View the User Manual - Star Electric Vehicles
Contents
1. 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 Chain or rope off these potentially hazardous areas or identify them with a suitable warning describing the nature of the hazard and the proper precautions to be taken to avoid the hazard Wet Areas Wet grass may cause a golf car to lose traction and may affect stability Reduce speed in wet areas or during periods of inclement weather Loose Terrain Loose terrain may cause a golf car to lose traction and may affect stability Repair loose terrain chain or rope off these areas or identify loose terrain with a suitable warning Golf Car and Pedestrian Interference Reroute golf car traffic or pedestrian traffic in congested areas wherever possible to prevent accidents If it is impractical to reroute traffic erect warning signs to warn pedestrians of golf car traffic and to warn golf car operators to drive slowly use caution and watch for pedestrians Ventilation Properly ventilate all maintenance and storage areas in accordance with applicable fire codes and ordinances to avoi2. Batteries produce explosive gases Keep sparks flames and cigarettes away from battery Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries WARNING Keep out of reach of children Eight 6 volt deep cycle batteries provide power for your electric golf car and must be properly maintained and recharged for maximum performance and service life To maintain your batteries 1 Clean the tops of the batteries with a solution of baking soda and water as necessary to remove corrosion CAUTION Do not allow cleaning solution to enter battery cells 2 Checkthe fluid level before and after charging Before charging Only add distilled water if fluid is below the top of the plates and then add just enough to cover plates After charging Add distilled water carefully until the water level is 1 4 to inches up to the plate or at the and 3 8 position in the level indicator Adding properly distilled water can help to prevent the water from boiling after charging 16 min level of electrolyte vent cap max level of electrolyte plates CAUTION Normal tap water contains minerals which are harmful to a battery therefore refill only with distilled water 3 Using a hydrometer check the specific gravity of the battery fluid in each cell against the readings on the chart below Consult a Star EV dealer if any low readings are found or if readings vary mor
3. Electric Vehicles Owner s Manual and Service Guide Magellan 2 and Magellan 2 2 May 2014 Table of Contents Introduction Vehicle Specifications Operator safety Safety precautions during maintenance Safety considerations Driver Qualifications Golf Course Safety Maintenance required for safety Controls Switches Pedals Battery indicator Tow switch Serial number Pre operation check Operation list Daily Checklist Operation Storage Maintenance Period maintenance chart Battery care Battery charging Battery installation Electrical Diagrams NOD OO U 10 10 11 11 11 12 12 13 14 14 16 18 19 20 Introduction Congratulations on your purchase of a Star EV Magellan This manual contains information you will need for proper operation maintenance and care of your Magellan 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 Magellan please consult a Star EV dealer Read and understand this manual completely before operating your Magellan This manual should be considered a permanent part of your golf car and should remain with the car when lending or resold This manual can also be applied to below types e Magellan 2 2 seat golf car e Magellan 2 2 2 seat golf car with 2 add seats Vehicle Specifications Passengers Batter
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5. 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 WARNING Explosive gases are released when batteries are charged or discharged Keep well ventilated Keep sparks flames and cigarettes away from batteri
6. complete stop Press down on the brake pedal to stop the golf car after releasing the accelerator pedal Your Diablo is equipped with an electromechanical parking brake It will engage automatically when car is ata complete stop or key switch is in OFF position Please wait until the car has come to a complete stop before leaving the vehicle Pay special attention if the car is on a steep hill or the road condition is wet or covered with ice or snow the parking brake may not be able to completely stop the vehicle The parking brake will automatically release when the accelerator pedal is depressed If the main switch is in the ON position depressing the accelerator may suddenly cause the golf car to move Main Switch The main switch can be found on the instrument desk below the steering wheel OFF Electrical circuit is switched off The key can be removed only in this position ON Electrical circuits are switched on The golf car can be driven Drive Select Switch F R switch The F R switch can be found on the front dashboard next to the key switch R OFF ON The drive select switch is used to shift the golf car into forward or reverse After coming to a complete stop move the lever to the desired position Switch Position Car Movement F Forward R Reverse 0 The back up buzzer will sound when the drive select switch is turned to reverse When switched to O position the car do
7. pedal is depressed To release the parking brake manually insert two M4 bolts on the back of the motor as shown Two M5x45mm bolts and an Allen key Q in a plastic bag in the battery compartment parking brake release Battery Indicator The battery indicator shows the electric level of the battery Tow Switch La The Tow switch is located in the front of the battery container The switch can be seen clearly when the seat bottom is being opened by means of pulling the armrest forward Pulling the switch to TOW or OFF will cut the power off and make the car stop 10 Before towing the car When the anti slide function is active pull the switch to TOW or OFF to cut off the power for the protection of the electric integrated circuit Before connecting or disconnecting cables Pull the switch to TOW or OFF to cut off the power and avoid a battery explosion At least a 10 minute interval should be allowed when changing the switch Serial Number NOTE The first three digits of the serial number are for the manufacturing date the remaining digits are the unit production number Keep a record of these numbers for reference when ordering parts from your dealer Pre Operation Check Every Star EV vehicle has been checked up and adjusted thoroughly Be familiar with controls indicators and operations Please use the check list as a guide Pre operation checks should be made each time you use your g
8. screws and S S S S S terminals Check brake pedal free play ae C CA CA CA CA and adjust if necessary Check steering operation C C C C C 14 Check tire pressure tread depth and tire surface for damage Check body and chassis for damage Check tightness of all bolts nuts screws and rivets Check reverse buzzer Check electrolyte level Check for loose or broken connections Clean and lube pedal control area Check all wire insulation for cracks and or worn spots Check shock absorbers for oil leaks and damaged springs Perform a discharge test Apply terminal protectant Check rear axle bearing play for roughness or free play Check steering knuckle bushing free play Adjust wheel alignment Check wheel nut tightness front wheel bearing play Check transaxle oil level and inspect for leakage Check pedal stop operation and adjust if necessary Replace transaxle oil Inspect internal wet brake and replace pads if necessary CA CA C C C CL C 15 CL CA CA CA Battery Care WARNING Battery electrolyte is poisonous dangerous and can cause severe burns It contains sulfuric acid Avoid contact with skin eyes or clothing Antidotes e External Flush with water Internal Call a physician immediately Drink large quantities of water or milk e Eyes Flush with water for 15 minutes and get prompt medical attention
9. arger is on or an arc could occur that may cause an explosion 3 The charger will turn off automatically when the batteries reach full charge 18 4 After the charger has turned off disconnect the DC output plug from the golf car receptacle by grasping the plug body and pulling the plug straight out of the receptacle Battery Installation WARNING When working with batteries do not put wrenches or other metal objects across the battery terminals This can cause explosion of the battery Install the battery tie down plates and torque to as shown left driver s side gt TROJAN 105 TROJAN 1 105 504 5091 5044 front WARNING When installing batteries carefully place battery cables and tie downs making sure that cables do not lay across vent caps Always remove the negative cable to the motor controller first and install it last CAUTION Do not over tighten the battery tie down nuts Excessive force will damage the battery casing 19 2 o od o qnop YOUIMS 4 210 8 Yo IMs UOT Ie 0Id 8 181 2 e od e qnop TAS wg teyeag YOUIMS ju8I 1 3 UANG qo3114s MI Jousep4 20 YOUIMS 1 Aepor igBrIpeeH DU 311 14817 14811 Buruan peop yeig puoy oxvig Surum
10. d fire hazards Ventilation is required to remove hydrogen gas from the car storage areas during the battery charging process For electric powered golf cars the amount of hydrogen gas emitted during charging depends ona number of factors such as the condition of the batteries the output rate of the battery charger and the amount of time the batteries are on charge Because of the highly volatile nature of hydrogen gas and its propensity to rise and accumulate at the ceiling in pockets a minimum of five air changes per hour is recommended Consult applicable fire and safety codes for the specific ventilation levels requirement as well as requirements for the use of explosion proof electrical apparatus Maintenance required for Golf Car Safety Preventative Maintenance Perform all scheduled maintenance in accordance with manufacturer s recommendations to provide the golfing patron with a safe properly operating golf car Personnel Allow only qualified trained and authorized personnel to inspect adjust and maintain golf cars Parts and Materials Use only replacement parts and materials recommended by the manufacturer Controls WARNING If lending or reselling the golf car make sure the driver is familiar with all the controls and rules The F R switch is used to shift the golf car into forward or reverse In order to avoid occupants injury and protect cars move the switch to the desired position after coming to a
11. e than one point between cells Temperature Satisfactory Uncorrected Hydrometer Reading 120 48 9 1 244 110 43 3 1 248 100 37 8 1 252 90 32 2 1 256 80 26 7 1 260 70 21 1 1 264 60 15 6 1 268 50 10 0 1 272 40 4 4 1 276 30 11 1 280 17 Battery Charging WARNING Read and understand the owner s manual provided with your golf car s battery charger before charging batteries WARNING Explosive hydrogen gas is produced while batteries are being charged Only charge batteries in well ventilated areas a minimum of five air changes per hour is recommended To charge the batteries in your golf car follow the instructions contained in your battery charger s owner s manual The following is a summary of the charging steps WARNING Do not attempt to recharge your golf car s batteries without thoroughly reading and understanding the owner s manual provided with your charger 1 Turn main switch key to OFF position 2 With the charger properly connected and grounded see charger s owner s manual insert the DC output plug into the golf car receptacle Do not connect the AC with the golf car directly charging socket charging plug CAUTION Use only battery chargers that are rated for use with 48 volt Star EV Golf Cars Thoroughly read and understand the user manual supplied with your 48 volt charger WARNING Do not disconnect the DC output cord from the battery receptacle when the ch
12. es 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 a
13. es not move even if the accelerator pedal is depressed brake pedal Accelerator Pedal accelerator pedal The accelerator pedal can be found on the right side labeled GO This pedal is different from the accelerator pedal in common car Turn on the main switch and select the F R switch to move forward or in reverse and the golf car s speed will accelerate gradually as the accelerator pedal is depressed Releasing the pedal causes the power to be cut and the motor to stop working gradually Brake Pedal The brake pedal is the larger one on the left side labeled STOP Press down on the brake pedal to stop the golf car Parking Brake Press down on the brake pedal to stop the golf car after releasing the accelerator pedal Your Diablo is equipped with an electromechanical parking brake It will engage automatically when car is complete stop or key switch is in OFF position Please wait until the car has come to a complete stop before leaving the vehicle Pay special attention if the car is on a steep hill or the road condition is wet or covered with ice or snow the parking brake may not be able to completely stop the vehicle The parking brake will automatically release when the accelerator pedal is depressed If the main switch is in the ON position depressing the accelerator may suddenly cause the golf car to move motor WARNING The parking brake will automatically release when the accelerator pedal or the brake
14. ge You should hear a click sound 3 Turnthe main switch to OFF Switch the F R switch to the O position and take out the key when not in use Storage Perform the following preparations when storing your golf car for extended periods of time 1 Turn main switch key to OFF position remove key and store key in a safe place 2 Verify the tire pressure is set to 35 psi 3 Clean the exterior of the golf car 13 4 Cover the golf car with a breathable cover and store it in a dry well ventilated area 5 Have the batteries recharged every 60 90 days to keep them fully charged The batteries must be kept fully charged to avoid damage 6 Have the car lubricated every 6 months 7 Clean the top of the batteries with a solution of baking soda and water as necessary to remove corrosion 8 Trap the wheels to avoid the car moving Maintenance Periodic Maintenance Chart Regular maintenance is required for the best performance and safe operation of your golf car Be sure the main switch is off and the parking brake is engaged when you perform maintenance unless otherwise specified If the owner is not familiar with machine servicing this work should be done by a Star EV dealer or other qualified mechanics C Check S Service CA Check and adjust CL Clean and lubricate R Replace L Lubricate daily thl i th 1 bros monthly six months yearly four years Charge S S S S S Clean battery tops check for tightness of
15. nd 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 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
16. olf car Get in the habit of performing the following checks WARNING Be sure the main switch key is removed before performing the pre operation checks to prevent accidental starting Pre Operation Checklist Before each use check the following Batteries Check that the batteries are held securely in place to prevent them from being damaged from vibration or jarring Also check that no battery caps are missing to prevent battery acid from spilling from the batteries Check the battery terminals for corrosion 11 Tire condition Check the tire air pressure before operating the golf car Check the tire surface for damage cracks or embedded objects When tire tread wears down to 0 04 1 mm replace the tire Body and chassis Before each use visually inspect the golf car body and chassis for damage and or missing parts Daily Checklist Please use the checklist as a guide to check the daily running condition and the car Drive select switch F R switch Check to make sure the switch works properly Pedal operation Check the following pedal controls for proper operation If a pedal does not work properly consult a Star EV dealer Make sure the brake pedal feels firm when pressed and returns to its original position when released Press down on the brake pedal The brake pedal should not touch the floor of car Make sure the parking brake works properly when the electromechanical park brake is engaged You should not be able to
17. push the vehicle and the brake should release automatically when the accelerator pedal is pushed Back up buzzer Check the buzzer by moving the drive select switch to REV for reverse The buzzer should sound Steering system Check the steering system for excessive free play by moving the steering wheel up down back and forth and turning the steering wheel slightly to the right and left If you feel excessive free play or hear rattling sounds which may indicate loose steering components consult a Star EV dealer Sounds Check for abnormal sounds when running Operation 1 Learn the controls of the vehicle 2 Make sure every occupatant remains seated 12 3 Read the warnings on the indicator board 4 Make sure the steering wheel works well 5 Turn the main switch to ON Check that your path is clear 6 Turnthe drive select switch to FWD for forward or REV for reverse 7 Slowly depress the accelerator pedal and the locked parking brake will automatically release The golf car will start to move The speed increases gradually as the accelerator pedal is depressed WARNING Control the speed when descending a slope The brake can control the speed when descending a slope CAUTION Pressing the F R switch to the O position cuts off the power and the car stops Stopping 1 To stop the golf car gradually press down on the brake pedal 2 When the car has come to a stop the parking brake will automatically enga
18. y group Motor Controller power amps Maximum speed mph Load capacity Ibs Dimensions in Weight including batteries Ibs Ground Clearance in Turing Radius ft Wheelbase in Climbing capacity Front suspension Rear suspension Steering system Brake system Tire size Tire pressure psi Magellan 2 2 8 x 6V Trojan T105 6 HP Continuous rating 275 Amp AC Curtis 19 5 20 25 LSV 650 94x47 74 1200 5 10 68 30 Independent A arm with coil over shocks Leaf spring and shock Rack and pinion 4 wheel hydraulic disc 205 50 10 30 Magellan 2 2 4 8 x 6V Trojan T105 6 HP Continuous rating 275 Amp AC Curtis 19 5 20 25 LSV 650 115x47x74 1300 5 10 68 30 Independent A arm with coil over shocks Leaf spring and shock Rack and pinion 4 wheel hydraulic disc 205 50 10 30 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
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