass
Fiberglass
Drive Train
Direct rear drive
Direct rear drive
Windshield
AS1 DOT 430 automotive windshield
AS1 DOT 430 automotive windshield

4
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

5
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.

6
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.

7
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.

8
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.

9
•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
and protected while the vehicle is moving.
Battery 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.
Cleaning
The exterior of the batteries, 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

10
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. 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 batteries should
be recharged fully on the same day. Any delay in re-charging will negatively affect the
batteries. 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 batteries should be fully
recharged first. After that, the batteries 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 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 recharged before the battery power meter shows 20%
power is left inside the batteries. An over-discharged battery will have a very short service life and
will make recharging difficult.
WARNING:During recharge, the vehicle should be parked in a well-ventilated area with the fill caps
tightly secured. Keep far away from any flame and sparks to avoid any explosion or fire that could
cause physical injury or damage to the property.
During recharge, if the vehicle had doors, keep the doors open. Lift the seat bottom to keep the
battery compartment open to the air.
Watering
Flooded batteries need water. More importantly, watering must be done at the right time and in the
right amount or else the battery's performance and longevity suffers. Water should always be
added after fully charging the battery. Prior to charging, there should be enough water to cover the
plates. If the battery has been discharged partially or fully, the water level should also be above the

11
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. Important things to remember:
•Do not let the plates get exposed to air. This will corrode the plates.
•Do not fill past the water level in the filling well to the cap. This most likely will cause the
battery to overflow acid, consequently losing capacity and causing corrosion.
•Do not use water with a high mineral content. Use distilled or de-ionized water only.
WARNING: The electrolyte is a solution of acid and water so skin contact should be avoided.
Watering procedure
1| Open the vent caps and look inside the fill wells.
2| Check electrolyte level; the minimum level is at the 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 charging is completed, open the vent caps and look inside the fill wells.
6| Add water until the electrolyte level is 1/8" below the bottom of the fill well.
7| A piece of rubber can be used safely to help determine the level.
8| Clean, replace, and tighten all vent caps.
CAUTION: Never add acid to a battery.
Testing: Visual inspection alone is not sufficient to determine the overall health of the battery. Both
open-circuit voltage and specific gravity readings can give a good indication of the batteries’ charge
level, age, and health. Routine voltage and gravity checks will not only show the state of charge but
also help spot signs of improper maintenance, such as undercharging and over-watering, and
possibly even locate a bad or weak battery. The following steps outline how to properly perform
routine voltage and specific gravity testing on batteries.

12
Specific Gravity Test (Flooded batteries only)
1| Do not add water at this time.
2| Fill and drain the hydrometer 2 to 4 times before pulling out a sample.
3| There should be enough sample electrolyte in the hydrometer to completely support the
float.
4| Take a reading, record it, and return the electrolyte back to the cell.
5| To check another cell, repeat the 3 steps above.
6| Check all cells in the battery.
7| Replace the vent caps and wipe off any electrolyte that might have been spilled.
8| Correct the readings to 80° F:
a| Add .004 to readings 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 specification of 1.277 +/- .007. If any specific gravity
readings register low, then follow the steps below.
1| Check and record voltage level(s).
2| Put battery/batteries on a complete charge.
3| Take specific gravity readings again.
If any specific gravity reading still registers lower than the factory specification of 1.277+/- .007
then one or more of the following conditions may exist:
1| The battery is old and approaching the end of its life.
2| The battery was left in a state of discharge too long.
3| Electrolyte was lost due to spillage or overflow.

13
4| A weak or bad cell is developing.
5| 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.
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 battery if it registers 0% to 70% charged.
If battery registers below the Table 1 values, the following conditions may exist:
•The battery was left in a state of discharge too long.
•The battery has a bad cell.
These batteries should be taken to a specialist for further evaluation or retired from service.

14
State of charge as related to specific gravity and open circuit voltage
Percentage of
Charge
Specific Gravity
Corrected to
80° F
Open-Circuit Voltage
6V
8V
12V
24V
36V
48V
100
1.277
6.37
8.49
12.73
25.46
38.20
50.93
90
1.258
6.31
8.41
12.62
25.24
37.85
50.47
80
1.238
6.25
8.33
12.50
25.00
37.49
49.99
70
1.217
6.19
8.25
12.37
24.74
37.12
49.49
60
1.195
6.12
8.16
12.24
24.48
36.72
48.96
50
1.172
6.05
8.07
12.10
24.20
36.31
48.41
40
1.148
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 battery cables to battery terminals with torque of 95 - 105 lbs. in. (10.7 - 11.9 N.M.)
Make sure there is nothing else between the battery cable lug and battery terminal post.
WARNING: When working with the battery, DO NOT put wrenches or any other metal objects
across the battery terminals, otherwise, an arc can occur, and it may cause explosion of the battery
and physical injury. Battery should be installed or replaced only by a qualified electrician.

15
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. If not flat, tighten the screws.
Change the gear oil inside the gear box periodically. 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 is 85W/90GL.
Clean the gear box before changing the oil.
CAUTION: Never mix different oils.
Traction/Motor Maintenance
The motor is designed for use up to 4000 feet above sea level and in a temperature between -15° F
and 105° F.
Never keep the motor running idly. Any mud, sand, and other clinging objects should be cleaned
away.
Check the carbon brush every three months. To change a worn or weakened carbon brush, press
spring.

16
Troubleshooting for Motor
Warning: Only a qualified electrician should change and adjust the carbon brush.
Symptoms Possible Causes
All copper plates turn
black
The pressure of brush is incorrect.
The commutator turns
black in a certain order
and in groups
Short circuit in the commutator or armature coil; poor welding or
disconnection between the commutators and the armature coil.
The commutator turns
black
The central line of the commutator deviates or its surface is not
round and smooth.
The brush wears out, turns
colors and becomes broken
The motor vibrates; the clearance between the brush and its holder
is too big; 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
smooth; mica or some commutators extrude; the brush is not
ground properly; the brush is the wrong type; the brush is jammed
in the brush holder; the brush holder become loose or vibrating;
the polarity and sequence of magnetic poles is wrong.
The brush and its wires get
hot
Big sparks of the brush; poor contact between brush and soft wires.
The brush is noisy
The surface of the commutators is not smooth.
Speed Controller Maintenance
The speed controller of the vehicle is wholly imported, which adopts high frequency MOS
technology to realize the control of speed, torque and brake with smoothness, silence, and high
energy efficiency.

17
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.
Brake System Maintenance
Depress the brake pedal with a force of 65 lbs. 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 gear from 5 to 10 ratchets. When the brake handle is released
completely, the brake function will stop.
Inspect and change brake shoe, and add lubrication into the brake bearing periodically.
Lubrication
Use 901 vehicle brake oil DOT3 as brake oil. Use 1L of 85W/90GL lubrication oil for gear box. Use
1L of 90GL hypoid gear oil for the rear axle.
Lubrication points: steering gears, horizontal bars, steering ball joints, and bearings.

18
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.
•The electricity system must be checked once every 3 months (especially main circuit) for its
fastening parts and wiring connections. Meanwhile the contactor should be checked. Any
defective parts should be replaced immediately. Dust should be cleaned with low pressure
air.
•The electric contactors easily become hot if their mutual contact is not in good condition, so
special attention should be paid regularly to the electric contactors.
•When changing a fuse, 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 of the controller.
•It is prohibited to pour any other liquids (such as battery addictives, mineral water and tap
water) into the battery. Only distilled water should fill battery.
Periodical Maintenance
•Check if the contact between contacting points of the contactor is in good condition, check
for any mechanical sticking or jamming.
•Check if the micro switch in the accelerator can be switched on and off properly.
•Check if the switch for the turn signal can be switched on and off properly.
•Check if all the connections between the motor, the battery, and the controller are in good
condition.
Please use the following cleaning procedure for routine maintenance:
1| Turn the power key to OFF position.
2| Remove power by disconnecting the battery.

19
3| 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.
4| 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.
5| Make sure the connections are tight, but do not over-tighten them.
NOTE: All above checks should be performed with the power off. Above checks shall be carried out
once every 3 months; after the power is turned off, the wave-filter capacitor in the controller unit
should continue discharging 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 performance and safe operation of the vehicle.
WARNING:Make sure to turn off the power key and apply the park brake when you do the
maintenance unless specified. If the owner is not familiar with the maintenance of this vehicle, the
dealer should do the work.
Item Descriptions Daily Weekly Monthly Quarterly Yearly
Battery
Check the liquid level. Add distilled water
if necessary.

Charge the battery.

Tighten the nut on the battery cable.

Check if the battery is over-discharged
(the battery power meter flashing).

Check the liquid density of the battery;
standard density should be 1.275±0.005.

Check if the battery is charged fully by
using the hydrometer and checking the
battery power meter.
