Club Car XRT 800 2005 Owner's Manual
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Club Car XRT 800 2005 Owner's Manual

Club Car XRT 800 2005 Owner's Manual

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2005
XRT 800 and XRT 810
Vehicles
Electric and Gasoline
Owner's Manual
XRT 800
XRT 800-E
XRT 810
XRT 810-E
An
business

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Summary of Contents for Club Car XRT 800 2005

  • Page 1 2005 XRT 800 and XRT 810 Vehicles Electric and Gasoline Owner’s Manual XRT 800 XRT 800-E XRT 810 XRT 810-E business...
  • Page 4 XRT 800 AND XRT 810 VEHICLE LIMITED WARRANTY REGISTRATION To allow us to provide the best warranty service, please provide the following information. Purchased from: 1. What will be the primary use of the vehicle(s)? ____ Commercial/business Date of delivery: ____ Personal 2.
  • Page 5 NOTICE The Club Car Limited Warranty for 2005 XRT 800 And XRT 810 Vehicles appears on the last pages of this manual. No other warranties, express or implied, are contained herein. Please complete and return the war- ranty registration card included in this manual.

  • Page 6: Regular Maintenance Items

    We hope you will consider this owner’s manual a permanent part of your Club Car vehicle. If you sell the vehi- cle, please include the manual so that the next owner will have the important operating, safety, and mainte- nance information it contains.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Vehicle Feature Identification ........................Safety Details ............................General Warnings ............................General Information ........................... 11 Front Bumper and Brush Guard ........................ 11 Model Identification ............................ 12 Controls and Indicators ..........................13 Pre-Operation and Daily Safety Checklist ....................19 Driving Instructions ............................

  • Page 8: Vehicle Feature Identification

    Vehicle Feature Identification XRT 800-E ELECTRIC VEHICLE BATTERY DANGER DECAL (ON BATTERY CAPS OR ON BODY UNDER SEAT) ELECTRICAL COMPONENT DECAL (ON SPEED CONTROLLER COVER) TOW SWITCH WARNING DECAL (ON TOW SWITCH BRACKET UNDER SEAT) SERVICE NOTICE DECAL (ON BODY UNDER BED) CHARGER RECEPTACLE FORWARD/REVERSE SWITCH...
  • Page 9 Vehicle Feature Identification XRT 800-E ELECTRIC VEHICLE WARNING ROLLOVER OR FALLING OFF MAY CAUSE SERIOUS INJURY OR DEATH • Before using vehicle, read operating instructions. • Remain seated while moving. • Do not start vehicle until all occupants are seated. •...
  • Page 10 Vehicle Feature Identification XRT 800 GASOLINE VEHICLE OPERATING INSTRUCTIONS WARNING • Read owner’s manual and dash-mounted safety warnings prior to driving. • Study and understand controls. ROLLOVER OR FALLING OFF MAY CAUSE SERIOUS INJURY OR DEATH TO START ENGINE • Place shift lever in “N” – Neutral position. •...
  • Page 11 Vehicle Feature Identification XRT 800 GASOLINE VEHICLE GASOLINE WARNING DECAL (ON VEHICLE FRAME NEAR FUEL TANK) OIL FILL ROTATING PARTS AND FUEL SHUT-OFF HOT MANIFOLD DECAL VALVE (ON STARTER/GENERATOR) FORWARD/REVERSE HANDLE DIODE WIRING DECAL CHOKE FRAME GROUND AND GOVERNOR WARNING DECAL (ON VEHICLE FRAME NEAR BATTERY) 2005 XRT 800, XRT 800-E, XRT 810, XRT 810-E Owner’s Manual Page 7...
  • Page 12 Page 8 2005 XRT 800, XRT 800-E, XRT 810, XRT 810-E Owner’s Manual...

  • Page 13: Safety Details

    If any of the operation or warning decals on the vehicle become damaged, have been removed or cannot be easily read, they should be replaced immediately to avoid possible property damage, personal injury, or death. Contact your Club Car dealer. ý...
  • Page 14 • A Club Car 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.

  • Page 15: General Information

    General Information ý WARNING • Use insulated tools when working near batteries or electrical connections. Use extreme caution to avoid shorting of components or wiring. All vehicles: • Wear safety glasses or approved eye protection when servicing the vehicle or battery charger. Wear a full face shield and rubber gloves when working on or near batteries.

  • Page 16: Model Identification

    Model Identification Figure 3 Bumper Figure 4 Brush Guard MODEL IDENTIFICATION The serial number of the vehicles are printed on two bar code decals. (Example: XH0601-583947) (Figure 5). One is mounted on the frame, under the bed, on the passenger side. There is also a second serial number decal mounted on the front frame behind the dash.

  • Page 17: Controls And Indicators

    Controls and Indicators CONTROLS AND INDICATORS See General Warnings on page 9. ý WARNING • If renting or loaning the vehicle, make sure the driver is familiar with all controls and operating procedures before allowing the vehicle to be driven. •...

  • Page 18: Forward/Reverse Control

    WARD) to operate the vehicle in the forward direction, or towards the passenger (REVERSE) to operate the vehicle in reverse. Club Car vehicles operate at reduced speed in REVERSE. The engine can be started only when the handle is in the straight up position (NEUTRAL). The engine must be at idle before shifting the Forward/Reverse handle.

  • Page 19: Accelerator Pedal

    Controls and Indicators Figure 7 Forward/Reverse Handle – Gas Vehicle Figure 8 Forward/Reverse Rocker Switch – Electric Vehicle Figure 9 Accelerator and Brake Pedals ACCELERATOR PEDAL The accelerator pedal is the pedal on the right, with the word GO molded into it (Figure 9). Electric Vehicles The operation of the accelerator pedal differs from that of an automobile.

  • Page 20: Park Brake Pedal

    30 minutes. However, the vehicle should be charged at the first opportunity. If the warning light illuminates and the vehicle is unable to operate for 30 minutes, have your Club Car distributor/ dealer check the vehicle for a possible battery or electrical system problem.

  • Page 21: Tow/Run Switch

    16 hours and the batteries are not sufficiently charged. See the battery charger owner’s man- ual. This indicates an abnormal charge cycle. The charger and batteries should be checked by your Club Car distributor/dealer. • The warning light will repeatedly illuminate for 10 seconds, with 4 second intervals during a charge cycle (DC plug is still connected) if AC power to the charger is interrupted.

  • Page 22: Low Oil Warning Light

    Controls and Indicators Figure 12 Tow/Run Switch CHOKE Gasoline Vehicles Only The choke is located on the seat support panel below and to the left of the driver’s left knee (Figure 13). If the vehicle is hard to start in cool or cold temperatures, simply push in the choke cover to activate it. Hold it during start up and release the choke cover after the engine starts and runs smoothly.

  • Page 23: Headlight Control

    Inspect the accessory outlet periodically to ensure the electrical connection is clean and free of corrosion. 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 24: Performance Inspection

    Use the following checklist as a guide to inspect the vehicle and check daily for proper operation. Any prob- lems should be corrected by a Club Car distributor/dealer or a trained technician. All Vehicles •...

  • Page 25: Driving Instructions

    Motor braking should quickly and smoothly slow the vehicle to approximately 11 mph (17.7 km/h). Motor braking will disengage when vehicle slows to 11 mph (17.7 km/h). This feature is adjustable for IQ System vehicles only. Contact your local Club Car dealer/distrib- utor to inquire about this adjustable feature.

  • Page 26: Starting The Vehicle

    Driving Instructions ý WARNING • To help avoid possible injury to an inattentive passenger and (or) damage to the vehicle, avoid sudden starts, sudden stops, and abrupt turns. • To help avoid the possibility of losing control of or overturning the vehicle, reduce speed for adverse driving conditions such as wet grass or rough terrain.

  • Page 27: Warning And Caution

    Driving Instructions 5. Turn the key all the way to the START position and hold, activating the choke as necessary, until the engine is running smoothly. The engine will idle in neutral. 6. Select direction by placing the Forward/Reverse handle in desired position (F = forward or R = reverse). A buzzer will sound as a warning when the Forward/Reverse handle is in the REVERSE position.

  • Page 28: Bed Latch

    • For use on public roads, the trailer must meet all federal, state, and local requirements such as taillights, brake lights, etc. • Do not tow a Club Car vehicle behind a passenger vehicle or truck on a public road unless it is on an approved trailer.

  • Page 29: Storage - Electric Vehicles

    Storage – Electric Vehicles If the vehicle must be transported over long distances or on public highways, it should be transported on an approved trailer that has the approved load rating of 1200 lb. (544 kg) per vehicle being transported. See fol- lowing NOTE.

  • Page 30: Returning The Stored Electric Vehicle To Service

    Storage – Gasoline Vehicles RETURNING THE STORED ELECTRIC VEHICLE TO SERVICE 1. If necessary, connect batteries, and tighten terminals to 110 in-lb (12.4 N·m). 2. Fully charge batteries. 3. Adjust tires to recommended tire pressure. See Vehicle Specifications on page 46. 4.
  • Page 31 Storage – Gasoline Vehicles 2.4. Plug the fuel tank vent nipple so that it is air tight. We recommend using a slip-on vinyl cap. 3. Disconnect the battery cables, negative (–) cable first. 4. Batteries should be clean and free of corrosion. Wash tops and terminals of batteries with a solution of baking soda and water (1 cup (237 mL) baking soda per 1 gallon (3.8 L) of water).

  • Page 32: Returning The Stored Gasoline Vehicle To Service

    Any vehicle not functioning correctly should be removed from use until it is properly repaired. This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions. Contact your local Club Car distributor/dealer to perform all repairs and semiannual and annual periodic service. ý...

  • Page 33: Periodic Service Schedules

    Periodic Service Schedules ý WARNING Gasoline vehicles only: • Moving parts: Do not attempt to service gasoline vehicle while the engine is running. • Hot! Do not attempt to service hot engine or exhaust system. Failure to heed this warning could result in severe burns.
  • Page 34 Periodic Service Schedules PERIODIC SERVICE SCHEDULE – ELECTRIC VEHICLES REGULAR INTERVAL SERVICE Daily service by owner Batteries Charge batteries (after each use only). Check electrolyte level. Add water if Weekly service by owner Batteries necessary. See page 35. Monthly service by owner Wash battery tops and clean terminals Batteries or trained technician...
  • Page 35 Periodic Service Schedules PERIODIC SERVICE SCHEDULE – GASOLINE VEHICLES REGULAR INTERVAL SERVICE Monthly service by owner Check engine oil level; change if or trained technician necessary. See Periodic Lubrication Schedules on page 32. Check engine cooling air intake; clean if Engine necessary.

  • Page 36: Periodic Lubrication Schedules

    Periodic Lubrication Schedules PERIODIC LUBRICATION SCHEDULES PERIODIC LUBRICATION SCHEDULE – ELECTRIC VEHICLES LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Semiannually by owner or Brake pedal shaft bearings Dry Moly Lube (CCI P/N 1012151) trained technician (or every 50 hours of operation, Brake linkage and pivots Dry Moly Lube (CCI P/N 1012151) whichever comes first)

  • Page 37: Lubrication Points

    Periodic Lubrication Schedules PERIODIC LUBRICATION SCHEDULE – GASOLINE VEHICLES LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Semiannually by owneror Brake pedal shaft bearings Dry Moly Lube (CCI P/N 1012151) trained technician (or every 50 hours of operation, Brake linkage and pivots Dry Moly Lube (CCI P/N 1012151) whichever comes first) Accelerator push rod pivots,...

  • Page 38: Vehicle Controller - Electric Vehicles

    Therefore, if any repair or servicing needs to be performed, we recommend that it be performed by an authorized Club Car distributor/dealer using Club Car parts. BATTERIES – ELECTRIC VEHICLES See General Warnings on page 9.

  • Page 39: Battery Care

    Batteries – Electric Vehicles BATTERY CARE To keep batteries in good working condition, follow this maintenance program on a regular basis: 1. The batteries should be kept clean and free of corrosion. Wash tops and terminals of batteries with a solu- tion of baking soda and water (1 cup (237 mL) baking soda per gallon (3.8 L) of water).

  • Page 40: Battery Charger - Electric Vehicles

    ý WARNING • Only trained technicians should repair or service the charger. Contact your nearest Club Car distributor/dealer. • Each charger should have its own dedicated 15 or 20 ampere separately protected (circuit breaker or fuse) single phase branch circuit, in accordance with all applicable electrical codes for the location.

  • Page 41: Charging Batteries

    Battery Charger – Electric Vehicles NOTE: Because the vehicle’s onboard computer (OBC) has a storage charge feature that automatically checks and recharges the batteries as necessary every 15 days, the charger can remain plugged to an electric vehicle throughout the storage period. Shortly after charging begins, the PowerDrive 2 Charger will shut off in order to run a self-diagnos- tic program (ammeter will drop to zero).

  • Page 42: Plug And Receptacle

    Figure 22 Correct Insertion of Charger DC Plug Figure 23 Incorrect Insertion of Charger DC Plug Club Car electric vehicles are supplied with a PowerDrive 2 battery charger (CCI P/N 101802204). Use Pow- erDrive 2 chargers with this electric vehicle.

  • Page 43: Receptacle Fuse Link

    ý WARNING • If the receptacle fuse link is blown, determine the source of the electrical problem and correct it before replacing the fuse. Contact your nearest Club Car distributor/dealer. BATTERY – GASOLINE VEHICLES See General Warnings on page 9.
  • Page 44 WARNING • Do not jump start a dead battery using another battery and jumper cables. The battery in the Club Car gasoline vehicle is a 12-volt, low maintenance battery that requires infrequent watering (Figure 25). Any corrosion around the positive (+) or negative (–) terminals should be washed off with a solution of baking soda and water (1 cup (237 mL) per gallon (3.8 L) of water).

  • Page 45: Engine Oil - Gasoline Vehicles

    Engine Oil – Gasoline Vehicles ENGINE OIL – GASOLINE VEHICLES See General Warnings on page 9. Even though the low oil warning light on the dash should illuminate if oil level becomes low, engine oil level should be checked monthly. Vehicle should be on a level surface when checking oil. Do not overfill with oil. ENGINE OIL LEVEL CHECK 1.

  • Page 46: Drain Plug

    Engine Oil – Gasoline Vehicles 3. Disconnect the battery cables, negative (–) cable first . See WARNING “To avoid unintentionally start- ing...” on page10. 4. Position a pan designed for oil changes under the front drain plug (Figure 28). 5. Use a 14 mm socket or box end (do not use an open end) wrench to remove the drain plug, turning it counterclockwise, and allow the engine oil to drain into the pan.

  • Page 47: Drain Pan

    NOTE: Use only Club Car oil filters (CCI P/N 1016467) designed for this engine. 12. Tighten the oil filter by hand until tight. Do not use a band wrench or channel lock plier to tighten.

  • Page 48: Fueling Instructions - Gasoline Vehicles

    Fueling Instructions – Gasoline Vehicles ° ° ° ° ° ° ° -20 C -10 C 10 C SAE 40 SAE 30 SAE 10W-30/SAE 10W-40 ° SAE 5W-20 ° ° ° ° ° ° ° 86 F 104 F -4 F 32 F 50 F 68 F...

  • Page 49: Cleaning The Vehicle

    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 of the vehicle to CLUB CAR, INC., P.O.

  • Page 50: Vehicle Specifications

    Vehicle Specifications VEHICLE SPECIFICATIONS Electric Electric Gasoline Gasoline SPECIFICATIONS XRT 800-E XRT 810-E XRT 800 XRT 810 POWER SOURCE Drive motor: Direct drive, 48 volts DC, shunt-wound, 3.2 hp • Engine: 4-cycle OHV, 286 cc, 9.0 hp rated, single-cylinder, air-cooled, with pressure •...
  • Page 51 Vehicle Specifications Electric Electric Gasoline Gasoline SPECIFICATIONS XRT 800-E XRT 810-E XRT 800 XRT 810 LIQUID CAPACITIES Transaxle 22 oz. (0.67 L) Engine crankcase (without filter) 32 oz. (0.95 L) Engine crankcase (with filter) 38 oz. (1.12 L) Unitized transaxle 27 oz.

  • Page 52: Voiding Of Warranty

    Repair shall mean remedying a defect in the vehicle or component thereof at no cost to the purchaser during the applicable limited warranty period. If CLUB CAR elects to repair the vehicle, it may provide factory-reconditioned parts or components.

  • Page 53: No Consequential Damages

    Onboard Computer, whichever first occurs, from the date of purchase. The battery should be returned to an authorized CLUB CAR distributor or dealer with evidence of proof of purchase date and number of rounds, freight prepaid. CLUB CAR reserves the right to test and recharge any battery returned for adjustment, and to verify number of rounds played by accessing information contained in the IQ System Onboard Computer.

  • Page 54: Warranty Limitations

    Without limiting the generality of the foregoing in any way, and as part of its limited warranty exclusion, CLUB CAR does not warrant that its PowerDrive battery is suitable for use in any application other than in its products. As in the use of any battery, a prudent owner will read and study the charger owner's manual, the electric vehicle owner's manual, the operator instructions, and the battery warning labels;...
  • Page 55 5) A battery damaged by a defective charger. Without limiting the generality of the foregoing in any way, and as part of its limited warranty exclusion, CLUB CAR does not warrant that its PowerDrive battery is suitable for use in any application other than in its products. As in the use of any battery, a prudent owner will read and study the charger owner’s manual, the electric vehicle owner’s manual, the operator...
  • Page 56 The limited warranty with respect to parts and labor only covers defects in material and workmanship for a period of four years from the date of purchase. Such repair labor shall be performed only by CLUB CAR or by an authorized distributor or dealer.
  • Page 57 4) Vehicles charged by systems other than the CLUB CAR PowerDrive Charger. Without limiting the generality of the foregoing in any way, and as part of its limited warranty exclusion, CLUB CAR does not warrant that the Computer or Controller is suitable for use in any application other than its PowerDrive System 48, PowerDrive Plus, and IQ System products.
  • Page 58 Therefore, the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights, and you may also have other rights, which vary from state to state. For further information contact WARRANTY SERVICES, CLUB CAR, INC., P.O. Box 204658, Augusta, Georgia, 30917- 4658, U.S.A., 706-863-3000.

  • Page 59: California Emission Control Warranty Statement

    If such a replacement part is used in the repair or maintenance of the engine, and an authorized CLUB CAR dealer determines it is defective or causes a failure of a warranted, part, your claim for repair of the engine may be denied. If the part in question in not related to the reason the engine required repair, the claim will not be denied.

  • Page 60: Emission Control Information

    System Warranty requires that you return your • Magneto or electronic ignition system blow-by gases are led to the breather chamber engine to an authorized Club Car Dealer for • Fuel filter element through the crankcase.Then, it is led to the air remedy under warranty.Please read the warranty...
  • Page 61 3. Clarity of Illustrations 4. Periodic Service and Periodic Lubrication Schedules Comments/Suggestions Please fax a copy of this page to (706) 228-2662. Thank You! Club Car Technical Publication Department 2005 XRT 800, XRT 800-E, XRT 810, XRT 810-E Owner’s Manual Page 57...
  • Page 64 Publication Part Number 102680228 Edition Code 0505C0705B Club Car, Inc. www.clubcar.com P.O. Box 204658 Phone 1.706.863.3000 Augusta, GA 30917-4658 1.800.ClubCar Intl’l +1 706.863.3000 1.706.863-5808...

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