Star CAPELLA CP-2, Owner'S Manual

Page 1: ...CAPELLA OW N ER S M A N UA L...

Page 2: ...page 2 Notes...

Page 3: ...page 3 Notes...

Page 4: ...or 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 vehi...

Page 5: ...s may be damaged Modification of vehicles is not allowed Modification may affect vehicle performance life or even safety and may violate regulations Vehicle damage caused by modification will not be c...

Page 6: ...teries while the charger is connected to an active electrical supply The batteries must be checked and charged again as required or at a minimum of 30 day intervals Check and keep correct fluid level...

Page 7: ...irection Selector 35 37 46 49 57 60 63 70 Power Meter if equipped 36 Headlight switch if equipped 36 Accelerator and Brake Pedals 36 46 Turn Signal Switch if equipped 34 36 46 Horn button if equipped...

Page 8: ...39 60 Rear Seat and Cargo Platform Operation 38 47 Regenerative Braking 48 Pedal Up Braking 48 High Pedal Disable Feature 49 STARTING AND DRIVING 49 Starting Vehicle on a Hill 49 COASTING 49 LABELS A...

Page 9: ...70 BATTERY CHARGING AND MAINTENANCE 63 72 Safety 63 Battery Maintenance 63 64 At Each Charging Cycle 64 Monthly 64 76 77 Electrolyte Level and Water 65 Battery Cleaning 68 Prolonged Storage 6 71 Batte...

Page 10: ...page 10 Notes...

Page 11: ...e 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 specified speed you can...

Page 12: ...NING indicates a dangerous condition that can cause death or serious injury A DANGER indicates a dangerous condition that will cause death or serious injury Never modify the vehicle in any way that wi...

Page 13: ...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 pos...

Page 14: ...erous 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 can cause high amperage or...

Page 15: ...e not familiar with Be careful when you drive on loose terrain Be careful when you operate the vehicle around people Read all of SAFETY and this section before attempting any procedure Pay particular...

Page 16: ...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 flame or sparks Know that a vehicle in need...

Page 17: ...page 17 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 18: ...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 19: ...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 20: ...page 20 Labels and Pictograms Label is above or below Charger port...

Page 21: ...page 21 Safety Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 22: ...page 22 Safety Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 23: ...page 23 Notes...

Page 24: ...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 Aluminum wheel Digital Display Emer...

Page 25: ...Cycle Speed Controller Curtis 350A AC Controller Curtis 350A AC Controller Curtis 450A AC Controller Drive Train Motor Shaft Direct Drive Motor Shaft Direct Drive Motor Shaft Direct Drive PERFORMANCE...

Page 26: ...cle Speed Controller Curtis 450A AC Controller Curtis 450A AC Controller Curtis 450A AC Controller Drive Train Motor Shaft Direct Drive Motor Shaft Direct Drive Motor Shaft Direct Drive PERFORMANCE Pa...

Page 27: ...PPROXIMATE VEHICLE DIMENSIONS Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Figure 1 CP 2 Vehicle Dimensions Fig...

Page 28: ...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 Figure 4 CP 4 2 Ve...

Page 29: ...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 Figure 4 CP 6 2 Ve...

Page 30: ...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 Specifica...

Page 31: ...Vehicle Incline Specifications and Turning Diameter 4 and 4 2 Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers TURN...

Page 32: ...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 Specific...

Page 33: ...page 33 Notes...

Page 34: ...ns Warnings and Dangers INTRODUCTION CONTROLS AND INDICATORS 1 Electricity meter 2 Forward and reverse switch 3 Head light switch 4 Emergency flash switch if equipped 5 Key switch 6 Turn signal switch...

Page 35: ...re to the main negative battery pack terminal as shown Figure 2 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...

Page 36: ...n before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Accidental movement of the accelerator pedal can cause the vehicle to move suddenly and cause severe...

Page 37: ...nd Dangers Before attempting to pull or start a vehicle please ensure that the parking pedal is loose otherwise the brake system control system and motor will be damage The parking pedal has three gea...

Page 38: ...handle while the vehicle is in motion Do not allow passengers to ride on the cargo platform A sudden move or stop can cause severe injury or death to passengers on the cargo platform The vehicle has a...

Page 39: ...es Figure 6 Weather Enclosure if equipped A weather enclosure provides protection from strong weather conditions Rear View Mirror if equipped The rear view mirror is adjustable for use during the day...

Page 40: ...ocated on the chassis frames Design changes occur on a continuous basis To get the correct components for the vehicle the manufacture date code serial number or vehicle model must be supplied Figure 1...

Page 41: ...4 concentra tion of hydrogen gas is explosive To prevent battery explosion keep all flammable materials open flame or sparks away from the batteries Explosive hydrogen gas is created during the charg...

Page 42: ...the charger Do not operate the charger if the AC cord is damaged Make sure qualified personnel does all repair work to the charger Do not allow children to use the charger To prevent over heating tha...

Page 43: ...er on a horizontal surface with the fins vertical Put the charger on a platform above the ground to allow air to flow around and below the charger If the charger is operate in an outdoor location rain...

Page 44: ...ents To decrease the possibility of electrical shock or electrocution make sure that the charger plug is not damage and is correctly connected to a grounded outlet The power AC cord has a plug with a...

Page 45: ...he key to the OFF position when the vehicle is parked When you leave the vehicle turn the key to the OFF position and remove from the switch to prevent accidental operation To prevent accidental movem...

Page 46: ...uzzer activates when the direction selector is moved to the REV reverse position The position between FWD forward and REV reverse is the neutral position When you leave the vehicle turn the key to the...

Page 47: ...inches 10 cm above the platform Do not put more than the specified capacity on the platform Increased loads can change drive properties of the vehicle Do not allow passengers to ride on the cargo pla...

Page 48: ...the regenerative braking system is activated by this sequence of events the motor generates power that is returned to the batteries When the vehicle speed is reduced below the maximum by using the br...

Page 49: ...cle is ready to run in reverse Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers HIGH PEDAL DISABLE FEATURE STARTING...

Page 50: ...oes not provide protection from roll over or falling objects The windshield does not provide protection from tree limbs or flying objects The roof and windshield provide some protection from the eleme...

Page 51: ...ser practice respect for all wildlife and their habitat Respect private property and comply with all local laws and regulations governing the use of light duty utility vehicles Always be respectful of...

Page 52: ...and behind the wheels that remain on the ground Do not allow any person in or on the vehicle being lifted When you lift the vehicle put the jacks and jack stands at the areas indicated only Tool List...

Page 53: ...port is attached to the frame 7 Lower the jack and test the stability of the vehicle on the jack stands How to lift the rear of the vehicle only 1 Install wheel chocks in front and behind each rear wh...

Page 54: ...1 Lift the vehicle enough to remove the jack stands 2 Carefully lower the vehicle to the ground with the jack WHEELS AND TIRES Please follow the inflation spec printed on the side of the tire To decr...

Page 55: ...k of tires cutting into a soft turf For hard surfaces or pavement tire inflation pressure must be in the higher allowed range but not more than recommended on the tire sidewall All four tires must hav...

Page 56: ...s sequence pattern when you install the lug nuts to make sure the wheel is evenly seated against the Cross Sequence hub With the valve stem to the outside of the wheel install the wheel on the hub wit...

Page 57: ...th the wick at 9 by wire Replace the wick and connect the wiring harness to 9 position Connect wiring harness 3 to 8 Change the whole headlight Disconnect wiring harness 3 and 8 Figure 1 Use cross scr...

Page 58: ...ing multiple vehicles Towing the vehicle above the recommended speed may result in severe injury and or damage to the vehicle and other property Tow bars are not intended for road use Never use ropes...

Page 59: ...e vehicle Be careful when you do work around batteries use solvents or compressed air To decrease the risk of electrical arc which can cause a battery explosion disable all electrical loads from the b...

Page 60: ...is set to the RUN position After you connect a battery or any other wires wait a minimum of 30 seconds before you move the key switch to the ON position ROUTINE MAINTENANCE To increase the life of a v...

Page 61: ...useful as a method of identifying subtle loss of performance over time REAR AXLE The only maintenance necessary for the first five years is the inspection of the rear axle for lubricant leakage Unless...

Page 62: ...in the vehicle Battery is standard other metric Grade 5 hard ware is identified by the three marks on the hexagonal head grade 8 hardware is identified by six marks on the head grade 2 hardware is not...

Page 63: ...t the batteries during removal or installation An electrolyte spill can cause burns and damage The electrolyte in a storage battery is an acid solution which can cause burns to the skin and eyes Treat...

Page 64: ...older battery can perform adequately except that its capacity is decreased Capacity describes the time that a battery can continue to supply its design amperes from a full charge A battery has a maxi...

Page 65: ...f the electrolyte is 1 2 13 mm above the plates in each cell This level will leave approximately 1 4 3 8 6 10 mm of space between the electrolyte and the vent tube The electrolyte level is important b...

Page 66: ...as will push it out the vent tube and battery cap The water will dry but the sulphuric acid will stay and damage the vehicle components and the storage facility floor Sulphuric acid loss will weaken t...

Page 67: ...e Matter 50 Nitrites 5 Nitrates 10 Chloride 5 Water Purity Table The electrolyte in a battery is an acid solution which can cause severe burns to the skin and eyes Clean all electrolyte spills to the...

Page 68: ...ose moves the acid from the top of the batteries to another area of the vehicle or storage facility where it can cause damage After spraying the batteries a conductive residue remains on the batteries...

Page 69: ...rminals Use a container with insulation to prevent an explosion Clean one time a month or more often in harsh conditions After the batteries are clean and dry apply a commercially available protectant...

Page 70: ...at a time then remove the three rear batteries 8 9 and 10 to the front of the vehicle just enough to clear the rear body and lift up and out of the vehicle one after another 7 Check the area around t...

Page 71: ...edure Pay particular attention to Notices Cautions Warnings and Dangers PROLONGED STORAGE Figure 4 Battery Connections Disconnect the battery charger controller and other electronic devices for ex ten...

Page 72: ...to prevent self discharge The batteries must be tested or charged again at 0 day minimum intervals BATTERY CHARGING The battery charger is designed to completely charge the battery set If the batteri...

Page 73: ...ide of the manufacturers specifi cation must be identified to replace it within the terms of the manufactur er s warranty Different manufacturers have different requirements Refer the battery manufact...

Page 74: ...a liquid that is compared to a base line The baseline is water which is assigned a base number of 1 0 The concentration of sulfuric acid to water in a NEW golf car battery is 1 280 times the weight of...

Page 75: ...ention 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 Move the plug bac...

Page 76: ...ck the tightness of each ball end of steering straightening rod Inspection of spline coupling fixed nuts for steering gear Check the tightness of steering mechanism and bracket Check and adjust front...

Page 77: ...enance Project weekly 20H monthly 80 H Quartely 250 H 6 months 500 H annually 1000H Check the bearing of rear axle Check and replace transmission gear oil Check the work of main reducer and bearing or...

Page 78: ...an 75 degrees Celsius and shutdown protection Reduce vehicle load and let the control ler cool down When a vehicle is running release the acceleration pedal and the vehicle will not slow down Accelera...

Page 79: ...n gear Replace Failure of Speed Control System Commissioning and maintenance Damage to wheel bearings or washers Replace Overfilling of oil Appropriate amount Wear of transmission gears or bearings Re...

Page 80: ...ress 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 s...

Page 81: ...service the vehicle always wear eye protection Be careful when you do work around batteries or you use solvents or compressed air Use wrenches with insulation to decrease the risk of a short circuit...

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