Star EV Classic-Series Owner'S Manual And Service Manual Download Page 3

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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

Table of Contents

Summary of Contents for Classic-Series

Page 1: ...Owner s Manual and Service Guide Star Classic Star Sport SS Limited H Series...

Page 2: ...structions will help you to obtain maximum enjoyment from your new Star EV If you have any questions about the operation or maintenance of your Star please consult your Star EV dealer Read and underst...

Page 3: ...peration Maintenance Battery maintenance Charger maintenance Motor maintenance Controller maintenance Rear axle maintenance Wheel maintenance Brake adjustment Lubrication Troubleshooting Periodic Main...

Page 4: ...ion instructions could cause damage to the vehicle Special Notice Because the seat backrest wrapping film may stick to the seat vi nyl and cause seat vinyl to fade or stain remove the seat backrest wr...

Page 5: ...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 6H Classic 48 2HCX with various box attachment options not shown...

Page 6: ...6 Classic 48 4HCX with various box attachment options not shown Sport 2 2 Sport 4 2 Sport 48 2H Sport 48 4H Sport 48 2HCX...

Page 7: ...y Four year limited warranty two year bumper to bumper warranty less wear items Star Classic Classic 48 2 and Classic 48 2 2 Passengers 2 or 4 2 facing backward Body Material Plastic Battery System Ei...

Page 8: ...educer 20 A 48 V to 12 V reducer included Warranty Four year limited warranty two year bumper to bumper warranty less wear items Star Classic Classic 48 6 and Classic 48 6 2 Passengers 6 or 8 2 facing...

Page 9: ...Trojan T 105 48 V Eight 6 V batteries Trojan T 105 Brake System 36 and 48 2H Rear drum 48 4H and 6H Hydraulic drum Motor Power 36 V 4 hp Advanced DC motor 48 V 5 5 hp Advanced DC motor Tire Size 36 2H...

Page 10: ...2HCX 12 ft 4HCX 15 ft Wheel Base 2HCX 96 4HCX 125 Ground Clearance 5 Steering System Rack and pinion Windshield Foldable tinted Voltage Reducer 20 A 48 V to 12 V reducer included Warranty Four year l...

Page 11: ...ed 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 The...

Page 12: ...e 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 dashboar...

Page 13: ...13...

Page 14: ...14...

Page 15: ...move forward down for reverse or in the middle for neutral WARNING This switch must be fully pressed into the proper position or the electric system and motor will be damaged NOTE The buzzer will beep...

Page 16: ...brake pedal is unlocked WARNING The foot park brake will automatically release when the accel erator pedal is stepped down If the power key is in ON position stepping down the accelerator pedal may su...

Page 17: ...al Pull the handle lever down to activate the left turn signal Headlight Switch Pull out the button to switch on the headlight 5 Safety Star EVs are designed for simple operation however make sure you...

Page 18: ...denly start moving 2 With the parking brake applied press the Forward Reverse switch and lock it in the desired position CAUTION Do not shift from Forward to Reverse while the vehicle is mov ing 3 Mak...

Page 19: ...tion Battery Maintenance NOTE STAR EVs are equipped with deep cycle flooded lead acid batteries If your vehicle is equipped with another type of battery follow the maintenance instruc tions provided b...

Page 20: ...ng 1 Regardless of how long you have used the vehicle the battery should be re charged fully on the same day Any delay on the re charging will reduce the life of the battery Note The lead acid battery...

Page 21: ...d causing a corrosive mess Do not use water with a high mineral content Use distilled water only CAUTION The electrolyte is a solution of acid and water so skin contact should be avoided Step by step...

Page 22: ...record 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 ha...

Page 23: ...eloping 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 a...

Page 24: ...produced while the battery is charged Only charge the battery in well ventilated areas Before using the charger check if the battery charger you are using is cor rectly rated as per your local AC ele...

Page 25: ...e 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 in use for an extend ed time Carefully read the operation...

Page 26: ...d stop the vehicle to force the user to charge the bat tery When the grid voltage is out of range of 90 260V the charger will stop charging At the same time the failure code light will come on When th...

Page 27: ...The brush wears out changes colors and breaks The motor vibrates the clearance between the brush and its holder is too big the clearance between the brush and commutator is too big the mica between d...

Page 28: ...Make sure the connections are tight but do not over tighten them Fault History File The handheld programmer to be ordered separately can be used to access the controller s fault history file The progr...

Page 29: ...erential 7 Check if the there is any section in the parking brake cable broken or loose and replace if necessary Periodic maintenance The axle should be maintained every month two months and six month...

Page 30: ...essure for the tire Immerse the tire in water to locate the leak and mark with chalk Place tire plug according to the manufacturer s specifications Brake Adjustment WARNING If you have any problem wit...

Page 31: ...31 Lubrication Points Spindle passenger side Spindle passenger side Rear End Middle Shaft...

Page 32: ...e gear between axle 1 and 2 is not tightly connected Adjust correctly The final drive is too noisy Replace the gear Axle 1 grinding gears Adjust or replace The rear axle is bent check if it is over lo...

Page 33: ...he controller Check that the solenoid is in order by check ing its touching point Motor Ensure that no water gets in and that it does not become too hot Check if the carbon brush should be replaced Ch...

Page 34: ...the exterior of the vehicle and apply rust inhibitor 6 Cover the vehicle with a breathable cover and store it in a dry safe and well ventilated place 7 If the vehicle is planned to store for a long ti...

Page 35: ...STAR EV a brand of JH Global Services Inc 378 Neely Ferry Road Simpsonville SC 29680 www starev com...

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