Star EV Diablo 2+2, Diablo 4+2 Owner's Manual And Service Manual

Owner’s Manual and Service Guide

Diablo 2+2 and Diablo 4+2

May 2014

Table of Contents

Introduction 2

Vehicle Specifications 3

Operator safety 4

Safety precautions during maintenance 5

Safety considerations 6

Driver Qualifications 6

Golf Course Safety 6

Maintenance required for safety 7

Controls 8

Switches 8

Pedals 9

Battery indicator 10

Tow switch 10

Serial number 11

Pre-operation checks 11

Operation list 11

Daily Checklist 12

Operation 12

Storage 13

Maintenance 14

Period maintenance chart 14

Battery care 16

Battery charging 18

Battery installation 19

Electrical Diagrams 20

1

Introduction

Congratulations on your purchase of a Star EV Diablo. This manual contains information you will

need for proper operation, maintenance, and care of your Diablo. A thorough understanding of

these simple instructions will help you to obtain maximum enjoyment from your new Star EV.

If you have any questions about the operation or maintenance of your Diablo, 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 Diablo and should remain with the

car when lending or resold.

This manual can also be applied to below types.

• Diablo 2+2: 2 seats golf cat with 2 add-seats

• Diablo 4+2: 4 seat golf car with 2 add-seats

2

Vehicle Specifications

Passengers

4

6 Battery group

8 x 6V, Trojan T105

8 x 6V, Trojan T105

Motor

6 HP Continuous; 22 Peak HP

6 HP Continuous; 22 Peak HP

Controller Power (amps)

275 Amp, AC Curtis

275 Amp, AC Curtis

Maximum speed (mph)

19.5 (20-25 LSV)

19.5 (20-25 LSV)

Load capacity (lbs)

800

1000

Dimensions (in)

118 x 53 x 79

148 x 53 x 82

Weight including batteries
(lbs)

1315

1500
Ground Clearance (in)

7 7 Turing Radius (ft)

11

14

Wheelbase (in)

68

101

Climbing capacity

30%

30%

Front suspension

Independent A-arm with coil
over shocks

Independent A-arm with coil
over shocks

Rear suspension

Leaf spring and shock

Leaf spring and shock

Steering system

Rack and pinion

Rack and pinion

Brake system

4-wheel hydraulic disc

4-wheel hydraulic disc

Tire size

23 x 10.5 x 12 CST Tires

23 x 10.5 x 12 CST Tires

Tire pressure (psi)

35

35

Diablo 2+2 Diablo 4+2

3

Operator Safety

Read and understand this manual completely before operating your golf car. Failure to follow

WARNING instructions could result in severe injury or death to the golf car occupants, a bystander,

or a person inspecting or repairing the golf car.

Particularly important information is distinguished in this manual by the following notations: the

safety alert symbols, warnings, cautions, and notes. Please read the following labels carefully before

operating your golf car, and promptly replace any labels which become damaged or removed.

Star EV golf cars are designed to be simple to operate.

However, be sure to observe the following:

Read this Owner’s/Operator’s manual and all safety and instruction labels on the golf car before

operating.

Do not allow more than one occupants per seat. The different vehicles are restricted to different

numbers of occupants unless equipped with a rear seat.

Do not operate the golf car while under the influence of alcohol or drugs; their affect on vision and

judgment makes operating a golf car dangerous.

Do not operate the golf car on public streets, roads, or highways unless allowed by law or local

regulating authority.

Keep your entire body inside the golf car, remain seated, and hold on when the car is in motion.

Do not start the golf car until all occupants are seated.

Keep your hands on the steering wheel and your eyes on the path ahead.

Use extra care in congested areas or when backing up. Always back up slowly, and watch carefully.

Avoid starting or stopping abruptly. Vary the speed of the golf car to match the terrain of the

course. Avoid turning the steering wheel too sharply at higher speeds. Always drive slowly straight

up or straight down slopes and never at an angle.

Do not make any modification or addition which affects capacity or safe operation, or make any

changes not in accordance with the owner’s operator’s manual.

4

WARNING: Explosive gases are released when batteries are charged or discharged. Keep

well ventilated. Keep sparks, flames and cigarettes away from batteries. Shield eyes when

working near batteries.

Star EV golf cars do not protect passengers from storms. When driving in a rainstorm,

passengers should leave the car and take shelter in safe areas.

Safety Precautions during Maintenance

When performing maintenance, follow all safety instructions contained in the manufacturer’s

operation and service manuals, as well as the following safety procedures:

Properly immobilize golf car before beginning any maintenance. Properly block chassis before

working underneath golf car.

Avoid fire hazards, and have appropriate fire protection equipment available.

Before working on an electric golf car, disable the car’s electrical system in accordance with the

manufacturer’s instructions. (Before disconnecting the batteries, push the button “Tow/Run” to

“Tow” side. If not, a battery explosion could occur.)

Use only properly insulated tools when working on electrically powered golf cars and around

batteries.

Maintain all safety devices including brakes, steering mechanisms, and warning devices in a safe

operating condition. Do not modify these safety devices as supplied by the manufacturer.

After each maintenance or repair, the car must be driven by a qualified, trained, and authorized

person – in an area free of pedestrian traffic – to ensure proper operation and adjustment.

Record all maintenance performed in a maintenance record log by date, name of person performing

maintenance, and type of maintenance. Periodically inspect maintenance log to ensure accurate and

complete entries.

Provide operator comment cards to assist in identifying non-periodic maintenance needs for

specific golf cars.

Maintain in a legible condition all nameplates, warnings, and instructions provided by the

manufacturer.

5

If new nameplates, warnings, or instructions are needed, contact your Star EV dealer.

Safety Considerations

Like all machines, golf cars can cause injury if improperly used or maintained.

This section contains broad safety practices required for safe golf car operation. Before golf cars are

operated, golf course personnel should establish any additional safety practices that may be

required for safe operation.

The information contained here is intended for golf course personnel responsible for golf car safety.

If you are responsible for the operation and maintenance of this golf car, we encourage you to

implement this golf car safety program.

Driver Qualifications

Allow only authorized people to operate golf cars. It is recommended that only people who possess

a valid motor vehicle driver’s license be allowed to operate golf cars.

Place operation and safety instructions recommended by the golf car manufacturer, along with the

golf course safety rules, in a conspicuous place near the golf car rental area or golf car pick-up area.

It is also recommended that the following warning be posted in a conspicuous location.

Golf Course Safety

Perform safety surveys regularly to identify hazardous areas where golf cars should not be

operated.

The following golf course hazards must be made safe:

Steep Grades: Where steep grades exist, restrict golf cars to designated golf car pathways where

possible. In addition, identify steep grades with a suitable warning like:

WARNING: Steep Grade, Descend Slowly With Foot On Brake Sharp Turns, Blind Corners,

Bridge Approaches.

6