Ingersoll-Rand Club Car XRT 800 2008 Owner's Manual
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Ingersoll-Rand Club Car XRT 800 2008 Owner's Manual

Ingersoll-Rand Club Car XRT 800 2008 Owner's Manual

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2008 XRT 800 and XRT 810 Utility
Vehicle Owner's Manual
Electric and Gasoline

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Summary of Contents for Ingersoll-Rand Club Car XRT 800 2008

  • Page 1 2008 XRT 800 and XRT 810 Utility Vehicle Owner’s Manual Electric and Gasoline...
  • Page 3 NOTICE Warranty information appears at the end 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: Regular Maintenance Items

    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 golf car on the market. Please protect your investment and ensure that your Club Car 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 ........................5 Practice Safety ..............................10 Proposition 65 – State of California ........................10 Safety Details ..............................11 General Warnings..............................11 General Information ............................13 Front Bumper and Brush Guard........................... 13 Model Identification............................. 14 Controls and Indicators ............................
  • Page 6 CLUB CAR® LIMITED FOUR YEAR WARRANTY FOR 2008 DEEP CYCLE 12-VOLT BATTERIES ......54 CLUB CAR® LIMITED FOUR YEAR WARRANTY FOR 2008 ONBOARD COMPUTERS AND SOLID STATE SPEED CONTROLLERS ..........................56 California Emission Control Warranty Statement ....................58 Page 4 2008 XRT 800 and XRT 810 Utility Vehicle Owner’s Manual...

  • Page 7: 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. 2008 XRT 800 and XRT 810 Utility Vehicle Owner’s Manual Page 5...
  • Page 8 Safety Decal and Feature Identification XRT 800-E/810-E ELECTRIC VEHICLE Decal, Battery Danger (on battery caps or on body Decal, Maintenance Notice (on vehicle body, under 1013677 102833301 under seat) bed) Decal, Tow Switch Warning (on Tow/Run switch 101908601 Battery Charger Receptacle plate, under seat) Decal, Component Cover Notice (on electrical 101931501...
  • Page 9 Safety Decal and Feature Identification XRT 800-E/810-E ELECTRIC VEHICLE 102825501 Decal, Rollover Warning (on instrument panel) Light Switch 102825701 Decal, Operating Instructions (on instrument panel) Key Switch Decal, Bed Latch Warning (on vehicle body, below 102831901 Battery Warning Light bed latch) Decal, Bed Latch Warning (on vehicle body, below 102832001 Accelerator Pedal...
  • Page 10 Safety Decal and Feature Identification XRT 800/810 GASOLINE VEHICLE 102825401 Decal, Rollover Warning (on instrument panel) Fuel Gauge 102825601 Decal, Operating Instructions (on instrument panel) Light Switch Decal, Bed Latch Warning (on vehicle body, below 102831901 Key Switch bed latch) Decal, Bed Latch Warning (on vehicle body, below 102832001 Low Oil Warning Light...
  • Page 11 Safety Decal and Feature Identification XRT 800/810 GASOLINE VEHICLE Decal, Gasoline Fuel Warning (at fuel fill or on 101547601 Forward/Reverse Control frame, near fuel tank) Decal, Frame Ground/Governor Warning (on 101915201 Fuel Shut-Off Valve vehicle frame near battery) Decal, Rotating Parts/Hot Manifold Warning (on 101960501 Oil Fill engine, starter/generator, and transaxle)

  • Page 12: 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 13: Safety Details

    Safety Details SAFETY DETAILS WARNING • This owner’s manual should be read completely before attempting to drive or service the vehicle. Failure to follow the instructions in this manual could result in property damage, severe personal injury, or death. It is important to note that some vital statements throughout this manual and on the decals affixed to the vehicle are preceded by the words DANGER, WARNING, or CAUTION.
  • Page 14 General Warnings WARNING • Follow the procedures exactly as stated in this manual, and heed all DANGER, WARNING, and CAUTION statements in this manual as well as those on the vehicle and battery charger. • Do not leave children unattended on vehicle. •...

  • Page 15: General Information

    General Information (–) (Viewed from driver side of vehicle) 1. Place TOW/RUN Switch in TOW before disconnecting or connecting battery cables. (Viewed from passenger side of vehicle) 2. Remove negative battery cable. 1. Remove negative battery cable. 3. Remove positive battery cable. 2.

  • Page 16: Model Identification

    Model Identification Figure 4 Bumper Figure 5 Brush Guard MODEL IDENTIFICATION The serial number of the vehicle is printed on a bar code decal mounted on the frame directly above the accelerator pedal (Example: XH0601-583947) (Figure 6). 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 11. 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. • Do not shift the Forward/Reverse handle or switch while the vehicle is moving. To avoid injury to an unsuspecting passenger or damage to the vehicle, always bring the vehicle to a full stop before shifting the Forward/Reverse handle or switch.

  • Page 18: Forward/Reverse Control

    Controls and Indicators Figure 7 Key Switch Electric Vehicles The key switch is mounted on the dash to the right of the steering column. It has two positions, OFF and ON, which are clearly labeled. See following NOTE. 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 is located on the seat support panel (Figure 8).

  • Page 19: Accelerator Pedal

    Controls and Indicators Figure 8 Forward/Reverse Handle – Gasoline Vehicle Figure 9 Forward/Reverse Rocker Switch – Electric Vehicle Electric Vehicles The Forward/Reverse rocker switch is located on the seat support panel (Figure 9). The F (FORWARD) and R (REVERSE) positions are clearly marked. Push down the FORWARD side of the switch to operate the vehicle in the forward direction, or push down the REVERSE side of the switch to operate the vehicle in reverse.

  • Page 20: Park Brake Pedal

    Controls and Indicators Figure 10 Accelerator and Brake Pedals BRAKE PEDAL The brake pedal is the large pedal on the left with the word STOP molded into it (Figure 10). To slow or stop the vehicle, press the brake pedal with your foot (Figure 11). Figure 11 Brake Pedal Figure 12 Park Brake Pedal PARK BRAKE PEDAL...

  • Page 21: Battery Warning Light

    Controls and Indicators WARNING • The park brake will release automatically when either the accelerator or brake pedal is pressed. The park brake has multiple locking positions and should be firmly pressed and locked to prevent the vehicle from rolling. BATTERY WARNING LIGHT Electric Vehicles Only Electric vehicles feature a dash-mounted warning light (to the right of the key switch) that, when the vehicle is in...
  • Page 22 Controls and Indicators Electric vehicles are equipped with a Tow/Run switch, located under the seat just above the Forward/Reverse switch (Figure 13). The switch must be in the RUN position in order to operate the vehicle. When the switch is in the TOW position, power to the vehicle electrical components is turned off and the vehicle will not operate.

  • Page 23: Low Oil Warning Light

    Controls and Indicators Figure 14 Choke Figure 15 Low Oil Warning light and Headlight Switch LOW OIL WARNING LIGHT Gasoline Vehicles Only The gasoline vehicle is equipped with a low oil warning light (1), located on the dash panel to the right of the key switch (Figure 15).

  • Page 24: Pre-Operation And Daily Safety Checklist

    Pre-Operation and Daily Safety Checklist CAUTION • Do not leave electronic devices connected to the accessory outlet while the vehicle batteries are being charged. The voltage output can fluctuate from 12 volts to 19 volts while the vehicle batteries are charging, and this voltage fluctuation can damage some electronic devices.

  • Page 25: Performance Inspection

    Pre-Operation and Daily Safety Checklist PERFORMANCE INSPECTION After you have familiarized yourself with the vehicle controls and have read and understood the driving instructions, take the vehicle for a test drive. Use the following checklist, in conjunction with the Pre-Operation and Daily Safety Checklist, as a guide to inspect the vehicle and check daily for proper operation.

  • Page 26: Driving Instructions

    Driving Instructions DRIVING INSTRUCTIONS WARNING • Only licensed drivers should be allowed to drive the vehicle. • 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 27: Stopping The Vehicle

    Driving Instructions Read safety warnings located on dash and (or) above pedals. Make sure wheels are turned in desired direction. Turn the key to the ON position and make sure nothing is in your path. Select direction by placing the Forward/Reverse switch in desired position (F = forward or R = reverse). A buzzer will sound as a warning when the Forward/Reverse switch is in the REVERSE position.

  • Page 28: Bed Latch

    Bed Latch PARKING AND LEAVING THE VEHICLE After stopping the vehicle, firmly press the park brake pedal until it locks. This will prevent the vehicle from rolling. Turn the key switch to the OFF position and place the Forward/Reverse handle or switch in the NEUTRAL position.

  • Page 29: Loading And Unloading

    Loading and Unloading LOADING AND UNLOADING WARNING • Firmly engage the park brake before loading the vehicle. • Do not allow riders in the cargo bed. • Do not exceed the rated capacity of the vehicle. Rated capacity is for level surfaces only. •...

  • Page 30: Towing With The Vehicle

    Towing with the Vehicle TOWING WITH THE VEHICLE WARNING • Do not tow a vehicle or trailer on public streets or highways. • Normal vehicle operating speed should be reduced when towing. • Extreme caution should be used when towing. •...

  • Page 31: Storage - Electric Vehicles

    Storage – Electric Vehicles STORAGE – ELECTRIC VEHICLES See General Warnings on page 11. WARNING • Turn the key switch to the OFF position, remove the key, and leave the Forward/Reverse handle or switch in the NEUTRAL position during storage. This is to prevent unintentionally starting the vehicle or a fire hazard.

  • Page 32: Storage - Gasoline Vehicles

    Storage – Gasoline Vehicles STORAGE – GASOLINE VEHICLES See General Warnings on page 11. DANGER • Do not attempt to drain fuel when the engine is hot or while it is running. • Be sure to clean up any spilled gasoline before operating the vehicle. •...
  • Page 33 Storage – Gasoline Vehicles 1. Fuel Shut-off Valve 2. Closed (OFF) 3. Open (ON) NOTE: When selecting valve position, ensure that it is fully opened or fully closed. Figure 17 Fuel Shut-off Valve 2.2. Loosen, but do not remove, the carburetor drain screw and drain fuel remaining in bowl into a small, clean container, then pour the fuel from the container into vehicle fuel tank.

  • Page 34: Maintenance

    Maintenance RETURNING THE STORED GASOLINE VEHICLE TO SERVICE Restore fuel system to operation (Figure 31, Page 49). 1.1. Remove plug from fuel tank vent. 1.2. Connect vent tube to fuel tank vent. Connect battery cables, positive (+) cable first, and tighten terminals to 12 ft-lb (16 N·m). Completely open the fuel shut-off valve (Figure 17).

  • Page 35: Periodic Service Schedules

    Periodic Service Schedules WARNING • To avoid unintentionally starting the vehicle, before servicing always disconnect the battery, negative (–) cable first (Figure 2, Page 13), and disconnect the spark plug wire from the spark plug. • Frame ground – Do not allow tools or other metal objects to contact frame when disconnecting batteries or other electrical wiring.
  • Page 36 Periodic Service Schedules PERIODIC SERVICE SCHEDULE – ELECTRIC VEHICLES REGULAR INTERVAL SERVICE See Pre-Operation and Daily Safety Pre-Operation and Daily Safety Checklist Checklist on page 22. Daily service by owner Performance Inspection See Performance Inspection on page 23. Batteries Charge batteries (after each daily use only). Check electrolyte level.
  • Page 37 Periodic Service Schedules PERIODIC SERVICE SCHEDULE – GASOLINE VEHICLES REGULAR INTERVAL SERVICE See Pre-Operation and Daily Safety Pre-Operation and Daily Safety Checklist Checklist on page 22. Daily service by owner Performance Inspection See Performance Inspection on page 23. Check engine oil level; change if necessary. See Periodic Lubrication Schedules on page 36.

  • Page 38: Periodic Lubrication Schedules

    Periodic Lubrication Schedules WARNING • If any problems are found during scheduled inspection or service, do not operate the vehicle until repairs are made. Failure to make necessary repairs could result in fire, property damage, severe personal injury, or death. PERIODIC LUBRICATION SCHEDULES PERIODIC LUBRICATION SCHEDULE –...
  • Page 39 Periodic Lubrication Schedules 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 trained technician (or every 50 Accelerator push rod pivots, mounts, Dry Moly Lube (CCI P/N 1012151) hours of operation, whichever...

  • Page 40: Vehicle Controller - Electric Vehicles

    Vehicle Controller – Electric Vehicles VEHICLE CONTROLLER – ELECTRIC VEHICLES The electric vehicle is equipped with a solid state speed controller. In order to properly service and maintain the solid state controller vehicle, it is necessary to understand the electrical circuitry and the functions of all components in both systems.
  • Page 41 Batteries – Electric Vehicles The batteries should be kept 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 gallon (3.8 L) of water). Rinse solution off of the batteries.

  • Page 42: Battery Charger - Electric Vehicles

    Battery Charger – Electric Vehicles BATTERY CHARGER – ELECTRIC VEHICLES DANGER • The charging area must be ventilated. Hydrogen level in the air must never exceed 2%. The total volume of air in the charging area must be changed five times per hour. Exhaust fans should be located at the highest point of the roof.

  • Page 43: Charging Batteries

    Battery Charger – Electric Vehicles Each electric vehicle is supplied with a fully automatic battery charger as standard equipment AC cord to each charger is to be connected to a source capable of supplying 15 amperes minimum per charger. To reduce the risk of electric shock, the battery charger must be grounded. The charger is equipped with an AC electric cord having an equipment-grounding conductor and a grounding type plug.

  • Page 44: Plug And Receptacle

    Battery Charger – Electric Vehicles Figure 21 Correct Insertion of Charger DC Plug Figure 22 Incorrect Insertion of Charger DC Plug Only PowerDrive System 48 and IQ System vehicles are compatible with PowerDrive chargers. Other Club Car models or vehicles made by other manufacturers are not compatible. As long as the charger is allowed to shut off by itself, the batteries will be fully charged.

  • Page 45: Battery - Gasoline Vehicles

    Battery – Gasoline Vehicles 1. Sense Lead Fuse 2. 48-Volt Fuse Link. Figure 23 Sense Lead Fuse RECEPTACLE FUSE LINK As an additional feature to protect the batteries and charging circuit from an overload, the electric vehicle is equipped with a receptacle fuse link (Figure 23). If the charger does not come on when the vehicle is placed on charge, visually inspect the fuse link.
  • Page 46 Battery – Gasoline Vehicles DANGER • Battery – Poison! Contains acid! Causes severe burns. Avoid contact with skin, eyes, or clothing. Antidotes: – External: Flush with water. Call a physician immediately. – Internal: Drink large quantities of milk or water followed with milk of magnesia or vegetable oil.

  • Page 47: Engine Oil - Gasoline Vehicles

    Engine Oil – Gasoline Vehicles ENGINE OIL – GASOLINE VEHICLES See General Warnings on page 11. 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 Remove the oil level dipstick from the oil filler tube and wipe oil from dipstick (Figure 26).
  • Page 48 Engine Oil – Gasoline Vehicles WARNING • For vehicles with cargo beds, remove all cargo before raising the bed or servicing the vehicle. If the vehicle is equipped with a prop rod, ensure that it is securely engaged while bed is raised. Do not close the bed until all persons are clear of cargo bed area.

  • Page 49: Oil Viscosity

    Engine Oil – Gasoline Vehicles NOTE: An oil drip guard can be used to prevent excess oil from dripping into the engine base plate. Use an empty quart (one liter) container and cut the bottom off at an angle, then slide the open area of the container up and under the oil filter prior to removing.

  • Page 50: Fueling Instructions - Gasoline Vehicles

    Fueling Instructions – Gasoline Vehicles NOTE: Using multi-grade oils (5W-20, 10W-30, and 10W-40) will increase oil consumption. Check oil level more frequently when using them. SAE 30 SAE 10W-30/ SAE 10W-40 SAE 5 W-30 Figure 30 Oil Viscosity Chart FUELING INSTRUCTIONS – GASOLINE VEHICLES See General Warnings on page 11.

  • Page 51: Cleaning The Vehicle

    Cleaning the Vehicle 1. Vent 2. Fuel Shut-off Valve 3. Vent Tube Figure 31 Fuel Tank CLEANING THE VEHICLE Each vehicle is equipped with an ABS front body and a TPO rear body. Use only commercially available automotive cleaners with a sponge or soft cloth for normal cleaning. A garden hose at normal residential water pressure is adequate.

  • Page 52: 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, 9.5 maximum hp @ 3600 RPM (per SAE J •...

  • Page 53: Liquid Capacities

    Vehicle Specifications ELECTRIC ELECTRIC GASOLINE GASOLINE SPECIFICATIONS XRT 800-E XRT 810-E XRT 800 XRT 810 Ground clearance 5.5 inches (14 cm) Front wheel tread 34.5 in (88 cm) Rear wheel tread 38.5 in. (98 cm) 874 lb. 889 lb. Weight (without batteries) (396 kg) (403 kg) 781 lb.

  • Page 54: Club Car® Limited Two Year Warranty For 2008 Xrt 800, Xrt 810 And Xrt 850 Utility Vehicles

    CLUB CAR® LIMITED TWO YEAR WARRANTY FOR 2008 XRT 800, XRT 810 AND XRT 850 UTILITY VEHICLES WARRANTY: CLUBCAR, 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: How To Make A Warranty Claim

    limited warranty period. If CLUB CAR elects to repair the vehicle, it may provide factory-reconditioned parts or components. All parts and components replaced under warranty shall become the property of CLUB CAR. 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.

  • Page 56: Warranty Limitations

    CLUB CAR® LIMITED FOUR YEAR WARRANTY FOR 2008 DEEP CYCLE 12-VOLT BATTERIES CLUB CAR, INC., ("CLUB CAR") hereby warrants to the original retail purchaser that the Deep Cycle 12 volt Battery installed in its new DS electric vehicle equipped with the IQ System™ purchased from CLUB CAR or an authorized distributor or dealer will be free from defects in material and workmanship and will provide 36-hole performance (60 minute discharge capacity) for a period of four years or 800 rounds, whichever first occurs, from the date of purchase subject to the terms and conditions contained herein.
  • Page 57 This battery is intended to be used by persons with training and experience with batteries and only in CLUB CAR electric vehicles. Any other use renders the Limited Warranties expressed herein and all implied warranties null and void and same are hereby excluded. ALSO EXCLUDED FROM THIS LIMITED WARRANTY ARE ANY AND ALL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING, BUT NOT LIMITED TO, LOSS OF USE OR REVENUE, LOSS OF TIME, INCONVENIENCE OR ANY OTHER ECONOMIC LOSS.

  • Page 58: Club Car® Limited Four Year Warranty For 2008 Onboard Computers And Solid State Speed Controllers

    CLUB CAR® LIMITED FOUR YEAR WARRANTY FOR 2008 ONBOARD COMPUTERS AND SOLID STATE SPEED CONTROLLERS CLUB CAR, INC., (“CLUB CAR”) hereby warrants to the original retail purchaser that the new Onboard Computer and the Solid State Speed Controller, hereinafter called “Computer” and “Controller” respectively, installed in its new electric vehicle equipped with the PowerDrive®...
  • Page 59 ALSO EXCLUDED FROM THIS LIMITED WARRANTY ARE ANY AND ALL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING, BUT NOT LIMITED TO, LOSS OF USE OR REVENUE, LOSS OF TIME, INCONVENIENCE OR ANY OTHER ECONOMIC LOSS. Damage not resulting from a defect in material or workmanship or that occurs due to abuse or neglect (including failure to provide reasonable and necessary maintenance), accident or alteration is excluded from this limited warranty.

  • Page 60: California Emission Control Warranty Statement

    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 61: Parts Description

    (4) Repair or replacement of any warranted part under the warranty provisions herein must be performed at a warranty station* at no charge to the owner. (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.

  • Page 62: No Consequential Damages

    THIS AND ANY OTHER WARRANTY SHALL BE VOID IF THE VEHICLE IS ABUSED OR USED IN AN UNINTENDED MANNER OR SHOWS INDICATIONS THAT IT HAS BEEN ALTERED IN ANY WAY, INCLUDING, BUT NOT LIMITED TO, MODIFICATION OF THE SPEED GOVERNOR, BRAKING SYSTEM, STEERING, TRANSAXLE, OR OTHER OPERATING SYSTEMS OF THE VEHICLE TO CAUSE IT TO PERFORM OUTSIDE CLUB CAR SPECIFICATIONS.
  • Page 63 2008 XRT 800 and XRT 810 Utility Vehicle Owner’s Manual Page 61...
  • Page 69 Club Car NOTES...
  • Page 72 Publication Part Number 103372914 Edition Code 0607B0608A...

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Club car xrt 810 2008

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