Table of Contents
Advertisement
Advertisement
Table of Contents
Related Manuals for Star EV Classic-Series
Summary of Contents for Star EV Classic-Series
- Page 1 Owner’s Manual and Service Guide Star Classic, Star Sport, SS Limited, H-Series...
- Page 2 Star, please consult your Star EV dealer. Read and understand this manual completely before operating your Star EV. This manual should be considered a permanent part of your Star EV and should remain with the vehicle when lending or resold.
-
Page 3: Table Of Contents
Table of Contents Models & Names Vehicle Specifications Overview Important labels Controls Functions Safety Operation Maintenance Battery maintenance Charger maintenance Motor maintenance Controller maintenance Rear axle maintenance Wheel maintenance Brake adjustment Lubrication Troubleshooting Periodic Maintenance Chart Storage... -
Page 4: Models & Names
Important Information Particularly important information is distinguished by the following notations: WARNING: Failure to follow Warning instructions could result in severe injury to the vehicle occupants, bystanders or persons inspecting or repairing the vehicle. CAUTION: Failure to follow Caution instructions could cause damage to the vehicle. Special Notice: Because the seat &... - Page 5 Classic 48-4 Classic 48-4+2 Classic 48-6 Classic 48-6+2 Classic 36-2H, Classic 48-2H Classic 48-4H Classic 48-2HCX (with various box attachment Classic 48-6H options, not shown)
- Page 6 Classic 48-4HCX (with various box attachment Sport 2+2 options, not shown) Sport 4+2 Sport 48-2H Sport 48-4H Sport 48-2HCX...
-
Page 7: Vehicle Specifications
2: Vehicle Specifications Star Classic Classic 36-2 and Classic 36-2+2 Passengers 2 or 4 (2 facing backward) Body Material Plastic Six 6 V (36 V) batteries, Trojan Battery System Front Suspension Leaf spring and shock T-105 Motor Power 4 hp Advanced DC motor Steering System Rack and pinion 300 A Curtis programmable... - Page 8 Star Classic Classic 48-4 and Classic 48-4+2 Passengers 4 or 6 (2 facing backward) Body Material Plastic Eight 6 V (48 V) batteries, Leaf spring and shock Battery System Front Suspension Trojan T-105 Motor Power 5.5 hp Advanced DC motor Rear Suspension Leaf spring and shock 400 A Curtis programmable...
- Page 9 Sport Sport 2+2 and Sport 4+2 4 of 6 (2 facing backwards on Passengers Body Material Plastic both) Eight 6 V (48 V) batteries, Battery System Front Suspension Leaf spring and shock Trojan T-105 5.5 hp Continuous Leaf spring and shock Motor Power Rear Suspension Controller Power...
- Page 10 H-Series Classic 48-2HCX, Classic 48-4HCX Passengers 2 or 4 Top Climbing Grade Eight 6 V batteries, Trojan Battery System Brake System Hydraulic drum T-105 Motor Power 5.5 hp Advanced DC motor Tire Size 20.5 x 8x 10, 6-ply DOT Controller Power 400 A Tire Pressure 50 psi...
-
Page 11: Important Labels
3: Overview WARNING: Always confirm whether there are restrictions in the area where you in- tend to use the vehicle. It is recommended that only people who possess a valid motor vehicle driver’s license be allowed to operate golf cars. Important Labels Safety Label Read carefully and understand the contents on the safety label. -
Page 12: Controls
Chassis number of the vehicle 4: Controls Note: There are two types of dashboards on STAR . The cup holder on the 2008 and later (current) style dashboard is on top of the instrument panel and the cup holder on the 2006 style dashboard is below the instrument panel. -
Page 15: Functions
Functions of Controls Power Key: The power key is used to switch on the electrical system of the vehicle. To engage the motor and start the vehicle, insert the key and turn it clockwise to the ON position. At this time the 12V accessory system (headlights, turn signals, taillights, brake lights and horn) will be engaged too. - Page 16 ent: refer to the figures below. NOTE: On the mechanical brake system, the service brake pedal is combined with the parking brake pedal. Parking Brake Pedal: The parking brake pedal is used in braking for parking. The parking brake of the mechanical brake system is different from hydraulic brake sys- tem.
-
Page 17: Safety
Tow/Run Switch (available for Curtis 1266 and 1268 controller): Before oper- ating the vehicle, make sure the TOW/RUN switch is on ‘RUN’ position. Make sure the TOW/RUN switch is on the “TOW’ position if towing the vehicle. The TOW/RUN switch is located under the seat on the passenger side either on the controller cover or just under the rear body as shown on p. -
Page 18: Operation
During operation: • Keep your entire body inside the vehicle, keep seated and hold 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. •... -
Page 19: Battery Maintenance
will cause the vehicle to move which could cause severe injury or death. • CAUTION: If the accelerator pedal is stepped down before the power key is on, the vehicle will not run. In this case, you should release the accelerator pedal first, and then turn the power key ON. - Page 20 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 as needed. Reconnect the clamps to the terminals and thinly coat them with petroleum jelly (Vaseline) to prevent corrosion.
- Page 21 Battery water maintenance Flooded batteries need water. 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. Prior to charging, there should be enough water to cover the plates.
- Page 22 care, 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. Specific Gravity Test (Flooded batteries only) Do not add water. Fill and drain the hydrometer 2 to 4 times before pulling out a sample.
- Page 23 If any specific gravity readings still register low then follow the steps below. Check voltage level(s). Perform equalization charge. Refer to the Equalizing section for the proper procedure. 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: The battery is old and approaching the end of its life.
-
Page 24: Battery Charging
State of charge as related to specific gravity and open circuit voltage Open-Circuit Voltage Percentage of Specific Gravity charge corrected to 80°F 12 V 24 V 36 V 48 V 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... -
Page 25: Charger Maintenance
Charging Process Turn the power key to OFF. Connect the plug to the vehicle receptacle first; then connect it to your local AC power outlet. • WARNING: Do not disconnect the cord from the battery receptacle when the charger is ON, otherwise an arc could occur which may cause an explosion. -
Page 26: Motor Maintenance
After the charger cord is connected, the red indicator on the charger will flash. The charger will start the procedure of self-inspection. After self-in- spection, a green indicator flashes, and the charger will begin to charge the batteries. When battery capacity is less than 80%, the green indicator flashes slowly. When battery capacity is more than 80%, the green indicator flashes fast. -
Page 27: Controller Maintenance
months as it is an easily worn part. If it is not replaced in time before it wears out, it will damage the motor. • Do not keep the motor running idly for long periods of time. Any idle run- ning of the motor should be avoided. - Page 28 Cleaning It is recommended that the controller be kept clean and dry and that its fault histo- ry file be checked and cleared periodically. Periodically cleaning the controller exterior will help protect it against corrosion and possible electrical control problems created by dirt, grime, and chemicals that are part of the operating environment and that normally exist in battery-powered systems.
-
Page 29: Rear Axle Maintenance
Rear Axle Maintenance While using your vehicle, the rear axle should be maintained daily, periodically and randomly. Daily maintenance before, during or after driving. The maintenance is focused on clearance and examine as followed: Clean the dust and mud on the cover to keep the axle clean Make sure all connections are in good condition. -
Page 30: Brake Adjustment
Use a jack to lift the vehicle, then remove the wheel nuts and the wheel. To install a wheel on the vehicle: Use a jack to lift the vehicle, then put the wheel onto the wheel hub. Finger tighten the lug nuts, then tighten lug nuts to 50-85 ft.lbs.(70-115 Nm) in 20 ft.lbs.(30 Nm) increments following the ‘cross sequence’... - Page 31 Lubrication Points Spindle (passenger side) Spindle (passenger side) Rear End Middle Shaft...
-
Page 32: Troubleshooting
8: Troubleshooting Symptoms Possible Causes Troubleshooting The gear oil is insufficient or used improperly. Oil gear or replace. The bearing is assembled incorrectly. Assemble correctly. Adjust the brake shoe pin shim or the interval. Adjust or replace. The axle housing gear and bearing are dam- The gear between axle 1 and 2 is not tightly connected. - Page 33 Item Description Daily Weekly Monthly Quarterly Annually 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 is flashing). Check the liquid density of the battery, Battery standard density should be 1.277±0.007g/...
-
Page 34: Storage
10: Storage Follow the steps as below when the vehicle is stored. Check the liquid level inside the battery; recharge it fully before storing the vehicle. WARNING: Charge the battery once a month if your vehicle will be stored more than one month. Turn the power key to OFF, remove the key, and store the key in a safe place. - Page 35 STAR EV, a brand of JH Global Services, Inc. 378 Neely Ferry Road | Simpsonville, SC 29680 www.starev.com...
Need help?
Do you have a question about the Classic-Series and is the answer not in the manual?
Questions and answers
when charging the light does not blink and no charge. the cable from the outlet to the cart is working but the cart not charging.
The Star EV Classic-Series may not be charging when the light does not blink due to the following reasons:
1. Grid Voltage Out of Range – If the voltage is outside the 90-260V range, the charger will stop charging, and the failure code light will turn on. Charging will resume automatically when the voltage returns to the correct range.
2. Over-Discharging Protection – If the battery is close to depletion and not charging, the system may have cut off the battery current to force charging.
3. Self-Inspection Failure – If the charger fails to complete its self-inspection process, it will not begin charging.
4. Battery Condition – If the battery has been left discharged too long or has a bad cell, it may not accept a charge and should be evaluated by a specialist.
This answer is automatically generated
I have a bouncing feeling as we are driving..
A bouncing feeling while driving a Star EV Classic-Series could be caused by issues with the suspension system, such as worn-out leaf springs or shocks. Uneven tire pressure or damaged tires could also contribute to the issue. Regular maintenance and inspection of these components can help prevent or resolve the problem.
This answer is automatically generated
Where do I find a wiring diagram for a 2017 Star EV golf cart?