Star CAPELLA CP-2 Owner's Manual
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Star CAPELLA CP-2 Owner's Manual

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Summary of Contents for Star CAPELLA CP-2

  • Page 1 CAPELLA O W N E R S M A N U A L...
  • Page 2 Notes page...
  • Page 3 Notes page...
  • Page 4 Periodic Service Schedule. Repair or replacement parts are available from your STAR EV dealer. When you contact STAR EV about service or parts for your vehicle, the information below is needed. Vehicle Model:...
  • Page 5 Starting Model Year 2018 OWNER’S GUIDE ELECTRIC POWERED VEHICLES - STARTING MODEL YEAR 2018 • The electric vehicle must be driven by qualified and professionally trained drivers. • Accelerator pedal and brake pedal cannot be stepped down at the same time, otherwise it will damage the control system and burn out the motor.
  • Page 6 Battery Storage and Disposal BATTERY PROLONGED STORAGE Batteries discharge over time. The rate of discharge changes according to the ambient temperature, the age and condition of the batteries. Completely charged batteries will not freeze in winter temperatures unless the temperature is less than -75°F ( - 60°C). For winter storage, the batteries must be clean, completely charged and disconnected from any electrical drain.

  • Page 7: Table Of Contents

    Table of Contents SAFETY General Notices, Cautions, Warnings and Dangers General Operations 13, 14, 15 Maintenance 15, 16 Labels and Pictograms 17-22 GENERAL SPECIFICATIONS Approximate vehicle dimensions 24-29 Turning diameter and incline information 30, 31, 32 INTRODUCTION CONTROLS AND INDICATORS FEATURES General Information Key Switch and Direction Selector...
  • Page 8 Table of Contents OPERATING PROCEDURES SERIAL NUMBER LOCATIONS BEFORE INITIAL USE PORTABLE CHARGER INSTALLATION HOW TO USE THE CHARGER CHARGER MAINTENANCE 44, 75 HOW TO OPERATE THE VEHICLE 45, 49, 51 Direction Selector Operation Accelerator and Brake Pedal Operation Horn (if equipped) 34, 36, 46 Tow Switch Operation 34, 36, 39, 60...
  • Page 9 Table of Contents TRANSPORTING VEHICLE Towing 11, 58 SERVICE AND MAINTENANCE 52, 59 ROUTINE MAINTENANCE TIRE INSPECTION BRAKES 37, 45, 61 REAR AXLE 61, 77, 79 Checking the Lubricant Level HARDWARE 58, 62, 70 BATTERY CHARGING AND MAINTENANCE 63, 72 Safety Battery Maintenance 63, 64...
  • Page 10 Notes page...

  • Page 11: Safety

    Safety Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers GENERAL For any questions about material in this manual, contact an authorized representative. Read and understand all labels on the vehicle. Always replace any damaged or missing labels.

  • Page 12: Notices, Cautions, Warnings And Dangers

    Do not change the vehicle in any manner that changes the weight distribution, decreases stability, increases speed or extends the necessary distance to stop more than the factory specification. STAR EV is not responsible for changes that cause the vehicle to be dangerous. page...
  • Page 13 Safety Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers GENERAL OPERATION Read the following warnings before attempting to operate the vehicle: • When you leave the vehicle, turn the key to the OFF position and remove the key from the vehicle.

  • Page 14: General Operations

    General Operation GENERAL OPERATION Read the following warnings before attempting to operate the vehicle: Read the following text and warnings before you service the vehicle. Normal use, wear or abuse can cause some components on the vehicle to fail. The manufacturer can’t predict when and where the failure will occur.

  • Page 15: Maintenance

    General Operation Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers When you maintain the vehicle, always wear eye protection. Be careful when you do work around batteries or you use solvents or compressed air. ALWAYS •...
  • Page 16 Safety MAINTENANCE • Use recommended tools. • Make sure that tools and procedures not specified by the manufacturer will not be a safety risk to personnel or operation of the vehicle. • Use wheel chocks and support vehicle with jack stands. NEVER get below a vehicle that is supported by a jack.

  • Page 17: Labels And Pictograms

    Labels and Pictograms Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers LABELS AND PICTOGRAMS page...
  • Page 18 Labels and Pictograms Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers LABELS AND PICTOGRAMS page...
  • Page 19 Labels and Pictograms Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers page...
  • Page 20 Labels and Pictograms Label is above or below Charger port page...
  • Page 21 Safety Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers page...
  • Page 22 Safety Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers page...
  • Page 23 Notes page...

  • Page 24: General Specifications

    378 Neely Ferry Road Simpsonville, SC 29680, USA STAR EV®, a brand of JH Global Services, Inc. | 378 Neely Ferry Road, Simpsonville, SC 29680, USA | Ph: 888-878-9988 | Fx: 864-297-7010 | www.starev.com | © 2020 JH Global Services, Inc.
  • Page 25 Phone: (864) 297-8833 Toll Free: (888) 878-9988 www.starev.com STAR EV®, a brand of JH Global Services, Inc. | 378 Neely Ferry Road, Simpsonville, SC 29680, USA | Ph: 888-878-9988 | Fx: 864-297-7010 | www.starev.com | © 2020 JH Global Services, Inc.
  • Page 26 Phone: (864) 297-8833 Toll Free: (888) 878-9988 www.starev.com STAR EV®, a brand of JH Global Services, Inc. | 378 Neely Ferry Road, Simpsonville, SC 29680, USA | Ph: 888-878-9988 | Fx: 864-297-7010 | www.starev.com | © 2020 JH Global Services, Inc.

  • Page 27: Approximate Vehicle Dimensions

    General Specifications Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers APPROXIMATE VEHICLE DIMENSIONS Figure 1 CP 2 Vehicle Dimensions Figure 2 CP 2+2 Vehicle Dimensions page...
  • Page 28 General Specifications Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers Figure 3 CP 4 Vehicle Dimensions page Figure 4 CP 4+2 Vehicle Dimensions...
  • Page 29 General Specifications Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers Figure 5 CP 6 Vehicle Dimensions page Figure 4 CP 6+2 Vehicle Dimensions...

  • Page 30: Turning Diameter And Incline Information

    General Specifications Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers TURNING DIAMETER AND INCLINE INFORMATION Figure 3 Vehicle Incline Specifications and Turning Diameter (2 and 2+2) page...
  • Page 31 General Specifications Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers TURNING DIAMETER AND INCLINE INFORMATION Figure 3 Vehicle Incline Specifications and Turning Diameter (4 and 4+2) page...
  • Page 32 General Specifications Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers TURNING DIAMETER AND INCLINE INFORMATION Figure 3 Vehicle Incline Specifications and Turning Diameter (6 and 8) page...
  • Page 33 Notes page...

  • Page 34: Introduction

    Introduction Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers INTRODUCTION CONTROLS AND INDICATORS Electricity meter Forward and reverse switch Head light switch Emergency flash switch (if equipped) Key switch Turn signal switch Horn button (if equipped) Parking pedal...

  • Page 35: Features

    If an accessory requires voltage different than 48 volts a DC to DC converter must be used to change the voltage to the correct amount. A DC to DC converter is available for purchase from STAR EV Service Parts. Key Switch and Direction Selector To decrease the risk of component damage, stop the vehicle before you move the key switch or the direction selector.

  • Page 36: Power Meter (If Equipped)

    Introduction Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers Power Meter (if equipped) • The power meter is on the dashboard. • The power meter identifies the remaining battery power in the battery pack.

  • Page 37: Parking Brake

    As the accident occurs when parking on a ramp larger than the ramp spec and parking without stepping on the parking pedal to the third grid or without stepping on the parking pedal, STAR EV will not bear any responsibility! page...

  • Page 38: Front Seat

    Introduction Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers Front Seat The front seat (5) is for two people, one person on each side of the seat (Figure 5) Front Hip Restraint The front hip restraints (6) help people stay in position while the vehicle is in motion.

  • Page 39: Charger Receptacle

    Introduction Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers Figure 5 Rear Seating Charger Receptacle • Connect the charger cord to this charger receptacle (12) to charge the batteries (Figure 6). Weather Enclosure (if equipped) •...
  • Page 40 Operating Procedures Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers SERIAL NUMBER LOCATION The serial number and manufacture date code is on the plate of the vehicle in the glove box. Two chassis numbers are also located on the chassis frames.
  • Page 41 Operating Procedures Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers BEFORE INITIAL USE Read, understand and follow the safety label on the steering wheel. Make sure you understand how to safely operate the vehicle and its equipment.
  • Page 42 Operating Procedures Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers PORTABLE CHARGER INSTALLATION Risk of electric shock. Connect the charger power cord to an outlet that is cor- rectly installed and connected to an electrical ground according to all codes and regulations.
  • Page 43 Operating Procedures Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers Portable chargers has supplied with the vehicles. Before vehicle or charger operation, remove the charger from the vehicle, unless an on-board charger is installed.
  • Page 44 Operating Procedures Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers The charger DC cord has a polarized connector which fits into a receptacle on the vehicle. If the vehicle is charged with a charger different from the one supplied with the vehicle, refer to the instructions supplied with the charger used.
  • Page 45 Operating Procedures Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers HOW TO OPERATE THE VEHICLE Incorrect use of the vehicle or lack of maintenance can cause damage or decreased performance. Read the following warnings before you operate the vehicle.
  • Page 46 Operating Procedures Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers DIRECTION SELECTOR OPERATION To prevent loss of control, do not move the direction selector to a different position while the vehicle is in motion. If you move the selector, the speed will immediately decrease and a warning device activates.
  • Page 47 Operating Procedures Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers REAR SEAT AND CARGO PLATFORM OPERATION (if equipped) To prevent damage to the rear seat, move any accessories that are installed on the hand rail, when you fold the seat.
  • Page 48 Operating Procedures Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers REGENERATIVE BRAKING To prevent the possibility of loss of control that could cause severe injury or death, use brake to reduce speed. This vehicle is equipped with a regenerative motor control system.
  • Page 49 Operating Procedures Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers HIGH PEDAL DISABLE FEATURE High pedal disable prevents acceleration if the key is turned on while the accelerator or brake are pressed. To reset the controller after a High Pedal Disable, place both feet on the floor, turn the key to the OFF position.

  • Page 50: Roof And Windshield (If Equipped)

    Operating Procedures Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers LABELS AND PICTOGRAMS Vehicles may be labeled with pictograms as a method of conveying information or warnings. The Vehicle Label Identification Section of this manual explains the labels that are used on this vehicle.

  • Page 51: Maintenance

    Maintenance Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers MAINTENANCE VEHICLE CLEANING AND CARE To decrease the risk of severe injury read and understand all instructions supplied by the manufacturer of the pressure washer before use. When you clean the outside of the vehicle with a pressure washer, do not use more than 700-psi pressure.

  • Page 52: Lifting The Vehicle

    Operating Procedures Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers LIFTING THE VEHICLE You must lift the front, the rear or the entire vehicle for some service and maintenance operations.
  • Page 53 Maintenance Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers Lift the vehicle and place two jack stands under the frame where the instrument panel support is attached to the frame. Lower the jack and test the stability of the vehicle on the jack stands.

  • Page 54: Wheels And Tires

    Maintenance Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers How to lift the front of the vehicle only: Install wheel chocks in front and behind each front wheel. Place the jack under the center front just behind the bumper.

  • Page 55: Tire Repair

    Maintenance Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers TIRE REPAIR Tool List Quantity Tool List Quantity Lug Wrench ⁄ ” Impact Socket ⁄ ” Impact Wrench Torque Wrench ft. lbs Use caution when you inflate the tires.

  • Page 56: Wheel Installation

    Maintenance Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers WHEEL INSTALLATION To decrease the risk of component damage, do not tighten lug nuts to more than 85 ft. lbs. (115 Nm) torque. Valve Stem Cap Always follow the cross-sequence pattern when you install the lug nuts to make...

  • Page 57: Light Bulb Replacement

    Maintenance Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers LIGHT BULB REPLACEMENT To decrease the risk of premature bulb failure, do not allow your fingers to contact new bulbs.

  • Page 58: Transporting Vehicle

    Features Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers TRANSPORTING VEHICLE (TOWING) • Use extra caution when towing a vehicle. • DO NOT ride on the vehicle being towed. •...

  • Page 59: Service And Maintenance

    Maintenance Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers SERVICE AND MAINTENANCE • Read all notices, cautions and warnings in this manual before you do any type of service operations. •...

  • Page 60: Routine Maintenance

    To access the power train for normal maintenance, lift or remove the seat and remove the rear access panel. For major repairs, please contact your STAR EV Dealer. Some service procedures make it necessary to lift the vehicle. Refer to LIFTING THE VEHICLE for correct lift procedure and safety information.

  • Page 61: Brakes

    Maintenance Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers BRAKES • Always inspect the pedal travel before you operate a vehicle to confirm some brake function is exist. •...

  • Page 62: Hardware

    Maintenance Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers HARDWARE Normally, three classes of standard hardware and three classes of metric hard- ware are used in the vehicle. (Battery is standard other metric) Grade 5 hard- ware is identified by the three marks on the hexagonal head;...

  • Page 63: Battery Charging And Maintenance

    Maintenance Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers BATTERY CHARGING AND MAINTENANCE (SAFETY) Always obey the following warnings when working on or near batteries. To prevent the risk of battery explosion, keep all flammable materials, open flames or sparks away from the batteries.

  • Page 64: Battery Maintenance

    Maintenance Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers BATTERY A battery is described as two dissimilar metals immersed in an acid. If the acid is absent or if the metals are not dissimilar, a battery has not been created. The batteries in this vehicle are lead acid.

  • Page 65: Electrolyte Level And Water

    Maintenance Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers ELECTROLYTE LEVEL AND WATER • The correct level of the electrolyte is ⁄ ” above the plates in each cell. (13 mm) •...
  • Page 66 Maintenance Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers DO NOT overfill batteries. The charge cycle will expel electrolyte and cause component damage. A battery being charged will gas with most gassing occurring at the end of the charging cycle.
  • Page 67 Maintenance Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers Water Purity Table Impurity Parts Per Million Color Clear Suspended Trace Total Solids Calcium and Magnesium Oxides Iron Ammonia Organic and Volatile Matter Nitrites Nitrates...

  • Page 68: Battery Cleaning

    Maintenance Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers BATTERY CLEANING • To prevent battery damage, make sure you correctly install all battery caps. • To decrease the risk of damage to vehicle or floor, neutralize acid before you spray the battery with water.
  • Page 69 Maintenance Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers • Be careful when you use aerosol containers near the battery terminals. Use a container with insulation to prevent an explosion. •...
  • Page 70 Maintenance Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers The batteries are heavy. Use correct lifting methods when you move them. Always lift the battery with a commercially available battery lifting device. Be careful not to tilt batteries when you remove or installing them;...

  • Page 71: Prolonged Storage

    Maintenance Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers PROLONGED STORAGE Disconnect the battery charger, controller and other electronic devices for ex- tended storage. All connected electronic components cause the dis-charge of batteries.

  • Page 72: Battery Charging

    Maintenance Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers In winter conditions, the battery must be completely charged to prevent the risk of freezing. A completely charged battery will not freeze in temperatures above - 75°...

  • Page 73: Ac Voltage

    Maintenance Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers • The charger connector must be completely inserted in the vehicle receptacle. • The charger connector and cord set must be protected from damage. The charger connector and cord set must be used in an area where it is not possible for personnel to run over or trip over the cord set.

  • Page 74: Hydrometer

    Maintenance Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers HYDROMETER A hydrometer is used to test the state of charge of a battery cell. This is performed by measuring the density of the electrolyte, which is accomplished by measuring the specific gravity of the electrolyte.

  • Page 75: Using A Hydrometer

    Maintenance Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers USING A HYDROMETER BATTERY CHARGER MAINTENANCE Connect the charger plug into the vehicle receptacle and wait for the relay to activate.

  • Page 76: Periodic Service Schedule

    Periodic Service Schedule Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers PERIODIC SERVICE SCHEDULE General Maintenance Project Advanced Maintenance Project Details of Regular Maintenance Users Maintenance Project weekly monthly Quartely 6 months...
  • Page 77 Periodic Service Schedule Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers PERIODIC SERVICE SCHEDULE General Maintenance Project Advanced Maintenance Project Details of Regular Maintenance Users Maintenance Project weekly monthly Quartely 6 months...
  • Page 78 Periodic Service Schedule Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers ANALYSIS AND ELIMINATION OF COMMON FAULTS Fault phenomenon Possible causes Solution Operator error See Operational Guidelines for Correct Operation Terminal oxidation (corrosion) Turn off the power supply, remove the...
  • Page 79 Periodic Service Schedule Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers ANALYSIS AND ELIMINATION OF COMMON FAULTS Fault phenomenon Possible causes Solution Lack of motivation and Batteries are under-charged Charge slow reaction Damage of transmission gear...

  • Page 80: Declaration Of Conformity

    Appendix A APPENDIX A DECLARATION OF CONFORMITY Read the following warnings before operating vehicle: When you leave the vehicle, turn the key to the OFF position and remove the key from the vehicle. Drive the vehicle only as fast as terrain and conditions allow. Consider the terrain and traffic conditions.
  • Page 81 Appendix A • Remove all jewelry before you service the vehicle. • Do not allow loose clothing or hair to contact the moving parts. • Do not touch hot objects. • The drive wheels must be lifted and sup- ported on jack stands before you do any service to the power train when the motor is in operation.
  • Page 82 Star EV Star Electric Vehicles 378 Neely Ferry Road | Simpsonville, SC 29680 | USA www.starev.com All contents © 2020 Star Electric Vehicles...

This manual is also suitable for:

Capella cp-2+2Capella cp-4Capella cp-4+2Capella cp-6Capella cp-6+2

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