Ingersoll-Rand Club Care Cafe Express 2008 Owner's Manual

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2008 Cafe Express Vehicle Owner's

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Page 1 2008 Cafe Express Vehicle Owner’s Manual Gasoline...
Page 3 NOTICE Vehicle warranty information appears on the last pages of this manual. No other warranties, express or implied, are contained herein. Your authorized representative checked the vehicle before it was delivered to you and will provide you a copy of the completed vehicle warranty registration form. Club Car is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual.
Page 4 FOREWORD Thank you for choosing Club Car, the name most widely recognized as the industry leader in vehicle efficiency and long-lasting value. You have chosen the finest utility vehicle on the market. Please protect your investment and ensure that your Club Car vehicle(s) provides years of reliable, superior performance by reading and following the maintenance instructions in this manual.
Page 5: Table Of Contents
TABLE OF CONTENTS Safety Decal and Feature Identification ........................4 Practice Safety ..............................9 Proposition 65 – State of California ........................9 Safety Details ..............................10 General Warnings............................... 10 General Information ............................12 Model Identification............................. 13 Controls and Indicators ............................13 Pre-Operation and Daily Safety Checklist ......................
Page 6: Safety Decal And Feature Identification
Safety Decal and Feature Identification SAFETY DECAL AND FEATURE IDENTIFICATION The following pages contain safety decal and feature identification information. For detailed information on specific features, read the appropriate section in this manual. Page 4 2008 Cafe Express Vehicle Owner’s Manual...
Page 7 Safety Decal and Feature Identification CAFE EXPRESS CHASSIS Decal, Bed Loading Warning (on cargo bed or seat 101553901 Serial Number back) Decal, Crush Area Warning (behind seat, near 101609401 Accelerator Pedal cargo bed) 101825101 Decal, On/Off Key Switch (above key switch) Brake Pedal 102519201 Decal, Operating Instructions (on steering wheel)
Page 8 Safety Decal and Feature Identification CAFE EXPRESS CHASSIS Decal, Trailer Hitch Tongue Weight Notice (on Decal, Bed Latch Warning (on vehicle body, below 1011553 102459301 trailer/receiver hitch) bed latch) Decal, Gasoline Fuel Warning (at fuel fill or on Decal, Maintenance/Operate Warning (on 101547601 103205501 frame, near fuel tank)
Page 9 Safety Decal and Feature Identification CAFE EXPRESS REFRESHMENT CENTER Decal, Food Safety Warning (on each side of 1011962 Dry Snack Compartment refreshment unit) Decal, Bed Loading Warning (on cargo bed or seat 101553901 Consumable Ice Compartments back) Decal, Beverage Unit Rollover Warning (under 102056401 Trash Compartment instrument panel)
Page 10 Safety Decal and Feature Identification CAFE EXPRESS REFRESHMENT CENTER Decal, Beverage Unit Rollover Warning (on each 101940101 102278901 Decal, Vehicle Loading (under instrument panel) side of refreshment unit) 102175901 Decal, Consumable Ice Page 8 2008 Cafe Express Vehicle Owner’s Manual...
Page 11: Practice Safety
Practice Safety PRACTICE SAFETY Figure 1 Practice Safety Safety signs like you see above may at first seem shocking, but their impact is mild compared with the reality of severe personal injury. Your safety and satisfaction are of the utmost importance to us. That is why before operating the vehicle, we urge you to review the information in this manual.
Page 12: Safety Details
Safety Details SAFETY DETAILS WARNING • This manual should be read completely before attempting to drive or service the vehicle. The safety video provided with the Cafe Express vehicle should also be viewed by all operators of the vehicle. Failure to heed the warnings or follow the instructions in this manual and the safety video could result in severe personal injury or death.
Page 13 General Warnings DANGER • The vehicle will not provide protection from lightning, flying objects, or other storm-related hazards. If caught in a storm while driving a Club Car vehicle, exit the vehicle and seek shelter in accordance with applicable safety guidelines for your location. WARNING •...
Page 14: General Information
General Information (Viewed from passenger side of vehicle) 1. Remove negative battery cable. 2. Remove positive battery cable. Connect battery cables in reverse order. Figure 2 Gasoline Vehicle GENERAL INFORMATION Throughout this manual, important vehicle features are highlighted. We urge the owner/operator to read and understand this manual, and to pay special attention to the features specific to their vehicle.
Page 15: Model Identification
Model Identification MODEL IDENTIFICATION The serial number of the vehicle is printed on a bar code decal (1) mounted on the frame directly above the accelerator pedal (Example: EG0601-123456) (Figure 3). There is also a second serial number decal mounted on the front body frame behind the center dash panel.
Page 16 Controls and Indicators NOTE: The key can be removed only when the key switch is in the OFF position. FORWARD/REVERSE CONTROL Gasoline Vehicles The Forward/Reverse handle (2) is located on the right-hand side of the instrument panel (Figure 4). The handle has three distinct positions: F (FORWARD), N (NEUTRAL), and R (REVERSE).
Page 17 Controls and Indicators CAUTION • Failure to add oil immediately when the low oil warning light stays on may result in permanent engine damage. FUEL GAUGE/HOUR METER The gasoline vehicle is equipped with a fuel gauge/hour meter (5), located on the instrument panel (Figure 4). The fuel gauge allows the operator to monitor the fuel level in the vehicle.
Page 18 Controls and Indicators PARK BRAKE PEDAL The park brake pedal is the small raised portion in the upper left corner of the brake pedal. It has the word PARK molded into it and the words PARK BRAKE marked on top of it (Figure 5). To set the park brake, press the brake pedal firmly and tilt the park brake portion of the pedal forward with your foot (Figure 7).
Page 19 Controls and Indicators • When the switch is in the MAINTENANCE position, it will allow the technician to run the engine in the NEUTRAL position to perform certain maintenance and/or repair functions. With the switch in this position, the vehicle will not operate if the Forward/Reverse handle is placed in either the FORWARD or REVERSE position.
Page 20: Pre-Operation And Daily Safety Checklist
Pre-Operation and Daily Safety Checklist PRE-OPERATION AND DAILY SAFETY CHECKLIST Each Club Car vehicle has been thoroughly inspected and adjusted at the factory; however, upon receiving your new vehicle(s), you should become familiar with its controls, indicators, and operation. Carefully inspect each vehicle to ensure that it is in proper working condition before accepting delivery.
Page 21: Vehicle Operation
Vehicle Operation • Brakes: Be sure the brakes function properly. When the brake pedal is fully pressed under moderate pressure, it should not go more than halfway to the floor, and the vehicle should come to a smooth, straight stop. If the brake pedal goes more than halfway to the floor, or if the vehicle swerves or fails to stop, have the brake system checked and adjusted as required.
Page 22 Vehicle Operation WARNING • All Cafe Express vehicles must be equipped with 18 x 8.50 x 8 6-ply rated tires on all four wheels. Never install oversized tires on the vehicle. Oversized tires can increase the vehicle’s maximum travel speed. Oversized tires can also raise the vehicle’s center of gravity, reducing the vehicle stability. •...
Page 23: Driving Instructions
Driving Instructions DRIVING INSTRUCTIONS WARNING • Only licensed drivers should be allowed to drive the vehicle. • Before allowing anyone to drive the vehicle, make sure the driver is familiar with all controls and operating procedures. • No more than two people should be on the vehicle at one time. •...
Page 24 Driving Instructions Make sure everyone is seated and holding onto hand holds or handrails. Driver should have both hands on the steering wheel. Make sure wheels are turned in desired direction and that nothing is obstructing vehicle’s path. Start the vehicle: 4.1.
Page 25: Bed Latch
Bed Latch BED LATCH CAUTION • The canopy frame must be disconnected from the top of the windshield frame before raising the bed. Failure to do so will result in vehicle or canopy damage. The vehicle is equipped with a bed latch on the driver side of the vehicle (Figure 10). To lift the bed, remove canopy pins, then pull the latch handle toward the rear of the vehicle and lift the bed.
Page 26: Loading And Unloading
Loading and Unloading DANGER • Use caution when working under bed. Be sure prop rod is secure. Otherwise the bed will fall, resulting in severe personal injury or death. WARNING • Do not disengage prop rod until all persons are clear of refreshment center bed area. •...
Page 27: Refreshment Center
Refreshment Center WARNING • An unevenly distributed load can cause vehicle instability. See the following chart for vehicle capacities. Cafe Express Maximum payload capacity 425 lb. (refreshment center load) (193 kg) 825 lb. Maximum vehicle capacity (refreshment center load, plus driver and passenger) (374 kg) Maximum payload capacity must be reduced accordingly when any option or accessory is installed on the vehicle.
Page 28: Towing With The Vehicle
Towing with the Vehicle TOWING WITH THE VEHICLE The Cafe Express vehicle must not be used to tow trailers or other vehicles. TRANSPORTING ON A TRAILER WARNING • Turn the fuel shut-off valve (1) (Figure 12) or (Figure 13) to the closed (OFF) position. •...
Page 29 Storage WARNING • Turn the key switch to the OFF position, remove the key, and leave the Forward/Reverse handle in the NEUTRAL position during storage. This is to prevent unintentionally starting the vehicle or a fire hazard. • Turn the fuel shut-off valve (1) (Figure 12) or (Figure 13) to the closed (OFF) position. •...
Page 30 Storage 3.3. Fill fuel tank to about 1 inch (2.5 cm) from top of fuel tank and, following manufacturer’s directions, add a commercially available fuel stabilizer (such as Sta-Bil ® 3.4. Disconnect fuel vent line from fuel tank vent nipple. 3.5.
Page 31: Maintenance
Maintenance MAINTENANCE See General Warnings on page 10. To ensure trouble-free vehicle performance, it is very important to follow an established preventive maintenance program. Regular and consistent vehicle maintenance can prevent vehicle downtime and expensive repairs that can result from neglect. Use the Pre-Operation and Daily Safety Checklist on page 18, the Performance Inspection on page 18, and the following Periodic Service Schedule and Periodic Lubrication Schedule to keep the vehicle in proper working condition.
Page 32: Periodic Service Schedule
Periodic Service Schedule PERIODIC SERVICE SCHEDULE See General Warnings on page 10. WARNING • Service, repairs, and adjustments must be made per instructions in the maintenance and service manual. NOTE: If the vehicle is constantly subjected to heavy use or severe operating conditions, these preventive maintenance procedures should be performed more often than recommended in the Periodic Service and Lubrication Schedules.
Page 33 Periodic Service Schedule PERIODIC SERVICE SCHEDULE – GASOLINE VEHICLES REGULAR INTERVAL SERVICE Section in the appropriate maintenance and service manual. Check brake cables for damage; replace as required. Check for leaks around gaskets, fill plugs, etc. Engine Inspect, clean and gap spark plug; replace if necessary.
Page 34: Periodic Lubrication Schedule
Periodic Lubrication Schedule PERIODIC LUBRICATION SCHEDULE PERIODIC LUBRICATION SCHEDULE – GASOLINE VEHICLES LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Brake pedal shaft bearings Dry Moly Lube (CCI P/N 1012151) Brake linkage and pivots Dry Moly Lube (CCI P/N 1012151) Semiannually by owner or trained technician (or every 50 Accelerator pivot rod supports and Dry Moly Lube (CCI P/N 1012151)
Page 35: Battery
Battery BATTERY See General Warnings on page 10. DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries.
Page 36: Engine Oil
Engine Oil WARNING • If battery wire terminals are damaged or corroded, replace or clean them as necessary. Failure to do so may cause them to overheat during operation and could result in a fire, property damage, or personal injury. Be sure battery clamp is properly tightened.
Page 37 Engine Oil Use a 14 mm socket or wrench to remove the drain plug, turning it counterclockwise, and allow the engine oil to drain into the pan. See following WARNING. WARNING • Do not attempt to change engine oil when the engine is hot or even warm. Engine oil can cause skin burns.
Page 38: Fueling Instructions
Fueling Instructions 13. Remove the dipstick and add engine oil into the dipstick port. Use a funnel or pour spout to direct the oil into the dipstick port. With filter change, the engine requires 38 ounces (1.12 liters) of oil per change. Refer to oil viscosity guidelines for selection of oil grade (Figure 20).
Page 39: Cleaning The Vehicle
Cleaning The Vehicle Remove the fuel cap located on the passenger-side panel and fill the fuel tank with fresh unleaded gasoline only. See preceding CAUTION and NOTE. Replace fuel cap on tank. Ensure cap is tightened securely. 1. Vent 2. Fuel Shut-off Valve 3. Vent Tube 4. Fuel Tank Figure 21 Fuel Tank –...
Page 40: Accessories
Accessories CAUTION • Do not use glass-cleaning products on the windshield. REFRESHMENT CENTER Interior Aluminum Surfaces The interior surfaces of the refreshment center should be cleaned and sanitized daily with an approved product before being used. Check with local Health Department for rules and regulations in your area. Exterior Aluminum Surfaces The exterior surfaces should be cleaned on a daily basis using a soap and water solution.
Page 41: Subsequent Owner Registration
Subsequent Owner Registration SUBSEQUENT OWNER REGISTRATION In the event a vehicle is bought as a used vehicle, we strongly urge the new owner to register the vehicle with Club Car. This will enable us to contact you if the need arises. Please send your name, address, and serial number(s) of the vehicle(s) to Club Car, Inc., P.O.
Page 42: Vehicle Specifications
Vehicle Specifications VEHICLE SPECIFICATIONS CAFE EXPRESS SPECIFICATIONS PEDAL-START GASOLINE POWER SOURCE Engine: 4 cycle, OHV, 351 cc, 11.5 maximum hp @ 3600 RPM (per SAE J 1940/1349), single cylinder, air cooled, with • pressure lubrication system Fuel system: Side draft carburetor with float bowl, fixed jets, fuel filter, and impulse fuel pump •...
Page 43 Vehicle Specifications CAFE EXPRESS SPECIFICATIONS PEDAL-START GASOLINE 38.5 in. Rear wheel tread (98 cm) 1076 lb. Weight: Standard gasoline vehicle with Cafe Express unit (dry fuel tank) (488 kg) Forward speed 14 mph (23 km/h) 20 ft.-8 in. (630 Curb clearance circle (diameter) 120 in.
Page 44: Cafe Express Refreshment Center Installation
Cafe Express Refreshment Center Installation CAFE EXPRESS REFRESHMENT CENTER INSTALLATION GENERAL INFORMATION Review the following instructions and safety precautions before beginning installation procedures. NOTE: Installation of the upper cabinets, canopy frame and canopy will require the aid of an assistant. Observe the following DANGER and WARNING statements and procedures.
Page 45 Cafe Express Refreshment Center Installation REFRESHMENT CENTER KIT Tools Required Figure 22 Tools Required Screwdriver, Flat-Blade Socket, 1/2-Inch, 3/8-Inch Drive Screwdriver, #2 Medium Phillips-Head Socket, 7/16-Inch, 1/4-Inch Drive Screwdriver, #3 Large Phillips-Head Extension, 3/8-Inch Drive, 4-Inch Long Nut Driver, 5/16-Inch Ratchet Wrench, 9/16-Inch Open-End Wrench, Torque (10-200 in-lb)
Page 46 Cafe Express Refreshment Center Installation Parts in Kit 18 - 23 Figure 23 Windshield and Windshield Frame Installation Parts 1010237 Bushing SVP178501 Beverage Container (2.5 Gal) 1010577 Screw, 5/16-18 X 1.50 Hex Cap 102427801 Cafe Express Canopy Frame 1011838 Windshield, 1982 102427901 Cafe Express Canopy Pacific Blue 1011862...
Page 47 Cafe Express Refreshment Center Installation 1011897 Bumper, Protective 1703 Screw, 1/4-20 X 1.50 Hx Head Cap 1011937 Bolt, 5/16-18 X 1.25 Hex Head 8233 Locknut, 1/4-20 Nylon Insert 1011964 Washer. 1/4 Flat Door Clip, Consumable Ice 1011965 Lockwasher, 1/4 Spring 1/4-20 x 1-1/2 Phillips Pan-Head Screw with Patch 1014441 Channel, Black Windshield...
Page 48 Cafe Express Refreshment Center Installation WINDSHIELD FRAME INSTALLATION Remove nuts (1), washers (2), and bolts (3) holding the trim (4) to the front body (5) (Figure 25). Retain nuts and washers for later use. Discard bolts. Remove the phillips-head screw (6) from each side of the front body (5). Figure 25 Remove Hardware from Front Body Place a windshield frame mounting pad (3) between each lug (5) on the windshield frame (1) and front body (2)
Page 49 Cafe Express Refreshment Center Installation Figure 26 Mount Windshield Frame CANOPY FRAME INSTALLATION NOTE: Install the canopy frame with the channels toward the front of the vehicle. Locate the four holes near the top edge of the upper cabinet (two in front and two in rear). With the aid of an assistant, position the canopy frame (1) so that the cross tubes with pre-drilled holes align with the nut inserts in the front and rear of the upper cabinet (Figure 27).
Page 50 Cafe Express Refreshment Center Installation Figure 27 Canopy Frame Installation Secure the canopy frame (1) to the upper cabinet (2) using four 1/4-20 x 1-1/2 phillips pan-head screws with patch (3) and stainless steel flat washers (4) (Figure 27). Tighten screws to 50 in-lb (5.6 N·m). See following CAUTION.
Page 51 Cafe Express Refreshment Center Installation Figure 28 Velcro Installation CANOPY COVER INSTALLATION Spread the canopy cover (1) out over the canopy frame with the velcro strip facing inward toward the canopy frame (Figure 29). Starting at one corner, align the bottom edge of the velcro strip on the cover with the bottom edge of the velcro strip on the frame.
Page 52 Cafe Express Refreshment Center Installation Figure 29 Canopy Cover Installation WINDSHIELD INSTALLATION Install the two rubber bumpers (2) on the frame side of the windshield (Figure 30). Install the three mounting channels (1) onto the windshield as shown. Push all three channels onto the frame evenly until the channels are firmly attached to the frame.
Page 53 Cafe Express Refreshment Center Installation QUESTIONS Questions or comments regarding this kit instruction should be referred to your local Club Car dealer or distributor. Please know your vehicle model and have this kit instruction available when you call. 2008 Cafe Express Vehicle Owner’s Manual Page 51...
Page 54: Warranties
Warranties WARRANTIES CLUB CAR® LIMITED TWO YEAR WARRANTY FOR 2008 TRANSPORTATION AND UTILITY VEHICLES WARRANTY: CLUB CAR, INC., (“CLUB CAR”) hereby warrants to the Original Retail Purchaser that its new 2008 Model Transportation and Utility Vehicles purchased from CLUB CAR or an authorized dealer shall be free from defects in material and workmanship under normal use and service as a transportation or utility vehicle for the periods stated below, subject to the provisions, limitations and exclusions contained in this limited warranty.
Page 55 Warranties HOW TO MAKE A WARRANTY CLAIM: To make a warranty claim under this limited warranty, you must present the vehicle or defective component to an authorized CLUB CAR dealer or send the defective component, freight prepaid, to WARRANTY SERVICES, CLUB CAR, INC., 4125 Washington Road, Evans, Georgia 30809, U.S.A., 706-863-3000.
Page 56 Warranties CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT Your new Club Car, Inc. (“CLUB CAR”) vehicle engine complies with both the U.S. EPA and State of California emission regulations. However, the use of gasoline powered golf cars in areas of California that do not attain the federal ozone standards is illegal.
Page 57 Warranties (5) Notwithstanding the provisions herein, warranty services or repairs will be provided at all of our distribution centers that are franchised to service the subject engines or equipment. (6) The engine or equipment owner will not be charged for diagnostic labor that is directly associated with diagnosis of a defective, emission-related warranted part, provided that such diagnostic work is performed at a warranty station*.
Page 58 Warranties NECESSARY MAINTENANCE AS OUTLINED IN THE OWNERS MANUAL AND MAINTENANCE AND SERVICE MANUAL WAS NOT PERFORMED AT THE TIME AND IN THE MANNER SPECIFIED IN SUCH MANUALS. 5. NO CONSEQUENTIAL DAMAGES: In no event shall Club Car be liable for any incidental or consequential damages including, but not limited to, loss related to property other than the vehicle, loss of use, loss of time, inconvenience, or any other economic loss.
Page 59 Warranties 2008 Cafe Express Vehicle Owner’s Manual Page 57...
Page 61 Club Car NOTES...
Page 64 Publication Part Number 103372926 Edition Code 0607C0608B...