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Old 03-08-2024, 10:41 AM   #1
Jim Shanks
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Join Date: May 2023
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Default 2007 Star EV Stops running when headlights engaged

I'm working on getting an older (2007) Star EV sport working, and after having the controller rebuilt, cleaning up the motor, replacing the contactor, it runs pretty well. My issue now is that when the headlight switch is engaged, it shuts down the cart. I've put 12V past the relay to check that the headlights, turning lights, tail lights and switches all work, and they do, but it appears that when the draw on the 12V side is more than about 3 amps it shuts everything down and then, after I shut everything off, it works again after about a minute or so.

It appears that there's circuit breaker or overload sensor somewhere that's faulty, but I don't see anything. Could it be the 48V to 12V converter, and would blowing the overload on that converter shut down everything?
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Old 03-12-2024, 08:57 AM   #2
Jim Shanks
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Default Re: 2007 Star EV Stops running when headlights engaged

For an update: The Curtis 1268 controller is throwing a flash code 3,3 which means "External Short or leakage path to B- on external B+ connection". I guess the next thing to check is the wiring to the 48V to 12V converter. I don't have a good schematic for a 2007 so have to try to make the 2008 schematic work. They're a little different.
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Old 08-13-2024, 08:51 PM   #3
Jim Shanks
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Default Re: 2007 Star EV Stops running when headlights engaged

Should have posted this earlier. Finally, after explaining to the Star EV factory support guy, that we paid a local Star EV dealer technician over $1000 and they still didn't fix it, they had a tech call me.

Figured out the problem in about in about a half hour. The tech that changed a bunch of parts . . . .wired the feeder line to the 12V converter to the B+ on the controller. It's supposed to be wired to the input side of the solenoid. That fixed it.
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12v converter, headlights, relay, wiring
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