Star CAPELLA User manual

OWNERS MANUAL

TABLE OF CONTENTS TABLE OF CONTENTS
2 3
CONTENTS
Forward 5
Starting Model Year 2018 5
SAFETY
General 6
Notices, Cautions, Warnings And Dangers 7
General Operation or Vehicle 8-10
Maintenance 10-11
Labels and Pictograms 12-15
SPECIFICATIONS
 GeneralSpecications    16-18
Vehicle Dimensions 19-22
Turning Diameter and Incline 22-23
INTRODUCTION
Introduction to Controls and Indicators 24
Features, Key Switch and Direction Selector 25
Power Meter (if equipped) 26
Accelerator and Brake Pedal 26
Parking Pedal 27
Front and Rear Seating Indicators 28
Front Hip Restraint 28
Cup Holder 28
Steering Wheel 28
Rear Seat And Cargo Platform 28
Rear Hand Rails 29
Charger Receptacle 29
Rear View Mirror (if equipped) 29
Battery Compartment 29
Serial Number Location 30
Before Initial Use and Service Chart 31

TABLE OF CONTENTS TABLE OF CONTENTS
2 3
GENERAL OPERATION OF VEHICLE
On-Board Chargers 32-33
How To Operate The Vehicle 34
Direction Selector Operation 35
Accelerator and Brake Pad Operation 35
Horn (if equipped) 35
Regenerative Braking 36
Pedal-Up Braking 36
High Pedal Disable Feature 36
Starting and Driving 37
Starting Vehicle On Hill 37
Coasting 37
Roof and Windshield 38
MAINTENANCE
Vehicle Cleaning And Care 39
Environmental Concerns 39
Battery Disposal 39
Lifting The Vehicle 40
How To Lift The Rear Of The Vehicle Only 41
How To Lift The Front Of The Vehicle Only 41
Lowering The Vehicle 41
Wheels and Tires 42
Tire Repair 43
Wheel Installation 44
Light Bulb Replacement 45
Headlight 45
Tail Light and Brake Light 46
Transporting Vehicle (Towing) 47
Service and Maintenance 48
Routine Maintenance 49
Tire Inspection 49
Brakes 50
Rear Axle 50
Checking the Lubricant Level 50
Hardware 51
Lead Acid Battery Charging and Maintenance 52
Lead Acid Battery and Applications 53

4 5
TABLE OF CONTENTS
Charging Cycle 53
Monthly Inspection 54
Electrolyte Level and Water 54
Over Filling Batteries 55
Water Purity Table 56
Battery Cleaning and Preparing Acid Solution 57-59
Battery Removal 60
Prolonged Storage and Battery Charging 60
Battery Charging 61
AC Voltage 62
Fault Diagnosis 62
Hydrometer 63
Using the Hydrometer 64
STAR Lithium Battery Line 65
Powering Your Battery Up 65
Lithium Maintenance 66
Operating the Lithium Battery 66
Lithium Battery Storage 66
Lithium Battery Winter Storage 67
Lithium Battery Warranty 67
Extreme Temperature Usage 68
Battery Prolonged Storage (Lead Acid/Lithium) 68
STAR SMART Lithium App 68
Lithium Battery Indicators 69
Periodic Service Schedule 70-71
Analysis and Elimination of Common Faults 72-73
APPENDIX A
Declaration of Conformity 74-75

4 5
TABLE OF CONTENTS
FORWARD
Dear STAR EV®Product Owner,
Thank you for purchasing this vehicle. Before you drive the vehicle, read this
Owner’s Guide. This guide contains maintenance and operation information.
The illustrations can show items that are optional for your vehicle.
You can do most of the service procedures in this guide with common,
automotive hand tools. If necessary, contact your service representative for
information about how to service the vehicle as shown in the 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:
VIN or Serial Number:
OWNER’S GUIDE ELECTRIC POWERED VEHICLES -
STARTING MODEL YEAR 2018
• Theelectricvehiclemustbedrivenbyqualiedandresponsibledrivers
• Accelerator pedal and brake pedal should not be applied at the same time,
otherwise it could damage the control system and motor.
• When the vehicle starts, the parking brake must be released. Otherwise,
permanent damage may be caused to the braking system and other parts.
• Modicationofvehiclesisnotallowed.Modicationmayaffectvehicle
performance, life, or even safety and may violate regulations. Vehicle
damagecausedbymodicationwillnotbecoveredbyfactorywarranty.
• Unreasonable installation of electrical equipment on the vehicle, such as
alarm devices, car phones, etc, may interfere with the vehicle’s control
system and affect vehicle performance. When installing such equipment,
you should consult our company.
• Due to product improvements, the contents of this manual may be
different than what you have. Contact dealer for updated information.
• Surpassing vehicle weight limits and overloading is strictly prohibited.

SAFETY SAFETY
6 7
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
STAR EV®Dealer. Read and understand all labels on the vehicle. Always replace
any damaged or missing labels.
Steephillsallowthevehicletomoveatfasterthannormalspeedsonaat
surface. To prevent the loss of vehicle control and possible injury, speeds must
be controlled to the maximum level ground speed indicated in the
GENERAL SPECIFICATIONS section. Apply the brake to control the speed.
Ifyouoperatethevehicleabovethemaximumspeciedspeed,youcandamage
the drive train components. The damage caused by speeds more than the
maximumspeciedcancausealossofvehiclecontrol,isabusive,andwillnot
be covered under the warranty.
Under age drivers should not operate the vehicle without adult supervision.
Use caution when you tow the vehicle. Towing the vehicle above the
recommended speed can cause personal injury or damage to the vehicle
and other property.
If the vehicle is used in a commercial environment, signs must be in position
to inform of possible conditions that could be dangerous. Examples are
shown below.

SAFETY SAFETY
6 7
Read all of SAFETY and this section before attempting any procedure.
Pay particular attention to Notices, Cautions, Warnings and Dangers
NOTICES, CAUTIONS, WARNINGS AND DANGERS
Read the NOTICES, CAUTIONS, WARNINGS and DANGERS. The person who
services the vehicle needs the mechanical skill and experience to see possible
hazardous conditions. Incorrect services or repairs can cause damage to the
vehicle or make the vehicle dangerous to operate.
NOTICE indicates and describes information not related to personal injury.
CAUTION indicates a dangerous condition that can cause injury that is not life threatening.
WARNING indicates a dangerous condition that can cause death or serious injury.
DANGER indicates a dangerous condition that will cause death or serious injury
Never modify the vehicle in any way that will alter the weight
distribution of the vehicle, decrease its stability, increase the speed
or extend the stopping distance beyond the factory specication
Such modications can result in serious personal injury or death.

GENERAL OPERATION OF VEHICLE GENERAL OPERATION OF VEHICLE
8 9
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, set the parking brake.
• Drive the vehicle only as fast as terrain and conditions allow.
Considertheterrainandtrafcconditions.Considerenvironmental
conditions that change the terrain and your ability to control the vehicle.
• DO NOT drive fast downhill. Sudden stops or change of direction can
cause a loss of control.
• Use the brake to control the speed of the vehicle when you drive down
a slope.
• When possible, stay in approved areas. DO NOT drive on steep slopes.
• Always keep feet, legs, hands and arms inside vehicle.
• DO NOT drive on rough terrain.
• Before you drive in the reverse direction, make sure the area behind the
vehicle is clear.
• Make sure the direction selector is in the correct position before you
press the accelerator pedal.
• Decrease speed before and during turns.
• Make sure you completely stop the vehicle before you move the
direction selector.
• See GENERAL SPECIFICATIONS for the vehicle load and seat capacity.

GENERAL OPERATION OF VEHICLE GENERAL OPERATION OF VEHICLE
8 9
Read all of SAFETY and this section before attempting any procedure.
Pay particular attention to Notices, Cautions, Warnings and Dangers
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.
A vehicle in need of repair does not function properly and can be dangerous.
(Discontinue use until repaired) Be careful when you service the vehicle.
Be aware of your safety and the safety of other people in the area.
Some components are heavy, spring loaded, corrosive, explosive, and can cause
electrical shock or get hot. Battery acid and hydrogen gas can cause injury.
DO NOT put your hands, face, feet or body in a location that can expose them
to injury if an unexpected situation occurs.
Always use the correct tools shown in the tool list and wear safety equipment.
Remove all jewelry before you service the vehicle.
Do not allow loose clothing or hair to contact the moving parts.
DO NOT TOUCH THE HOT OBJECTS.
( SUCH AS BRAKE PARTS OR THE CHARGER FINS )

GENERAL OPERATION OF VEHICLE / MAINTENANCE MAINTENANCE
10 11
Read all of SAFETY and this section before attempting any procedure.
Pay particular attentions 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 REMEMBER TO:
• Use the vehicle in a responsible manner and keep the vehicle in safe
condition for operation.
• Read and obey all warnings and operation instruction labels on the vehicle.
• Follow all safety rules in the area where the vehicle is operated.
• When there is a risk of lightning, leave the vehicle and look for a safe location
to wait until the lightning has stopped.
• Drive the vehicle only as fast as terrain and conditions allow.
• Apply the brake to control speed on steep grades.
• Keep enough distance between vehicles.
• Decrease speed in wet areas.
• Be careful when you make sharp turns, or turns you are not familiar with.
• Be careful when you drive on loose terrain.
GENERAL MAINTENANCE
• Replace damaged or missing warning, caution or information labels.
• Service the vehicle according to the periodic service schedule in
this manual.
• Makesurethatapprovedandqualiedpersonneldoallrepairs.
• Follow the manufacturer’s maintenance procedures.
• Use insulated tools within the battery area to prevent sparks or
battery explosion.
• Usespeciedreplacementparts.DO NOT use replacement parts
of less quality.

GENERAL OPERATION OF VEHICLE / MAINTENANCE MAINTENANCE
10 11
Read all of SAFETY and this section before attempting any procedure.
Pay particular attentions to Notices, Cautions, Warnings and Dangers
GENERAL MAINTENANCE (CONTINUED)
• Keep complete records of the maintenance history of the vehicle.
• Use recommended tools.
• Makesurethattoolsandproceduresnotspecied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. Lift the vehicle according to the
manufacturer instructions.
• Makesureyouservicethevehicleinanareaawayfromopename
or sparks.
• Test drive the vehicle after any repairs or maintenance in a safe area
thatisfreeofbothvehicularandpedestriantrafc.

LABELS AND PICTOGRAMS LABELS AND PICTOGRAMS
12 13
Read all of SAFETY and this section before attempting any procedure.
Pay particular attentions to Notices, Cautions, Warnings and Dangers

LABELS AND PICTOGRAMS LABELS AND PICTOGRAMS
12 13
Read all of SAFETY and this section before attempting any procedure.
Pay particular attentions to Notices, Cautions, Warnings and Dangers

LABELS AND PICTOGRAMS LABELS AND PICTOGRAMS
14 15
Read all of SAFETY and this section before attempting any procedure.
Pay particular attentions to Notices, Cautions, Warnings and Dangers
Label is above or below Charger port

LABELS AND PICTOGRAMS LABELS AND PICTOGRAMS
14 15
Read all of SAFETY and this section before attempting any procedure.
Pay particular attentions to Notices, Cautions, Warnings and Dangers

SPECIFICATIONS SPECIFICATIONS
16 17
VEHICLE STANDARD FEATURES
Four year limited warranty, two year
bumper -to-bumper warranty
(less wear items)
CP-2 and 2+2
Motor: 4 kW QDS™ AC Motor
Controller: 48V 350A Controller
CP-4, CP-4+2, CP-6, CP-6+2
Motor: SkW QDS™ AC Motor
Controller: 48V 450A Controller
Charger: 48Vl8A, on-board with
remote LED
Batteries: 6, 8volt or 8, 6 volt
deep cycle batteries
Drive Train: Direct Drive
Brakes: Rear wheel mechanical drum
brake (2, 2+2) 4 Wheel
hydraulic (4, 4+2, 6, 6+2)
QDS™ Drive System with over
temperature protection
Front independent suspension
10” DOT Radial Tire and Machined
Black Honeycomb Rim
Digital Display
Emergency Flashers
Turn Signals
High / Low Beams
LED Tail lights
Daytime Running Lights
VEHICLE OPTIONS AND UPGRADES
Low Speed Vehicle Package
Bluetooth speakers
Third brake light
USB port
Battery lling system
CAPELLA 2 CAPELLA 2+2
CAPELLA 4 CAPELLA 4+2
CAPELLA 6 CAPELLA 6+2
COLOR AND SEAT OPTIONS
arctic white with
tan seats
candy apple red
with black seats
coastal blue
with black seats
jet black with
tan seats
forest blue mist
with black seats

SPECIFICATIONS SPECIFICATIONS
16 17
Specications are subject to change without notication.
CAPELLA 2 CAPELLA 2+2 CAPELLA 4
DIMENSIONS
Overall Dimensions 95” L x 48.625” W x 74” H
(241 cm x 124 cm x 188 cm)
121” L x 48.625” W x 80.25” H
(307 cm x 124 cm x 204 cm)
124.75” L x 48.625” W x 76” H
(317 cm x 124 cm x 193 cm)
Wheel Base 65.7” (167 cm) 65.7” (167 cm) 95.3” (242 cm)
Front Wheel Base 36.7” (93 cm) 36.7” (93 cm) 36.7” (93 cm)
Rear Wheel Base 38.6” (98 cm) 38.6” (98 cm) 38.6” (98 cm)
Ground Clearance 4.8” (12 cm) 4.8” (12 cm) 4.8” (12 cm)
BODY & CHASSIS
Frame Welded structural steel,
powder coated
Welded structural steel,
powder coated
Welded structural steel,
powder coated
Body Material Injection molded plastic with
automotivepaintandnish
Injection molded plastic with
automotivepaintandnish
Injection molded plastic with
automotivepaintandnish
Roof Plastic, extended,
color-matched
Plastic, extended,
color-matched
Plastic, extended,
color-matched
POWER
Motor 48 Volt AC, 4kW w/thermistor 48 Volt AC, 4kW w/thermistor 48 Volt AC, 4kW w/thermistor
Batteries 6, 8 Volt deep cycle 6, 8 Volt deep cycle 6, 8 Volt deep cycle
Lithium Batteries 80AH, 105AH, 210AH 80AH, 105AH, 210AH 105AH, 210AH
Speed Controller 350A AC Controller 350A AC Controller 350A AC Controller
Drive Train Motor shaft direct drive Motor shaft direct drive Motor shaft direct drive
PERFORMANCE
Passengers 2 4 4
Curb Weight 1089 lbs (494 kg) 1244 lbs (564 kg) 1378 lbs (625 kg)
Load Capacity 800 lbs (362 kg) 800 lbs (362 kg) 1156 lbs (524 kg)
Turning Radius 10.17 ft (3.1 m) 10.17 ft (3.1 m) 16.4 ft (5 m)
Maximum Speed 19.5 mph (25 mph if LSV) 19.5 mph (25 mph if LSV) 19.5 mph (25 mph if LSV)
STEERING AND SUSPENSION
Tires and Rims
10” DOT radial tires and
machined black
honeycomb rims
10” DOT radial tires and
machined black
honeycomb rims
10” DOT radial tires and
machined black
honeycomb rims
Steering System Rack and pinion double
output, self-compensated
Rack and pinion double
output, self-compensated
Rack and pinion double
output, self-compensated
Front Suspension Double swing arm
independent coil over shock
Double swing arm
independent coil over shock
Double swing arm
independent coil over shock
Rear Suspension Longitudinal leaf spring +
shock absorption
Longitudinal leaf spring +
shock absorption
Longitudinal leaf spring +
shock absorption
Service Brake Mechanical braking Mechanical braking 4-wheel hydraulic brake
Parking Brake Mechanical foot parking Mechanical foot parking Mechanical hand operated

VEHICLE DIMENSIONS VEHICLE DIMENSIONS
18 19
Specications are subject to change without notication.
CAPELLA 4+2 CAPELLA 6 CAPELLA 6+2
DIMENSIONS
Overall Dimensions 150.75” L x 48.625” W x 77” H
(383 cm x 124 cm x 196 cm)
152” L X 47.6” W X 73.4” H
(386 cm x 121 cm x 186 cm
168”L x 47.6”W x 73.4”H
(426 cm x 121 cm x 186 cm)
Wheel Base 95.3” (242 cm) 124” (315 cm) 124” (315 cm)
Front Wheel Base 36.7” (93 cm) 36.7” (93 cm) 36.7” (93 cm)
Rear Wheel Base 38.6” (98 cm) 38.6” (98 cm) 38.6” (98 cm)
Ground Clearance 4.8” (12 cm) 4.8” (12 cm) 4.8” (12 cm)
BODY & CHASSIS
Frame Welded structural steel,
powder coated
Welded structural steel,
powder coated
Welded structural steel,
powder coated
Body Material Injection molded plastic with
automotivepaintandnish
Injection molded plastic with
automotivepaintandnish
Injection molded plastic with
automotivepaintandnish
Roof Plastic, extended,
color-matched
Plastic, extended,
color-matched
Plastic, extended,
color-matched
POWER
Motor 48 Volt AC, 5kW w/thermistor 48 Volt AC, 5kW w/thermistor 48 Volt AC, 5kW w/thermistor
Batteries 8, 6 Volt deep cycle 8, 6 Volt Deep Cycle 8, 6 Volt Deep Cycle
Lithium Batteries 160AH, 210AH 160AH, 210AH 160AH, 210AH
Speed Controller 450A AC Controller 450A AC Controller 450A AC Controller
Drive Train Motor shaft direct drive Motor Shaft Direct Drive Motor Shaft Direct Drive
PERFORMANCE
Passengers 6 6 8
Curb Weight 1422 lbs (645 kg) 1556 lbs (705 kg) 1556 lbs (705 kg)
Load Capacity 1156 lbs (524 kg) 1422 lbs (645 kg) 1422 lbs (645 kg)
Turning Radius 16.4 ft (5 m) 19.7 ft (6 m) 19.7 ft (6 m)
Maximum Speed 19.5 mph (25 mph if LSV) 19.5 mph (25 mph if LSV) 19.5 mph (25 mph if LSV)
STEERING AND SUSPENSION
Tires and Rims
10” DOT radial tires and
machined black honeycomb
rims honeycomb rims
10” DOT radial tires and
machined black honeycomb
rims honeycomb rims
10” DOT radial tires and
machined black honeycomb
rims honeycomb rims
Steering System Rack and pinion double
output, self-compensated
Rack and pinion double out-
put, self-compensated
Rack and pinion double out-
put, self-compensated
Front Suspension Double swing arm
independent coil over shock
Double swing arm
independent coil over shock
Double swing arm
independent coil over shock
Rear Suspension Longitudinal leaf spring +
shock absorption
Longitudinal leaf spring +
shock absorption
Longitudinal leaf spring +
shock absorption
Service Brake 4-wheel hydraulic brake 4-wheel hydraulic brake 4-wheel hydraulic brake
Parking Brake Mechanical hand operated Mechanical hand operated Mechanical hand operated

VEHICLE DIMENSIONS VEHICLE DIMENSIONS
18 19
Read all of SAFETY and this section before attempting any procedure.
Pay particular attention to Notices, Cautions, Warnings and Dangers
APPROXIMATE VEHICLE DIMENSIONS
Figure 2 CP 2+2 Vehicle Dimensions
Figure 1 CP 2 Vehicle Dimensions

VEHICLE DIMENSIONS VEHICLE DIMENSIONS
20 21
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
Figure 4 CP 4+2 Vehicle Dimensions