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1. 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 e Do not leave children unattended in vehicle at any time Prior to leaving the vehicle unattended or servicing the vehicle set the park brake place the Forward Reverse handle or switch in the NEUTRAL position turn the key switch to the OFF position and remove the key Chock the wheels when servicing the vehicle e Improper use of the vehicle or failure to properly maintain it can result in decreased vehicle performance serious personal injury or death Any modification or change to the vehicle that affects the electrical system stability or handling of the vehicle or increases maximum vehicle speed beyond factory specifications can result in serious personal injury or death e Check the vehicle for proper location of all vehicle safety and operation decals and make sure they are in place and are easy to read For vehicles with cargo beds remove all cargo including accessories 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 bed until all persons are clear of cargo bed area Keep hands clear of all crush areas Do not drop cargo bed lower gently and keep entire body clear Failure to heed this warning can result in serious personal
2. CubCar CAFE EXPRESS Vehicle Owner s Manual Gasoline Refer to back cover for applicable build code range LY Ingersoll Rand Industrial Technologies NOTICE This manual is valid for vehicles manufactured in the build code range provided on the back cover of this manual If the vehicle build code is different from that shown on the back cover of this manual please contact your nearest dealer or go to www clubcar com to retrieve the proper owner s manual for the vehicle See also Model Identification in this manual 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 This manual contains proprietary information that is protected by copyright All rights are reserved No part of this manual may be photocopied reproduced or translated to another language without the written consent of Club Car LLC The information contained in this document is subject to change without notice Club Car reserves the right to make design changes to vehicles without obligation to make these changes on units previously sold These utility vehicles are four wheel general
3. 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 Use the following checklist as a guide to inspect the vehicle This checklist should be used daily to ensure that the vehicle is in proper working condition and in conjunction with the Performance Inspection on page 19 and the Periodic Service Schedule on page 28 Any problems should be corrected by a Club Car distributor dealer or a trained technician Do not operate the vehicle until the upper cabinet canopy and windshield have been installed Safety Video Have all operators view the safety video that was provided with the vehicle and understand the safety warnings it illustrates before operating the vehicle General All the parts should be in place and properly installed Be sure that all nuts bolts and screws are tight On gasoline vehicles check all hose clamps for tight fit as well as the starter belt for tightness e Windshield Ensure that the windshield is installed before driving the vehicle e Safety and information decals Check to ensure that all safety and information decals are in place See Safety Decal Identification on page 4 e Tires Check for proper tire pressure upon delivery and on a daily basis when the vehicle is in service See Vehicle Specifications on page 39 e Loading Before driving the vehicle ensure that the load weigh
4. NEUTRAL and R REVERSE Push the handle up to operate the vehicle in the forward direction or pull the handle down to operate the vehicle in reverse e The engine will not run when the handle is in the NEUTRAL position Club Car vehicles operate at reduced speed in reverse The reverse buzzer will sound as a warning when the Forward Reverse handle is in the REVERSE position 2821 Figure 6 Instrument Panel HEADLIGHT CONTROL Vehicles with Headlights The headlight switch 3 is located on the right side of the instrument panel Figure 6 Press the side of the switch with the headlight symbol to turn the headlights on and press the other side to turn the headlights off NOTE Using the headlights for extended periods of time without the engine running or with the engine idling will discharge the battery LOW OIL WARNING LIGHT The gasoline vehicle is equipped with a low oil warning light 4 located at the top of the instrument panel Figure 6 If the warning light comes on oil should be checked and added to the engine as necessary before continuing to use the vehicle See following CAUTION The vehicle should never be driven when the low oil warning light remains on If the CAFE EXPRESS Vehicle Owner s Manual Page 13 Controls and Indicators warning light goes on and off the vehicle may be driven but oil should be added at the first opportunity The light will flash repeatedly to indicate a possi
5. or less on a level surface With the neutral lockout switch in the MAINTENANCE position check the maximum engine RPM with a tachometer The correct setting for safe operation is 2350 RPM 30 Forward Reverse control Check for proper operation See Controls and Indicators on page 12 Brakes Be sure the brakes function properly When brake pedal is fully pressed under moderate pressure it should not go more than halfway to the floor and 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 Brake adjustment must be maintained so that the brake pedal cannot be pressed to the floor under any circumstance e Park brake When latched the park brake should lock the wheels and hold the vehicle stationary on an incline of 20 or less It should release when either the accelerator or brake pedal is pressed e Reverse buzzer The reverse buzzer should sound as a warning when the Forward Reverse handle or switch is in the REVERSE position e Steering The vehicle should be easy to steer and should not have any play in the steering wheel e General Listen for any unusual noises such as squeaks or rattles Check the vehicle ride and performance Have a Club Car distributor dealer or a trained technician investigate anything unusual e Accelerator pedal With the key switch in the ON position
6. B 1932 Sint Stevens Woluwe Belgium Geoff Stewart September 17 2013 Director Product Safety Evans Georgia USA Page 48 CAFE EXPRESS Vehicle Owner s Manual NOTES NOTES NOTES NOTES BC56671 Publication Part Number 105062712 Edition Code 1113B0114A This manual is valid for vehicles with build codes between 56658 and the one indicated at the top of this page Cuca o REGISTERED ff ol Q o a Club Car LLC Web www clubcar com y P O Box 204658 Phone 1 706 863 3000 N Augusta GA 30917 4658 1 800 ClubCar USA Int 1 706 863 3000 Fax 1 706 863 5808
7. 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 6 Start the vehicle 6 1 Turn the key to the ON position 6 2 Select direction by placing the Forward Reverse handle or switch in the desired position F Forward or R Reverse A buzzer will sound as a warning when the Forward Reverse handle or switch is in the REVERSE position 6 3 Slowly press the accelerator pedal The park brake will release automatically and the vehicle will start to move As the accelerator pedal is pressed speed will increase until full speed is reached See following WARNING and NOTE 4 WARNING PDN ss a Operator must control vehicle speed when going downhill e Stop the vehicle before shifting the Forward Reverse handle or switch Failure to do so can result in injury to inattentive passengers and or damage to the vehicle e Press the brake pedal as necessary and partially press the accelerator when descending a hill With the accelerator pedal partially pressed the governor will cause the engine to assist the brakes in controlling downhill speed STOPPING THE VEHICLE A WARNING Driving through water can affect the brakes After driving through water check effectiveness of the brakes by gently pressing the brake pedal If the vehicle does not slow down at the normal rate continue to press the brake pedal until the brakes dry out an
8. If any problems are found during scheduled inspection or service do not operate the vehicle until repairs are made Failure to make necessary repairs can result in fire property damage serious personal injury or death Only trained technicians should service or repair the vehicle Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair The appropriate instructions must be used when performing maintenance service or accessory installation e Do not work on vehicle powertrain or under the cargo bed when it is loaded Do not wear loose clothing or jewelry such as rings watches chains etc when servicing the vehicle Turn the key switch to OFF remove the key place the Forward Reverse handle or switch in the NEUTRAL position and chock tires prior to servicing Do not close bed until all persons are clear of the bed area Failure to follow these instructions can result in serious personal injury 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 can result in serious burns To avoid unintentionally starting the vehicle disconnect battery and spark plug wire See Disconnecting the Battery on page 10 Frame ground Do not allow tools or other metal objects to contact frame when disconnecting batteries or other electrical wirin
9. OFF and remove key A 105048101 101609401 VEHICLE ROLLOVER CAN CAUSE SERIOUS INJURY OR DEATH Operate vehicle only With 6 ply rated 20x10 10 tires With all compartment loads equally On cart paths or improved surfaces With 28 to 32 psig 193 to 221 kPa tire distributed pressure checked daily A 105185201 Vehicle rated capacity 850 Ibs 385 6 kg on level Cargo should be evenly distributed in the beverage surface only Weight to include driver passenger unit as far forward as possible and secured and total cargo load e For vehicle stability when fully loaded drive slowly Maximum cargo load 450 Ibs 204 1 kg Weight and avoid stopping on or backing down steep hills to include total cargo load in ALL storage locations When driving on uneven terrain or down steep hills Avoid top heavy loads reduce speed and load corva Decal Crush Area Warning behind seat near 1 101609401 4 104026801 Decal Occupant Warning cargo bed 101825101 Decal On Off Key Switch above key switch 105046101 Decal Operating Instructions 102278901 Decal Vehicle Load 6 105185901 Decal Rollover Warning Page 4 CAFE EXPRESS Vehicle Owner s Manual Safety Decal Identification CAFE EXPRESS VEHICLE CONTINUED GASOLINE EXPLOSION FIRE CAN CAUSE SERIOUS GASOLINE EXPLOSION FIRE CAN CAUSE INJURY OR DEATH SERIOUS INJURY OR DEATH CAN CAUSE SEVERE INJURY No sparks or open flame near fuel or fuel tank Do n
10. See Preparing the Gasoline Vehicle for Extended Storage on page 26 1 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 2 Replace fuel cap on tank Ensure cap is tightened securely tighten until it clicks cc 1 Vent 2 Fuel Vent Line 3 Fuel Tank 2832 Figure 21 Fuel Tank CLEANING THE VEHICLE VEHICLE CHASSIS The vehicle is equipped with an ArmorFlex front body and an all aluminum 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 To remove oxidation or discoloration from aluminum use a commercially available aluminum cleaner paste and fine grade No 00 steel wool Club Car does not recommend any type of pressure washer or steam cleaning Such a process will expose electrical components to moisture Moisture entering electrical components can result in water damage and subsequent component failure Use non abrasive wax products Battery acid fertilizers tars asphalt creosote paint or chewing gum should be removed immediately to prevent possible stains The seats of the vehicle will last longer with proper cleaning Use a solution of 10 liquid soap and warm water applied with a soft cloth For imbedded dirt a soft bristle brush may be used For heavy soiling difficult stains or scratches
11. battery Be sure terminals are tight Let the terminals dry and then spray them with Battery Terminal Protector Spray See Connecting the Battery on page 10 See following WARNING 4 WARNING e If battery wire terminals are damaged or corroded replace or clean them as necessary Failure to do so can cause them to overheat during operation and can result in a fire property damage or personal injury Be sure battery clamp is properly tightened Tighten to 144 in Ib 16 N m A loose clamp may allow the battery to become damaged from vibration or jarring If battery appears weak have it charged by a trained technician The battery should never be left discharged any longer than absolutely necessary do not leave discharged overnight ENGINE OIL GASOLINE VEHICLE 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 Remove the oil level dipstick from the oil filler tube and wipe oil off dipstick Figure 18 See following CAUTION CAUTION e Do not remove dipstick while engine is running Check oil by fully inserting the dipstick into the oil filler tube and immediately removing it 3 If the oil level is at or below the low level mark on the dipstick gauge add oil until the level is between low and full levels safe level 4 Insert
12. blemishes or other body damage see the Maintenance and Service Manual or contact your local Club Car dealer NOTE Dispose of waste water properly Page 36 CAFE EXPRESS Vehicle Owner s Manual Accessories WINDSHIELD Use only mild liquid dishwasher soap with a sponge or soft cloth for cleaning the windshield 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 your 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 Periodic cleaning with an aluminum or stainless steel cleaner is recommended CAUTION Using abrasive cleaners on aluminum will damage or scratch the surface Use a soft cloth with an industrial type aluminum cleaner polish to clean the aluminum surfaces Do not use steel wool on refreshment center aluminum surfaces Drains The drains should be flushed with a hose on a daily basis Periodically the drains should be cleaned and sanitized Refreshment Center Doors The sliding doors should be cleaned daily with a mild soap and water solution Dry with a clean damp chamois Do not use window cleaning sprays or paper towels Canopy Cover Periodically clean the canopy cover by s
13. generator gasoline 3 YEARS 3000 vehicle motor transaxle assembly electric vehicle and main frame assembly LIMITED TWO YEAR Solenoid MCOR limit switches voltage regulators FNR switches brake components wiring harness electrical switches canopy systems seats pedal group assembly body cab assembly and 2 YEARS 2000 doors and driving range protective enclosure portable refreshment center and all original equipment options and accessories supplied by CLUB CAR and all remaining components of the vehicle not specified otherwise 6 VOLT BATTERY STANDARD DUTY 6 VOLT BATTERY HEAVY DUTY 8 VOLT BATTERY STANDARD HEAVY DUTY ONBOARD COMPUTER IF SO EQUIPPED BATTERY CHARGER EXCLUSIONS Excluded from any CLUB CAR warranty is damage to a vehicle or component resulting from a cause other than a defect including poor maintenance neglect abuse accident and collision maintenance adjustments unreasonable or unintended strain or use improper installation of accessories installation of parts or accessories that are not original equipment including Club Car approved or non approved GPS systems non approved alteration and acts of God Also excluded from any CLUB CAR warranty are all fuses filters decals except safety decals lubricants routine wear items such as the charger plug and receptacle engine mounts bed floor lining mats pads spark plugs light bulbs brake shoes belts brushes bushings drive buttons cosmetic deter
14. on a hill avoid sudden starts or rolling backwards and stopping suddenly Failure to heed this warning can cause vehicle to overturn possibly resulting in serious personal injury To help avoid shifting the vehicle load and possibly overturning the vehicle avoid sudden starts sudden stops and abrupt turns e The cargo s center of gravity can affect the handling steering and braking of the vehicle Avoid top heavy loads When the vehicle is loaded reduce speed and drive slowly in turns To help prevent cargo from shifting and possibly injuring a passenger or affecting the vehicle s handling make sure cargo is well secured Unload refreshment center before raising vehicle with a lift hoist or jack e Cargo load includes the weight of optional equipment When stocking the Cafe Express refreshment center make sure the load weights are approximately equal in all lower cold storage compartments containing ice and or beverages VEHICLE LOAD CAPACITIES Occupant Capacity The occupant capacity is the maximum allowable weight for occupants operator and passengers to operate the vehicle safely Cargo Capacity The cargo capacity is the maximum amount of load that the vehicle can haul in the cargo areas and cargo bed and includes the weight of optional equipment Vehicle Rated Capacity The vehicle rated capacity is the maximum amount of weight on the vehicle This capacity includes the weight of occupants cargo b
15. personal injury or death A CAUTION e A CAUTION with the safety alert symbol indicates a hazard or unsafe practice that can result in minor personal injury CAUTION e A CAUTION without the safety alert symbol indicates a potentially hazardous situation that can result in property damage GENERAL WARNINGS The following safety statements must be heeded whenever the vehicle is being operated repaired or serviced See Safety Decal Identification on page 4 Other specific safety statements appear throughout this manual and on the vehicle Page 8 CAFE EXPRESS Vehicle Owner s Manual General Warnings A DANGER e 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 e Gasoline Flammable Explosive Do not smoke Keep sparks and flames away from the vehicle and service area Service only in a well ventilated area Do not operate engine in an enclosed area without proper ventilation The engine produces carbon monoxide which is an odorless deadly poison 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 A WARNING
16. purpose vehicles intended to transport people and cargo on improved or groomed surfaces These vehicles do not conform to U S Federal Motor Vehicle Safety Standards FMVSS for automobiles or to FMVSS 500 for low speed vehicles and are not equipped for operation on public streets roads or highways If in English this manual is the Original Instructions provided by the manufacturer If in any language other than English this manual is a translation of the Original Instructions Club Car i P O Box 204658 Augusta Georgia 30917 4658 USA Telephone 706 863 3000 Service Parts Fax 706 855 7413 www clubcar com Copyright 2013 Club Car LLC Club Car Tranquility and ArmorFlex are registered trademarks of Club Car LLC This manual effective January 1 2014 CAFE EXPRESS Vehicle Owner s Manual Page 1 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 Your comfort and safety are important to us so we urge you to read and follow the step by step operating instructions and safety procedures in this manual These instructions must be followed in order to avoid the risk of serious personal injur
17. 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 LLC P O Box 204658 Augusta Georgia 30917 4658 Attention Vehicle Registration Page 38 CAFE EXPRESS Vehicle Owner s Manual Vehicle Specifications VEHICLE SPECIFICATIONS NOTE Engine horsepower and torque specifications are provided by the engine manufacturer Actual horsepower and torque in use may differ and are dependent on environmental conditions as well as maintenance condition of the engine SPECIFICATIONS CAFE EXPRESS POWER SOURCE GASOLINE Engine 4 cycle OHC 404 cc 14 0 Horsepower 10 4 kW rated engine 3600 RPM per SAE J 1940 single cylinder air cooled with splash lubrication system Fuel system Electronic fuel injection EFI high pressure rotary fuel pump with 10 micron fuel filter Pe Governor Automatic ground speed sensing internally geared in transaxle ETT E ol Ignition Digital CDI with electronic RPM limiter O S Transaxle Precision helical gears forward reverse with neutral position 11 47 1 forward 15 63 1 reverse with optional limited slip differential Electrical system 12 volt 500 cca at 0 F 17 8 C 650 cca at 32 F 0 C 105 minute reserve capacity Gasoline Vehicle Electrical Charging System 23 amps at max RPM Torque converter Automatic variable speed dry type STEER
18. switch to the OFF position before fueling Do not pour fuel into the fuel tank when the engine is hot or while it is running Be sure the fuel tank ground wire on the tank is properly connected before fueling the vehicle e To avoid electric arc caused by static electricity the fuel storage pumping device must be grounded If the pump is not grounded the vehicle must be grounded to the pump before and during the fueling operation Ifthe vehicle has an all weather enclosure installed be sure the fuel tank is properly vented as shown in Figure 21 To avoid the possibility of fire clean up any spilled fuel before operating the vehicle CAUTION e Use unleaded gasoline only e Whenever possible avoid using oxygenated and blended fuels Do not use any fuel with an alcohol content that exceeds 10 by volume such as E15 and E85 Ethanol is an alcohol that readily absorbs moisture causing corrosion of fuel system components It also damages neoprene and other plastic and rubber components Use of these fuels in this vehicle will void the warranty Do not repeatedly attempt to start a vehicle when the fuel pump is dry no gas in tank Doing so can damage the fuel pump CAFE EXPRESS Vehicle Owner s Manual Page 35 Cleaning the Vehicle NOTE Whenever possible avoid using oxygenated fuels and fuels that are blended with alcohol Vehicles to be stored for extended periods should be prepared for storage as instructed
19. the dipstick into the oil filler tube See following NOTE NOTE Properly recycle or dispose of used oil in accordance with local state and federal regulations Page 32 CAFE EXPRESS Vehicle Owner s Manual Engine Oil Gasoline Vehicle ANG DAN e ION gt Ly 1 Full level 2 Safe level 3 Low level 2662 Figure 18 Engine Oil Level Check ENGINE OIL CHANGE Engine oil should be changed after the first 100 hours of operation After that it should be changed every 200 hours of operation or annually whichever comes first 1 Turn the key switch to the OFF position then remove the key Place the Forward Reverse handle in the NEUTRAL position Chock the front wheels 2 Access the engine compartment 3 Disconnect battery and spark plug wire See Disconnecting the Battery on page 10 Position a pan designed for oil changes under the drain plug 1 Figure 19 CAFE EXPRESS Vehicle Owner s Manual Page 33 Engine Oil Gasoline Vehicle 1 Drain pan 2 Drain plug 2667 Figure 19 Engine Oil Drain Plug and Pan 5 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 A WARNING Do not attempt to change engine oil when the engine is hot or even warm Engine oil can cause skin burns e Wear safety glasses or approved eye protection when servicing the vehicle We
20. with the listed Directives Declaration of Conformity Model Model Code Number MD 104030601 Caf Express Serial numbers 1401000001 and greater Model Name Four wheel vehicles in the above series that bear the CE mark fulfill all the relevant provisions of the following Directives Enspricht den Bestimmungen Conforme Aux Directives Conforme Con Las Directivas Voldoet aan Richtlijnen De Acordo com Directiva Conforme Alla Direttiva Opfylder folgende direktiver Upptyller foljande direktiv 2006 42 EC Machinery 2006 66 EC Batteries and Accumulators and Waste Batteries and Accumulators Standards used for verification Standards fur Uberprufung Normes Utilisees pour Verification Normas Usado por Comprobacion Waarden Aangewend voor Verificatie Modelos Utilizado para Verifcacao Standard per la Verifica Standarder Anvendte Nemlig Efterprovning Standarden Anvand for Bekraftanden N A Manufacturer Hersteller Fabricant Fabricante Fabrikant Fabricante Fabbricante Producent Tillverkare Club Car LLC 4125 Washington Road Evans Georgia 30809 USA Authorized representative and person authorized to compile the technical file Autorisierter Handler Representant Dument Accr dit Representante Autorizado Wettige Vertegenwoordiging Representate Autorizado Rappresentante Autorizzato Autoriscret repreesentant Auktoriserad representant Club Car Ingersoll Rand Alma Court Building Lenneke Marelaan 6
21. 1 WARRANTY CLUB CAR warrants to the ultimate purchaser and each subsequent purchaser that the SORE and related emissions equipment is designed built and equipped so as to conform with all applicable California environmental emission regulations and free from defects in materials and workmanship that cause the failure of a warranted part to be identical in all material respects to that part as described in CLUB CAR s application for certification with CARB The warranty period begins on the date the engine or equipment is delivered to an ultimate purchaser or first placed into service The warranty period is two years from the date of purchase 2 COVERAGE Subject to certain conditions and exclusions as stated below the warranty on emission related parts is as follows 1 Any warranted part that is not scheduled for replacement as required maintenance in the written instructions supplied is warranted for the warranty period stated above If the part fails during the period of warranty coverage the part will be repaired or replaced by CLUB CAR according to subsection 4 below Any such part repaired or replaced under warranty will be warranted for the remainder of the original warranty period 2 Any warranted part that is scheduled only for regular inspection in the written instructions supplied is warranted for the warranty period stated above Any such part repaired or replaced under warranty will be warranted for the remaining original wa
22. E EXPRESS Vehicle Owner s Manual Warranties WARRANTIES CLUB CAR LIMITED WARRANTY FOR TRANSPORTATION AND UTILITY VEHICLES WARRANTY CLUB CAR LLC CLUB CAR hereby warrants to the Original Purchaser or Lessee as those terms are defined herein and subject to the provisions limitations and exclusions in this limited warranty that its new vehicle or new component purchased from CLUB CAR or an Authorized Dealer or Distributor shall be free from defects in material and workmanship under normal use and service for the periods stated below subject to the provisions limitations and exclusions in this limited warranty This limited warranty covers material workmanship and repair labor cost as to those items specifically listed below for the periods specified Such repair labor shall be performed only by CLUB CAR its Authorized Dealers or Distributors or a service agency approved by CLUB CAR For repairs made by qualified technicians other than CLUB CAR s factory technicians or an Authorized Dealer or Distributor CLUB CAR will provide only the replacement parts or components IF THE WARRANTY REGISTRATION FORM IS NOT COMPLETED AND RETURNED TO CLUB CAR AT THE TIME OF THE ORIGINAL RETAIL SALE PURCHASER MUST PROVIDE PROOF OF DATE OF PURCHASE WITH ANY WARRANTY CLAIM HOURS TERMS TO THE ORIGINAL OWNER ONLY NON TRANSFERABLE AMP HOURS COVERED COVERED LIMITED THREE YEAR Engine assembly transaxle assembly gasoline vehicle starter
23. EXPRESS Vehicle Owner s Manual Page 7 Proposition 65 State of California PROPOSITION 65 STATE OF CALIFORNIA A WARNING This product contains or emits chemicals or substances that have been determined by the state of California to cause cancer and birth defects or other reproductive harm SAFETY DETAILS A WARNING This manual should be read completely before attempting to drive or service the vehicle The safety video provided with the Cafe Express vehicle and the online training should also be viewed by all operators of the vehicle Failure to heed the warnings or follow the instructions in this manual and the training material can result in serious 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 For your protection we recommend that you take special notice of these safety precautions Safety precautions are essential and must be followed If any of the operation or safety 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 distributor dealer A DANGER A DANGER indicates an immediate hazard that will result in severe personal injury or death A WARNING A WARNING indicates an immediate hazard that can result in severe
24. G Rotating Parts 399 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 Understand and become familiar with the DANGER WARNING and CAUTION statements and procedures it contains along with the safety decals that are affixed to your vehicle Take time to understand the language of safety It is a language that can save your life SAFETY VIDEO AND ONLINE TRAINING PROGRAM A vehicle safety video is provided with the vehicle Have all operators view the safety video and understand the safety warnings it illustrates before operating the vehicle If a safety video was not provided with your Cafe Express vehicle you may obtain one through your service parts representative Online training for this product is available on the Club Car website at www clubcar com resources pages eLearn ing aspx Prior to operating the vehicle operators should complete the training Our e learning program allows our customers to document employee training and to monitor each employee s achievement record The program will record an employee s completion status and establishes a record of training for supervisors and managers based on information provided by the employee at login CAFE
25. HER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED BY CLUB CAR AND EXCLUDED FROM THIS WARRANTY THE PURCHASER AND CLUB CAR EXPRESSLY AGREE THAT THE SOLE REMEDY OF THE REPLACEMENT OR REPAIR OF THE DEFECTIVE VEHICLE OR COMPONENT THEREOF IS THE SOLE REMEDY OF THE PURCHASER CLUB CAR MAKES NO OTHER REPRESENTATION OR WARRANTY OF ANY KIND AND NO REPRESENTATIVE EMPLOYEE DISTRIBUTOR OR DEALER OF CLUB CAR HAS THE AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION PROMISE OR AGREEMENT WHICH IN ANY WAY VARIES THE TERMS OF THIS WARRANTY Page 42 CAFE EXPRESS Vehicle Owner s Manual Warranties In the event that another pre printed warranty document certificate or both offered by or through Club Car at the time of sale of this vehicle each an Additional Warranty Document is deemed to conflict with the limitations or exclusions contained herein the limitations and exclusions contained herein shall continue to apply to both this limited warranty statement and to the maximum extent permitted by law to each Additional Warranty Document 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 Some states allow neither limitation on the duration of an implied w
26. ING SUSPENSION BRAKES Steering Self adjusting rack and pinion Suspension Independent leaf spring with dual hydraulic shocks Brakes Mechanical brake cable system to manually adjusted drum brakes on all four wheels Park brake is automatically released Multi latch ratchet and pawl BODY CHASSIS Frame chassis Twin Beam welded aluminum Side and rear body Aluminum Front body ArmorFlex Front body finish Automotive grade paint with clear coat finish Tires 20 x 10 10 tubeless 6 ply rated load range front and rear DIMENSIONS WEIGHT Overall length Standard configuration 125 5 in 318 7 cm Add for Heavy Duty Bumper 1 8 in 4 5 cm Overall width 51 4 in 130 5 cm with mirrors 62 6 in 159 0 cm Overall height at steering wheel Overall height with canopy Ground clearance Front wheel tread Rear wheel tread CAFE EXPRESS Vehicle Owner s Manual Page 39 Vehicle Specifications SPECIFICATIONS CAFE EXPRESS POWER SOURCE GASOLINE Weight Standard gasoline vehicle with Cafe Express unit dry fuel tank 1147 Ib 520 2 kg Curb weight 1175 Ib 532 9 kg Maximum forward speed 12 to 14 mph 19 to 23 km h 144 x 128 2 x 105 4 cm 28 to 32 psig Front and rear 193 to 221 kPa NOISE AND VIBRATION Drive by noise level to operator 77 2 dBa Test method EN 12053 2001 Uncertainty 2 dBa Vibration at driver s seat Unknown at time of printing Test method EN 13059 2002 Uncertainty 0 23 m s2 Page 40 CAF
27. ION OF THE SPEED GOVERNOR BRAKING SYSTEM STEERING TRANSAXLE OR OTHER OPERATING SYSTEMS OF THE CAR TO CAUSE IT TO PERFORM OUTSIDE CLUB CAR SPECIFICATIONS THE WARRANTY IS LIKEWISE VOID IF THE VEHICLE SHOWS INDICATIONS THAT REASONABLE OR NECESSARY MAINTENANCE AS OUTLINED IN THE OWNER S MANUAL AND MAINTENANCE AND SERVICE MANUAL WAS NOT PERFORMED AT THE TIME AND IN THE MANNER SPECIFIED IN SUCH MANUALS SOLE REMEDY CLUB CAR s liability under this limited warranty or in any action whether based upon warranty contract negligence strict product liability or otherwise shall be the repair or replacement at CLUB CAR s option of the vehicle or component thereof that CLUB CAR deems to be defective Replacement shall mean furnishing during the applicable limited warranty period a new vehicle or factory reconditioned vehicle or component thereof that is identical or reasonably equivalent to the warranted product or component at no cost to the purchaser Repair shall mean remedying a defect in the vehicle or component thereof at no cost to the purchaser during the applicable limited warranty period CLUB CAR reserves the right to test and recharge any component returned for adjustment If CLUB CAR elects to repair the vehicle or component it may provide factory reconditioned parts or components All parts and components replaced under warranty shall become the property of CLUB CAR DISCLAIMER THIS LIMITED WARRANTY IS EXCLUSIVE CLUB CAR MAKES NO OT
28. Line Fuel Line Fittings Clamps Fuel Tank Fuel Cap Vapor Hoses Carbon Canister Carbon Canister Mounting Brackets Air Cleaner Purge Port Connector ODNOaA PWN gt REPLACEMENT PARTS DISTRIBUTION CENTER Replacement parts are provided to the market upon request by the customers Replacement parts distribution center is located at the Service Parts Department Club Car 4125 Washington Road Evans Georgia 30809 U S A 706 863 3000 If you have a question regarding your replacement part you should contact CLUB CAR at 706 863 3000 OBTAINING WARRANTY SERVICE To obtain warranty service take your engine to the nearest authorized CLUB CAR service dealer Bring your sales receipts indicating date of purchase for this engine The service dealer authorized by CLUB CAR will perform the necessary repairs or adjustments within a reasonable amount of time and furnish you with a copy of the repair order All parts and accessories replaced under this warranty become the property of CLUB CAR For owners located more than 100 miles from an authorized service center the following will be provided to those applicable owners excluding the states with high altitude areas e CLUB CAR will either pay for the shipping costs of replacement parts to and from an authorized service center e Or CLUB CAR will provide for a service technician to come to the owner to make the warranty repair Or CLUB CAR will pay for the repair to be made at a local non au
29. Schedule PERIODIC LUBRICATION SCHEDULE PERIODIC LUBRICATION SCHEDULE LUBRICATION REGULAR INTERVAL SERVICE POINTS RECOMMENDED LUBRICANT Brake pedal shaft bearings Dry Moly Lube CC PN 1012151 Brake linkage and pivots Dry Moly Lube CC PN 1012151 Semiannually by owner or trained technician or every 50 Accelerator pivot rod supports and f i Dry Moly Lube CC PN 1012151 hours of operation whichever shifter cable pivots Brake slides Annually by trained technician Transaxle Check fill to plug level only or every 100 hours of operation whichever comes Inspect front wheel bearings Repack O first as necessary First change 100 hours a 40 5 fl oz 1 2 L 10W 30 or additional change every 200 y Change engine oil O 5W 30 grade SE or higher hours of operation or annually j f See also Figure 20 Page 35 whichever comes first Dry Moly Lube CC PN 1012151 67 6 fl oz 2 L SAE 80W 90 API Class GL 5 Chassis Lube EP NLGI Grade 2 comes first QTA ANN y 2823 Figure 15 Lubrication Points Page 30 CAFE EXPRESS Vehicle Owner s Manual Battery BATTERY See General Warnings on page 8 4 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 Tools wires and metal objects can cau
30. a circuit that has the parameters specified in the vehicle owner s manual Number of operational chargers must equal the number of operational vehicles 8 Improper charging of a vehicle due to the use of a battery charger model not approved by Club Car for use with the vehicle 9 Failed semiconductor parts such diodes and fuses that are vulnerable to electrical overloads including lightning beyond the control of CLUB CAR 10 Damaged charger DC cord set with plug which is a wear item and subject to user abuse 11 Use of gasoline containing more than 10 ethanol 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 vehicle or components such as batteries computer controller or electrical device are suitable for use in any application other than in its products As in the use of any vehicle batteries computer controller or electrical device a prudent owner will read and study the owner s manual the operator instructions and the warning labels and will exercise due care in working on or around vehicles batteries or electrical devices Transportation expenses for warranty services are also excluded from this warranty VOIDING OF WARRANTY THIS AND ANY OTHER WARRANTY SHALL BE VOID IF THE VEHICLE OR COMPONENT IS ABUSED OR USED IN AN UNINTENDED MANNER OR SHOWS INDICATIONS THAT IT HAS BEEN ALTERED IN ANY WAY INCLUDING BUT NOT LIMITED TO MODIFICAT
31. able of securing themselves in a vehicle before allowing them to ride in one For night use the vehicle must be equipped with headlights taillights and reflectors e Stop the vehicle before shifting the Forward Reverse handle or switch Failure to do so can result in injury to inattentive passengers and or damage to the vehicle e Do not leave children unattended in vehicle at any time To help avoid being struck do not stand in front of or behind the vehicle e Operate the vehicle from the driver seat only To help prevent falls from the vehicle remain seated in a moving vehicle and hold on to hand holds or handrails at all times Driver should keep both hands on the steering wheel when the vehicle is in motion To help prevent the possibility of serious injury keep entire body inside the vehicle To help prevent overturning the vehicle drive slowly in turns Driving the vehicle over curbs or on steep slopes fairways or extremely uneven terrain could cause vehicle rollover resulting in serious injury or death To help prevent overturning the vehicle drive slowly straight up and down slopes Avoid driving the vehicle on slopes exceeding 20 incline e Avoid stopping a loaded vehicle on a hill If a loaded vehicle must be stopped on a hill avoid sudden starts or rolling backwards and stopping suddenly Failure to heed this warning can result in overturning the vehicle To help avoid possible injury to
32. and the Forward Reverse handle in the FORWARD position as the accelerator pedal is pressed the engine should start and the vehicle should accelerate smoothly to full speed When the pedal is released it should return to the original position and the engine should stop VEHICLE OPERATION STABILITY To maintain proper stability the Cafe Express vehicle must not be driven over curbs or on steep slopes fairways or extremely uneven terrain CAFE EXPRESS Vehicle Owner s Manual Page 19 Vehicle Operation A WARNING Driving the vehicle over curbs or on steep slopes fairways or extremely uneven terrain can cause vehicle rollover resulting in serious injury or death ENGINE SPEED A Club Car vehicle with a Cafe Express refreshment center installed must have a maximum level ground travel speed of 14 mph 23 km h or less This is controlled by the maximum governed engine RPM See Performance Inspection A WARNING e Excessive speed can result in vehicle rollover Engine RPM must be maintained at the specified setting TIRES CAFE EXPRESS SPECIFICATIONS VEHICLE 28 to 32 psig Tire pressure 193 to 221 kPa 4 WARNING All Cafe Express vehicles must be equipped with 20 x 10 10 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 veh
33. ar rubber gloves when handling oil drain plug and oil drain pan 6 Clean the oil drain plug threads with solvent to remove oil and oil residue Make sure that the compression washer remains on the drain plug 7 Use a 14 mm socket or wrench and replace the oil drain plug turning it clockwise and tighten to 18 ft lb 24 4 N m 8 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 The engine requires 40 5 fl oz 1 2 L of oil per change 10W 30 or 5W 30 grade SE or higher is recommended Refer to oil viscosity guidelines for selection of oil grade Figure 20 Replace the dipstick Page 34 CAFE EXPRESS Vehicle Owner s Manual Fueling Instructions Gasoline Vehicle 20 C 10 C 0 C 32 F 50 F 68 F 86 F 104 F 213 Figure 20 Oil Viscosity Chart 9 Connect battery and spark plug wire See Connecting the Battery on page 10 10 With the Forward Reverse handle in the NEUTRAL position and the Maintenance Service switch in the SERVICE position start and run the engine for a few minutes Observe the drain plug from under the vehicle and watch for oil leaks If leaks appear begin with step 1 and repeat the appropriate steps as needed to correct the problem 11 Remove the dip stick and check the engine oil as a final step Replace the dip stick FUELING INSTRUCTIONS GASOLINE VEHICLE See General Warnings on page 8 A DANGER e Turn the key
34. arranty nor exclusions or limitation of incidental or consequential damages 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 HOW TO MAKE A WARRANTY CLAIM To make a warranty claim under this limited warranty you must present the vehicle or defective component with evidence of proof of purchase date and number of amp hours if applicable to an authorized CLUB CAR dealer For warranty related communication contact Warranty Services Club Car 4125 Washington Rd Evans GA 30809 USA 706 863 3000 WARNING Any modification or change to the vehicle that affects the electrical system stability or handling of the vehicle or increases maximum vehicle speed beyond factory specifications can result in serious personal injury or death FEDERAL EMISSIONS COMPONENT DEFECT WARRANTY EMISSIONS COMPONENT DEFECT WARRANTY COVERAGE This emission warranty is applicable in all States except the State of California Club Car LLC CLUB CAR warrant s to the initial retail purchaser and each subsequent owner that this Non road engine engine has been designed built and equipped to conform at the time of initial sale to all applicable regulations of the U S Environmental Protection Agency EPA and that the engine is free of defects in materials and workmanship which would cause this engine to fail to conf
35. auna rannte nenn antenne 38 Vehicle Specifications 2 32 2 ad 39 Wa ante nesepi eek Rules Babies O opta 41 EC Declaration Of Conformity urn el dias 48 CAFE EXPRESS Vehicle Owner s Manual Page 3 Safety Decal Identification SAFETY DECAL IDENTIFICATION The following pages contain safety decal information For detailed information on specific features read the appropriate section in this manual CAFE EXPRESS VEHICLE UNINTENDED MOVEMENT ROLLOVER OR FALLING OUT CAN CAUSE SERIOUS INJURY OR DEATH Vehicle to be operated by licensed and authorized persons only Remain fully seated while moving Use in authorized areas only Do not operate on public roads Hold on and keep entire body inside vehicle while moving One 1 person per bucket seat maximum Never attempt jumps and avoid extreme braking in reverse Two 2 persons per bench seat maximum Do not leave children unattended in vehicle at any time Operate from driver s seat only Children requiring a child safety seat must not ride in vehicle Do not start vehicle until all occupants are fully seated Never operate under the influence of alcohol or drugs 2 Dive Siowly IR tums afd straight up and Gown slopes AAA MA Unintended vehicle movement may cause severe injury or death Before using vehicle read owner s manual and vehicle safety warnings Before leaving vehicle Engage park brake to lock wheels Place vehicle in NEUTRAL Turn key to
36. be equivalent to the parts authorized by CLUB CAR in their performance and durability HOW TO MAKE A CLAIM All repairs qualifying under this limited warranty must be performed by a service dealer authorized by CLUB CAR In the event that any emission related part is found to be defective during the warranty period you shall notify CLUB CAR customer service department at 706 863 3000 and you will be advised of the appropriate warranty service dealer or service providers where the warranty repair can be performed CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board CARB and Club Car LLC CLUB CAR are pleased to explain the emission control system warranty on your 2014 or newer vehicle engine the emission warranty In California new small off road engines SORE must be designed built and equipped to meet the State s stringent anti smog standards CLUB CAR shall warrant the emission control system on the vehicle engine for the periods of time listed below provided there has been no abuse neglect or improper maintenance of your small off road engine CAFE EXPRESS Vehicle Owner s Manual Page 45 Warranties Your emission control system may include parts such as the carburetor or fuel injection system the ignition system the catalytic converter and related hoses belts connectors and other emission assemblies or components Where a warrantab
37. ble problem with the electronic fuel injection EFI system If the oil level is correct and the warning light stays on have a trained technician check the vehicle CAUTION Failure to add oil immediately when the low oil warning light stays on can result in permanent engine damage FUEL GAUGE HOUR METER OPTIONAL If so equipped the fuel gauge hourmeter 5 is located on the instrument panel Figure 6 The fuel gauge allows the operator to monitor the fuel level in the vehicle The hour meter should be used by the trained technician to track vehicle usage and determine when periodic service procedures are required See Periodic Service Schedule on page 28 ELECTRIC BED LIFT OPTIONAL The electric bed lift switch 6 is located on the upper left side of the instrument panel Figure 6 To lift the bed press the side of the switch with the up arrow and press the other side of the switch to lower the bed The bed lift will make a loud clicking sound to signal the bed is in the rest position A WARNING e Keep clear of moving parts when bed is in the raised position and the engine is running Keep hands and fingers clear of crush area between the bed and the seat back support CAUTION e Canopy pins must be removed before lifting the bed 12 VOLT POWER POINT A 12 volt power point is located in the driver s side dash pocket and is rated at 6 5 amps Figure 7 When the key switch is in the ON position the power poi
38. cle press the brake pedal with your right foot Figure 9 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 8 To set the park brake press the brake pedal firmly and tilt the park brake portion of the pedal forward with your foot Figure 10 See following WARNING A 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 78 79 Figure 9 Brake Pedal Figure 10 Park Brake NEUTRAL LOCKOUT SWITCH 81 Figure 11 Neutral Lockout Switch Page 16 CAFE EXPRESS Vehicle Owner s Manual Controls and Indicators For the convenience of the trained technician there is a neutral lockout switch located on the seat support panel under the seat Figure 11 The neutral lockout switch has two positions MAINTENANCE and OPERATE which are clearly marked 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 4 WARNING e With the switch in the MAINTENANCE
39. d normal performance returns After stopping the vehicle firmly set the park brake until it is fully engaged and prevents the vehicle from rolling 4 CAUTION When stopped on a hill use the brake pedal to hold your position Do not use the accelerator pedal to hold position To stop vehicle release the accelerator pedal and press the brake pedal until vehicle comes to a complete stop PARKING AND LEAVING THE VEHICLE 1 After coming to a complete stop engage the park brake until it locks the wheels and prevents the vehicle from rolling 2 Turn the key switch to the OFF position and place the Forward Reverse handle or switch in the NEUTRAL position Remove the key when the vehicle is not in use Page 22 CAFE EXPRESS Vehicle Owner s Manual Loading and Unloading LOADING AND UNLOADING A WARNING Engage park brake to lock wheels before loading the vehicle Do not allow riders on the refreshment center e Do not exceed the rated capacity of the vehicle Rated capacity is for level surfaces only Overloading can affect vehicle handling or cause component failure resulting in loss of control of vehicle and possible serious personal injury e Reduce vehicle load and speed when driving up or down slopes or on uneven terrain e Reduce speed and avoid sudden stops when backing up Failure to do so can cause the vehicle to overturn or flip over backwards e Avoid stopping on a hill when loaded If you must stop
40. d passenger sides of the Cafe Express refreshment center should be used for consumable ice only In order to prevent contamination of consumable ice do not place food in these compartments Consumable ice should not be stored in any other compartment of the Cafe Express refreshment center Page 24 CAFE EXPRESS Vehicle Owner s Manual Towing with the Vehicle Trash Compartment The trash compartment is located in the rear of the base unit The trash bin should be lined with a disposable plastic bag to maintain cleanliness This compartment should not be used for storing or transporting consumable ice drinks or food TOWING WITH THE VEHICLE The Cafe Express vehicle must not be used to tow trailers or other vehicles TRANSPORTING ON A TRAILER A WARNING Do not allow riders in the trailer being towed Avoid sudden starts sudden stops and tight turns when towing e Avoid stopping on a hill when towing If you must stop on a hill avoid sudden starts or rolling backwards and stopping suddenly Failure to heed this warning can cause the vehicle to overturn possibly resulting in serious personal injury For use on public roads the trailer must meet all federal state and local requirements such as taillights brake lights etc e Reduce normal driving speed when transporting a Club Car vehicle on a trailer Do not tow a Club Car vehicle behind a passenger vehicle or truck on a public road unless it is on an approved
41. e in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position Crank the engine until the engine starts Turn the engine off and return the neutral lockout switch to the OPERATE position See following NOTE NOTE Due to the oil added to the engine in preparation for storage engine may smoke excessively for a short time when it is run for the first time after storage 4 Adjust tires to recommended tire pressure See Vehicle Specifications on page 39 5 Perform the Pre Operation and Daily Safety Checklist on page 18 and the Performance Inspection on page 19 CAFE EXPRESS Vehicle Owner s Manual Page 27 Maintenance MAINTENANCE See General Warnings on page 8 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 and the following Periodic Service Schedule and Periodic Lubrication Schedule to keep the vehicle in proper working condition 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 4 WARNING e
42. ed load and optional equipment Maximum Gross Vehicle Weight The maximum gross vehicle weight includes the vehicle weight and the vehicle rated capacity The stated maximum gross vehicle weight must not be exceeded to maintain safe vehicle operation Refer to Figure 14 for the following specifications CAFE EXPRESS Vehicle Owner s Manual Page 23 Refreshment Center E ETS A B Vehicle Weight Maximum Gross Vehicle Weight 2925 Figure 14 Vehicle Load Capacity REFRESHMENT CENTER REFRESHMENT CENTER COMPARTMENTS Cold Storage Compartments The cold storage compartments are designed to carry canned beverages and cooling ice Pre packaged non hazardous foods and snacks can also be served from these compartments We recommend they be kept in plastic containers if placed directly on the ice so that food will remain dry Pre cooling the canned beverages will minimize the amount of ice required to keep the product cool Maintaining ice in the cold storage compartments when they are not in service will help to maintain a colder temperature when the unit is put back into service 4 WARNING e Operate vehicle only with all compartment loads equally distributed Do not use the cold storage compartments to store unprotected food or ice that is intended for human consumption Failure to heed this warning can result in food poisoning Consumable Ice Compartments The consumable ice compartments located in the rear driver an
43. g Never allow a positive wire to touch the vehicle frame engine or other metal component PERIODIC SERVICE SCHEDULE See General Warnings on page 8 A WARNING Service repairs and adjustments must be made per instructions in the maintenance and service manual If any problems are found during scheduled inspection or service do not operate the vehicle until repairs are made Failure to make necessary repairs can result in fire property damage serious personal injury or death NOTE If the vehicle is constantly hauling heavy loads or hauling a trailer these preventive maintenance procedures should be performed more often than recommended in the Periodic Service Schedule Both the Periodic Service Schedule and the Periodic Lubrication Schedule must be followed to keep vehicle in optimum operating condition Page 28 CAFE EXPRESS Vehicle Owner s Manual Periodic Service Schedule PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE k See Pre Operation and Daily Safety Pre Operation and Daily Safety Checklist Checklist on page 18 Daily service by owner Performance Inspection See Performance Inspection on page 19 Tires Check air pressure and adjust if necessary i See Vehicle Specifications on page 39 Check engine oil level change if necessary See Periodic Lubrication Schedule on page 30 Dispose of used oil properly Engine Check engine cooling air intake visually Monthly service by owner or trained
44. icians should service or repair the vehicle Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair The appropriate instructions must be used when performing maintenance service or accessory installation e 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 Do not attempt to charge frozen batteries or batteries with bulged cases Discard the battery Frozen batteries can explode A CAUTION e Batteries in a low state of charge will freeze at low temperatures PREPARING THE GASOLINE VEHICLE FOR EXTENDED STORAGE Unload the vehicle so that tires are supporting only the weight of the vehicle Store vehicle in a cool dry place This will minimize battery self discharge If the battery appears to be weak have it charged by a trained technician Use an automotive type 12 volt battery charger rated at 10 amps or less Seal the fuel tank 3 1 Fill fuel tank and following manufacturer s directions add a commercially available fuel stabilizer such as Sta Bil 3 2 Disconnect fuel vent line from fuel tank vent nipple 3 3 Plug the fuel tank vent nipple so that it is air tight We recommend using a slip on vinyl cap NOTE It is not necessary to drain the fuel line 7 8 9 Disconnect battery and spark p
45. icle on page 9 2 Disconnect the battery cables negative cable first as shown Figure 2 3 Disconnect the spark plug wire from the spark plug CONNECTING THE BATTERY Connect the battery cables positive cable first Tighten battery terminals to 80 in Ib 9 N m Coat terminals with Battery Terminal Protector Spray to minimize corrosion Connect the spark plug wire to the spark plug PW we Figure 2 Battery Cable Removal RECYCLING LEAD ACID BATTERIES A WARNING Lead acid batteries contain lead Pb other metals acids and other compounds If improperly handled they can contaminate both water and soil causing environmental damage and personal injury Lead acid batteries are identified by the symbol shown below and should be properly recycled Figure 3 They cannot be disposed as municipal waste and must be collected separately Responsibility for environmental protection must be shared not only by the manufacturers of the batteries but by people who use the batteries as well Please contact your nearest Club Car dealer or distributor for information on how to properly recycle your batteries Page 10 CAFE EXPRESS Vehicle Owner s Manual General Information 1403 Figure 3 Dispose of Lead acid Batteries Properly INTERNATIONAL SAFETY SYMBOLS ON BATTERIES Anyone using repairing or servicing the vehicle must understand and heed the safety symbols on the vehicle battery or batteries 1 Shield eyes 3 N
46. icle stability e Never install tires that are rated below 6 ply on the vehicle Less than 6 ply rated tires may not have sufficient side wall strength to adequately support the vehicle e Correct tire pressure is essential Low air pressure will reduce vehicle travel speed and result in weakened tire sidewall strength Tires with weakened sidewall strength will not adequately support the vehicle when making sharp turns e Tire pressure must be checked daily and adjusted as required on a regular basis WINDSHIELD The Cafe Express vehicle is often driven in the opposite direction of play This exposes the driver to the hazard of flying golf balls A WARNING A Club Car vehicle with a Cafe Express refreshment center installed must be equipped with the one piece windshield supplied with this kit to reduce the hazard of flying golf balls Page 20 CAFE EXPRESS Vehicle Owner s Manual Driving Instructions DRIVING INSTRUCTIONS A 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 in the vehicle at one time Do not allow riders in the cargo bed e The vehicle is not specially equipped for handicapped persons Be sure all persons can properly operate the vehicle prior to allowing them to drive the vehicle Be sure all passengers are cap
47. inattentive passengers 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 Do not use the vehicle on public roads It is neither designed nor intended for street use and should not be licensed for use on public roads e The vehicle should be driven in only specified areas by trained drivers Do not drive while under the influence of alcohol drugs or medications Use brakes to reduce speed when coasting downhill e Do not drive the vehicle under tree limbs bridges tunnels or other objects that are less than 80 inches 203 cm from the ground No one should drive the vehicle without first being instructed in the proper operation and use of the vehicle s controls An experienced operator should accompany each first time driver on a test drive before allowing them to operate the vehicle alone To ensure safe operation of the vehicle follow exactly and in order all of the following procedures Read and understand all instructions prior to driving the vehicle CAFE EXPRESS Vehicle Owner s Manual Page 21 Driving Instructions STARTING THE VEHICLE Read safety and information decals located on the vehicle Study and understand controls Make sure load is secure Make sure everyone is seated and holding onto hand holds or handrails
48. injury or death Only trained technicians should service or repair the vehicle Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair The appropriate instructions must be used when performing maintenance service or accessory installation To avoid unintentionally starting the vehicle disconnect the battery and spark plug wire See Disconnecting the Battery on page 10 Frame ground Do not allow tools or other metal objects to contact frame when disconnecting battery cables or other electrical wiring Do not allow a positive wire to touch the vehicle frame engine or any other metal component Wear safety glasses or approved eye protection when servicing the vehicle Wear a full face shield and rubber gloves when working on or near batteries Do not wear loose clothing or jewelry such as rings watches chains etc when servicing the vehicle Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring DISABLING THE VEHICLE 1 Engage park brake to lock wheels 2 Turn the key switch OFF and remove the key CAFE EXPRESS Vehicle Owner s Manual Page 9 General Warnings 3 Place the Forward Reverse control in the NEUTRAL position 4 In addition chock the wheels if servicing or repairing the vehicle DISCONNECTING THE BATTERY 1 Disable the vehicle See Disabling the Veh
49. inspect unshrouded area around engine technician exhaust for grass and debris and clean if necessary f Wash engine compartment and underside of General vehicle y vehicle Do not wash engine when hot Door locks Lubricate with a dry lubricant Baite Clean terminals and wash dirt from casing y check electrolyte level Figure 16 Check and adjust if necessary Front wheel alignment and camber See Steering and Front Suspension section in the maintenance and service manual Semiannual service by trained technician Electrical wiring and connections Check for tightness and damage only or every 50 hours of operation whichever comes first Check brake shoes replace if necessary or adjust as required Brake system Check brake cables for damage replace as required Check brake cable equalizer adjustment adjust if necessary Check for leaks around gaskets fill plugs etc Engine Inspect clean and gap spark plug replace if necessary Check air filter element clean or replace if Annual service by trained technician only BR necessary Engine air intake system or every 100 hours of operation whichever Check clamps for tightness check hose for comes first cracks Check for loose hardware and tighten if General vehicle necessary Check safety decals Replace if damaged or Safety decals EN illegible Two ice by trained technici only CAFE EXPRESS Vehicle Owner s Manual Page 29 Periodic Lubrication
50. ioration and items that deteriorate fade or fail due to exposure or ordinary wear and tear The provisions of this limited warranty shall not apply to failure due to the following conditions 1 Abuse such as overcharging undercharging improper fluid levels loose wiring and fasteners or rusted or corroded hardware 2 Use of water in batteries including tap water that contains impurities Distilled water or a properly maintained Club Car approved battery water deionizer and filter system should be used to ensure water quality CAFE EXPRESS Vehicle Owner s Manual Page 41 Warranties 3 Lack of proper maintenance such as preventive maintenance checks proper rotation of vehicles in a fleet application maintaining proper tire pressure and alignment and tightening loose wire connections as outlined in the owner s manual Damages caused by improper installation of the component 5 Neglect breakage freezing fire explosion wreckage melted terminal posts the addition of any chemical or the operation of the battery in an uncharged condition below half charge 1 200 specific gravity the installation of the batteries in reverse or recharging in reverse breakage of containers covers or terminal post or batteries used in applications for which they were not designed 6 A battery damaged by a defective charger or batteries in vehicles that do not receive proper charging 7 A vehicle not having an operational charger on
51. itted are defined in n 113845 If you have any question concerning whether N SERIOUS ILLNESS OR DEATH any particular prep food complies with those standards please con manufacturer or supplier of those foods before conveying them with this vehicle This bin is not intended to store ice for human consumption Do not put unprotected food in this bin CCI 1011962 Remove canopy pins before lifting bed CCI 102160601 X VEHICLE ROLLOVER CAN CAUSE TERM SERIOUS INJURY OR DEATH Riding in cargo bed Operate vehicle only can cause severe injury IL On cart paths or improved surfaces or death A Y With 6 ply 20x10 10 tires Do not ride in cargo bed With 28 to 32 psig 193 to 221 kPa tire pressure checked daily CC1 101553901 With all compartment loads equally distributed A MA Decal Food Safety Warning on each side of 1011962 Dry Snack Compartments refreshment unit 101553901 Decal Bed Loading Warning Cold Storage Compartment CONSUMABLE ICE COMPARTMENT i DEE 102160601 Decal Canopy Pin Caution E Consumable Ice Compartment Decal Consumable Ice on each side of 4 102175901 10 Carafe Compartment refreshment unit Decal Beverage Unit Rollover Warning on each 5 105185902 f 11 Trash Compartment side of refreshment unit Decal Proper Use Notice on each side of SVP203101 p refreshment unit Page 6 CAFE EXPRESS Vehicle Owner s Manual Practice Safety PRACTICE SAFETY N WARNIN
52. le condition exists as defined herein CLUB CAR will repair your vehicle engine at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE This emission control system is warranted for two years from the vehicles date of purchase If any emission related part on your CLUB CAR SORE is defective the part will be repaired or replaced by CLUB CAR OWNER S WARRANTY RESPONSIBILITIES As the vehicle engine owner you are responsible for the performance of the required maintenance listed in your owner s manual CLUB CAR recommends that you retain all receipts covering maintenance on your vehicle engine but CLUB CAR cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the vehicle engine owner you should however be aware that CLUB CAR may deny you warranty coverage if vehicle engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting vehicle engine to a CLUB CAR distribution center as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding your warranty rights and responsibilities you should contact WARRANTY SERVICES CLUB CAR LLC P O Box 204658 Augusta Georgia 30917 4658 U S A 1 706 863 3000 CLUB CAR EXPLANATION OF EMISSION CONTROL WARRANTY
53. lug wire See Disconnecting the Battery on page 10 Batteries should be clean and free of corrosion Wash tops and terminals of batteries with a solution of baking soda and water use 1 cup 237 mL baking soda per 1 gallon 3 8 L of water Rinse solution off batteries Do not allow this solution to enter the batteries Let the terminals dry and then coat them with Battery Terminal Protector Spray To protect the engine remove spark plug and pour 0 5 fl oz 14 2 mL of SAE 10 weight oil into the engine through the spark plug hole Rotate engine crankshaft by hand several times and then install the spark plug and tighten it to 20 ft lb 27 N m Adjust tires to recommended tire pressure See Vehicle Specifications on page 39 Perform semiannual periodic lubrication See Periodic Lubrication Schedule on page 30 Thoroughly clean front body rear body seats cargo bed engine compartment and underside of vehicle 10 Thoroughly clean and wipe dry all storage compartments in the refreshment center Page 26 CAFE EXPRESS Vehicle Owner s Manual Storage 11 Do not engage the park brake Chock the wheels to prevent the vehicle from rolling RETURNING THE STORED GASOLINE VEHICLE TO SERVICE 1 Restore fuel system to operation 1 1 Remove plug from the fuel tank vent Figure 21 Page 36 1 2 Connect vent tube to fuel tank vent 2 Connect battery and spark plug wire See Connecting the Battery on page 10 3 Place the Forward Reverse handl
54. nt provides power to accessories plugged into it The electrical circuit to the power point also powers all additional electrical accessories on the vehicle and is protected by a 10 amp fuse Exceeding a 10 amp total draw on the circuit will result in a blown fuse NOTE The power point is not for continuous use Extended use can cause the vehicle battery to become heavily discharged Do not use the power point for long periods of time when the engine is not running Page 14 CAFE EXPRESS Vehicle Owner s Manual Controls and Indicators 2848 Figure 7 12 Volt Power Point ACCELERATOR PEDAL The accelerator pedal is the pedal on the right with the word GO molded into it Figure 8 When the key switch is in the ON position and the Forward Reverse handle or switch is in either the FORWARD or REVERSE position pressing the accelerator pedal will automatically release the park brake and start the vehicle moving in the direction selected forward or reverse When the accelerator is released power will be cut off and the motor or engine will stop running See following WARNING and CAUTION A WARNING e Moving parts Keep clear of the engine compartment while the engine is running 77 Figure 8 Accelerator and Brake Pedals CAFE EXPRESS Vehicle Owner s Manual Page 15 Controls and Indicators BRAKE PEDAL The brake pedal is the large pedal on the left with the word STOP molded into it Figure 8 To slow or stop the vehi
55. o smoking no open flames no sparks 5 Battery acid hazard 2 Read and follow operating instructions 4 Keep away from children 6 Explosive gas hazard Refer to General Warnings for more information 1642 Figure 4 International Safety Symbols on Batteries GENERAL INFORMATION This manual features the Cafe Express gasoline vehicle which is equipped with a Subaru engine and accompanying powertrain and a pedal start configuration Throughout this manual important features are highlighted We urge the owner operator to read and understand this manual CAFE EXPRESS Vehicle Owner s Manual Page 11 Model Identification MODEL IDENTIFICATION The serial number of each vehicle is printed on a bar code decal mounted below the center dash panel Example CC5819 123456 Figure 5 The two letters 1 at the beginning of the serial number indicate the vehicle model The following four digits 2 indicate the model year and production week during which the vehicle was built The six digits 3 following the hyphen represent the unique sequential number assigned to each vehicle built within a given model year See following NOTE NOTE Have the vehicle serial number available when ordering parts or making inquiries Build Code The build code 4 is a five digit number that appears on the vehicle serial number decal The build code exists to enable the user to identify the correct owner s manual for a vehicle This owner s manual is
56. oblem exists If you have any questions regarding your warranty rights and responsibilities you should contact the CLUB CAR customer service department at 706 863 3000 for the information THINGS YOU SHOULD KNOW ABOUT THE EMISSION CONTROL SYSTEM WARRANTY MAINTENANCE AND REPAIRS You are responsible for the proper maintenance of the engine You should keep all receipts and maintenance records covering the performance of regular maintenance in the event questions arise These receipts and maintenance records should be transferred to each subsequent owner of the engine CLUB CAR reserves the right to deny warranty coverage if the engine has not been properly maintained Warranty claims will not be denied however solely because of the lack of required maintenance or failure to keep maintenance records MAINTENANCE REPLACEMENT OR REPAIR OF EMISSION CONTROL DEVICES AND SYSTEMS MAY BE PERFORMED BY ANY REPAIR ESTABLISHMENT OR INDIVIDUAL HOWEVER WARRANTY REPAIRS MUST BE PERFORMED BY A SERVICE DEALER AUTHORIZED BY CLUB CAR THE USE OF PARTS THAT ARE NOT EQUIVALENT IN PERFORMANCE AND DURABILITY TO AUTHORIZED PARTS MAY IMPAIR THE EFFECTIVENESS OF THE EMISSION CONTROL SYSTEM AND MAY HAVE A BEARING ON THE OUTCOME OF A WARRANTY CLAIM If other than the parts authorized by CLUB CAR are used for maintenance replacements or for the repair of components affecting emission control you should assure yourself that such parts are warranted by their manufacturer to
57. old Air Induction Air filter housing air filter crankcase breather tube Ignition Flywheel magneto ignition pulse generator ignition coil assembly ignition control module spark plug cap spark plug Positive Crankcase Ventilation PCV System PCV valve oil filler cap Evaporative System Fuel Tank Fuel Cap Fuel Lines Fuel Line Fittings Clamps Pressure Relief Valves Purge Valves Vapor Hoses Carbon Canister Canister Mounting Brackets Carbon Canister Purge Port Connector Misc Parts Belts hosing tubing fittings seals gaskets clamps and switches associated with the above systems Emission related parts will vary between vehicles therefore certain vehicles may not include all of the listed parts or may include equivalent parts 3 VOIDING OF WARRANTY 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 4 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 CAFE EXPRESS Vehicle Owner s Manual Page 47 EC Declaration of Conformity EC DECLARATION OF CONFORMITY When properly configured the vehicle complies
58. on and Daily Safety Checklist PROP ROD CAUTION e 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 an automatically engaging prop rod and prop rod track on the driver side of the rear body Figure 13 Remove canopy pins before lifting bed When pulling the bed latch handle and lifting the bed the prop rod will come to rest in one of the notches in the prop rod track 4 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 A WARNING Do not disengage prop rod until all persons are clear of refreshment center bed area Do not drop tilt bed lower gently and keep entire body clear Failure to follow these instructions could result in severe injury Keep hands clear of crush area between bed and seat back support To lower the bed lift the bed so that the prop rod is no longer supported in one of the track notches Push the prop rod toward the front of the vehicle to free it from the track notch and gently lower the bed DO NOT drop the bed Connect the canopy frame to the top of the windshield frame by installing the canopy pins 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
59. orm with EPA regulations during its warranty period For the components listed under PARTS COVERED the service dealer authorized by CLUB CAR will at no cost to you make the necessary diagnosis repair or replacement necessary to ensure that the engine complies with applicable U S EPA regulations EMISSION COMPONENT DEFECT WARRANTY PERIOD The warranty period for this engine begins on the date of sale to the initial purchaser and continues for a period of three years PARTS COVERED Listed below are the parts covered by the Emission Components Defect Warranty Some of the parts listed below may require scheduled maintenance and are warranted up to the first scheduled replacement point for that part EXHAUST EMISSIONS 1 Fuel Metering System 1 1 Carburetor and internal parts and or pressure regulator or fuel injection system 1 2 Air fuel ratio feedback and control system if applicable 1 3 Cold start enrichment system if applicable 2 Air Induction System 2 1 Intake manifold if applicable CAFE EXPRESS Vehicle Owner s Manual Page 43 Warranties 2 2 Air filter 3 Ignition System 3 1 Spark plugs 3 2 Magneto or electronic ignition system 3 3 Spark advance retard system if applicable 4 Catalyst or Thermal Reactor System 4 1 Exhaust Manifold if applicable 5 Miscellaneous Items Used in Above Systems 5 1 Electronic controls if applicable 5 2 Hoses belts connectors and assemblies EVAPORATIVE EMISSIONS Fuel
60. ot disconnect No sparks or open flame near fuel or fuel tank No smoking near fuel or fuel tank pressurized fuel lines No smoking near fuel or fuel tank i Stop engine and allow to cool before refueling Stop engine and allow to cool before refueling ez 0 Rotating parts 105082301 BAU A 105084701 ee manifold amp muffler KEEP CLEAR cci 101960501 Crush area Can cause severe injury Stay clear when closing bed cs Uy Negative frame ground Can cause severe injury Excessive speed Do not contact positive battery post or cable to frame Can cause severe injury or death Disconnect negative battery lead first Do not tamper with engine governor adjustment CC 101915201 2905 Decal Frame Ground Governor Warning on Decal Maintenance Operate Warning on 101915201 4 103205501 vehicle frame near battery Maintenance Operate switch plate under seat i ing on ZO gt r Decal Rotating Parts Hot Manifold W 2 101960501 P022 Rotating Parts Hot Manifold Warning 5 105082301 Decal Gasoline Fuel Warning on fuel tank starter generator 102459301 Decal Bed Latch Warning 6 105084701 Decal Gasoline Fuel Warning at fuel fill CAFE EXPRESS Vehicle Owner s Manual Page 5 Safety Decal Identification CAFE EXPRESS UNIT IMPORTANT NOTICE This vehicle is designed only for the conveyance of certain nonhazardous prepackaged FOOD POISONING CAN CAUSE is In California those foods not perm
61. position and the engine running the vehicle can move suddenly if the Forward Reverse handle is shifted or accidentally bumped To prevent this chock the front and rear wheels and firmly set the park brake before servicing or leaving the vehicle NOTE Be sure to return the switch to the OPERATE position after servicing the vehicle or it will not run with the Forward Reverse handle in either the FORWARD or REVERSE position 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 12 To lift the bed remove canopy pins then pull the latch handle toward the rear of the vehicle and lift the bed To close the bed lower it gently until the bed latch engages DO NOT drop the bed Connect the canopy frame to the top of the windshield frame by installing the canopy pins A WARNING Keep hands and fingers clear of crush area between the bed and the seat back support e Unload the refreshment center before lifting the bed NOTE The vehicle is equipped with an automatically engaging prop rod Figure 13 unless equipped with the electric bed lift option 2827 2828 Figure 12 Bed Latch Figure 13 Prop Rod CAFE EXPRESS Vehicle Owner s Manual Page 17 Pre Operati
62. praying the fabric with water and allowing fabric to dry on the canopy frame ACCESSORIES There is a complete line of accessory equipment available from Club Car and our dealers distributors You can obtain the name and phone number of your closest Club Car contact by visiting our web site at www clubcar com and clicking the Dealer Locator link Care should be taken that these accessories are properly installed by trained technicians and they are used in the manner for which they were designed See following WARNING A WARNING e Custom cab assemblies weatherproof enclosures door kits and tinted windshields will not protect occupants from flying objects e If the vehicle is equipped with an electric powered lift bed remove the bed before servicing the bed lift system Cargo load includes the weight of optional equipment See Vehicle Load Capacities on page 23 CAFE EXPRESS Vehicle Owner s Manual Page 37 Subsequent Owner Registration CAUTION Combined use of electric powered accessories for an extended period of time can discharge the battery even with the engine running Be aware of charging system capacity rating and keep combined accessory use at or below that rating See Vehicle Specifications on page 39 Failure to heed this caution can result in the vehicle shutting off possibly leaving operator and passenger stranded SUBSEQUENT OWNER REGISTRATION In the event a vehicle is bought as a used vehicle we
63. rranty period 3 Any warranted part that is scheduled for replacement as required maintenance in the written instructions supplied is warranted for the period of time before the first scheduled replacement date for that part If the part fails before the first scheduled replacement the part will be repaired or replaced by CLUB CAR according to subsection 4 below Any such part repaired or replaced under warranty will be warranted for the remainder of the period prior to the first scheduled replacement point for the part 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 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 7 CLUB CAR is liable for damages to other engine or equipment components proximately caused by a covered failure under warranty of any warranted part 8 Throughout the engine or equipment warranty period stated above CLUB CAR will maintain a supply of warranted parts sufficient to meet the expected demand for such parts 9 Any replacement part ma
64. se sparks when shorted across a battery Follow all instructions carefully when working with batteries Charge battery in a well ventilated area only e Battery Poison Contains acid Causes serious 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 Call a physician immediately Eyes Flush with water for 15 minutes Call a physician immediately A WARNING Do not jump start a dead battery using another battery and jumper cables The battery in a Club Car gasoline vehicle is a 12 volt low maintenance battery that requires infrequent watering Figure 16 1 Level Indicator 2 Cap 3 Plates Electrolyte level at least 1 2 inch 13 mm above plates or to level indicator 2831 22 Figure 16 Gasoline Vehicle Battery Figure 17 Electrolyte Level for Battery 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 1 gallon 3 8 L of water Rinse solution off the battery Do not allow this solution to get into CAFE EXPRESS Vehicle Owner s Manual Page 31 Engine Oil Gasoline Vehicle the
65. t is evenly distributed in the Cafe Express refreshment center Battery Check electrolyte to ensure that it is at its proper level Figure 17 Check battery posts Wires should be tight and free of corrosion On electric vehicles charge batteries fully before first use of vehicle Page 18 CAFE EXPRESS Vehicle Owner s Manual Vehicle Operation Engine Check for proper engine oil level See Engine Oil Gasoline Vehicle on page 32 Inspect air intake for blockage e Fuel Check fuel level See Fueling Instructions Gasoline Vehicle on page 35 Check fuel tank fuel injector lines cap and pump for fuel leakage on a daily basis Performance Inspection Inspect as instructed See Performance Inspection on page 19 A WARNING Be sure the plastic has been removed from the seat bottom before operating the vehicle Failure to do so can result in a fire property damage personal injury or death 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 Any problems should be corrected by a Club Car distributor dealer or a trained technician Governor Check maximum speed of the vehicle The vehicle should operate at 14 mph 23 km h
66. te of California 0 cccccecceceeeeceeeee ce eee cece cece eeeee ce eeceaeeeeaeeeeaaeeeeaeeeseaeeeeaaeeeeaeeesseeeesseeeeaeeeesaeeeeas 8 Safety Details A A ee ee 8 General WamingS totali iii 8 General IMO ANON namens al a dl a 11 Model Identification xiii dada dana dida 12 CONOS and MAC S a O a ada 12 Pre Operation and Daily Safety CheckliSt ooooooooccconnociccconoccccnccnncccnnnonononnncnonannnnnnnnnnnnnnnnnannn cnn naa nan nnnnananr nn nadaan annann 18 Vehicle Operation ii nal ie io a ad 19 Driving InstrUCtIONS uscar dd dd AA LA a pd ad 21 Loading and Unloading 2 3 ico 23 Vehicle oad CapacitieSsrcicsccteitic a a ina maaan 23 Refreshment Center un en Ae eee Seg eee eee ee eaten ene eee 24 Towing withthe Veneheiton ea O A aA ode 25 Transporting ona Tralo apaa T AA na 25 EE EE A E T EEE A AEE A OE A LAA AONE A A E A E AEE A a etd IA EA OE S AE 25 Maintenance eiiiai a ia AUL a NADAN 28 Periodic Service Schedule eanas akene A Ne aa a a 28 Ponodie Lubrication Schedule s is ke lt ida 30 Bae eina E E A AAT T A A A 31 Engine Qil Gasoline Vehicle ci A E 32 Fueling Instructions Gasoline Vehicle uuunnnssessennsnnennnnnnnnnnnnnnnnnnnnnnnen nn nnnnennnnnnennnnnnnennnnnnennnnnnnen nenn 35 Cleaning the Vehicle sarre aiaeei iaiia a Haar Hess Hass Hl nase need nee era nee nee 36 ACCESS MES ricotta liliana ddkanacdy sade needs abrio 37 Subsequent Owner Registration 24444242402 nenn een tan s
67. thorized service center WHAT IS NOT COVERED e Conditions resulting from tampering misuse improper adjustment unless they were made by the service dealer authorized by CLUB CAR during a warranty repair alteration accident failure to use the recommended fuel and oil or not performing required maintenance services The replacement parts used for required maintenance services Consequential damages such as loss of time inconvenience loss of use of the engine or equipment etc Page 44 CAFE EXPRESS Vehicle Owner s Manual Warranties e Diagnosis and inspection charges that do not result in warranty eligible service being performed Any non authorized replacement part or malfunction of authorized parts due to use of non authorized parts OWNER S WARRANTY RESPONSIBILITIES As the engine owner you are responsible for the performance of the required maintenance listed in your owner s manual CLUB CAR recommends that you retain all receipts covering maintenance on your engine but CLUB CAR cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the engine owner you should however be aware that CLUB CAR may deny warranty coverage if your engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your engine to the nearest service dealer authorized by CLUB CAR when a pr
68. trailer e The vehicle to be transported should be tied securely to the trailer with the Forward Reverse handle or switch in the NEUTRAL position the key switch in the OFF position and the park brake engaged to lock wheels Because of the added length of the trailer use caution when making turns e Remove the vehicle windshield and canopy and secure the seat bottom before transporting on a trailer e When trailering the vehicle make sure the removable front body is correctly installed to prevent separation from the vehicle during transport Remove any loose items prior to transporting on a trailer Stay clear from the area between the tow vehicle and the towed vehicle or trailer If the vehicle or vehicles must be transported over long distances or on public highways they should be transported on an approved trailer that has an approved load rating in excess of the weight of the vehicles being transported STORAGE See General Warnings on page 8 CAFE EXPRESS Vehicle Owner s Manual Page 25 Storage A 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 Store fuel in an approved fuel container only Store in a well ventilated area away from sparks open flames heaters or heat sources e Keep fuel out of the reach of children Do not siphon fuel from the vehicle A WARNING e Only trained techn
69. valid for the build code range indicated on the back cover of this owner s manual wer eo iq a SERIAL NUMBER CC5819 123456 ASSEMBLED IN USA BC54679 2843 Figure 5 Serial Number Decal CONTROLS AND INDICATORS See General Warnings on page 8 A WARNING Before allowing anyone to drive the vehicle make sure the driver is familiar with all controls and operating procedures Do not tamper with the governor Doing so will void the warranty as well as damage the engine and other components and can result in property damage personal injury or death due to unsafe speeds KEY SWITCH The key switch 1 is mounted on the dash to the right of the steering column Figure 6 Each vehicle is equipped with a two position key switch Gasoline vehicles equipped with a two position key switch are referred to as pedal start Page 12 CAFE EXPRESS Vehicle Owner s Manual Controls and Indicators A WARNING Moving parts Keep clear of the engine compartment while the engine is running NOTE When the key is turned to the OFF position the main vehicle systems are disabled The key switch may be used as an emergency shut off 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 at the bottom center of the instrument panel Figure 6 The handle has three distinct positions F FORWARD N
70. y If you rent or loan your vehicle to others we recommend that you ask them to read this manual before they operate the vehicle Club Car products are backed by a customer support system designed to offer you fast courteous service In the event your Club Car vehicle needs repairs or service please contact your local authorized Club Car dealer or distributor who will be able to provide technical advice perform warranty work and sell parts and service manuals For the name and address of the authorized Club Car dealer or distributor nearest you logon to our web site at ClubCar com or call 1 800 ClubCar 258 2227 If you would prefer to write to us direct your letter to Club Car Attention Marketing Services P O Box 204658 Augusta Georgia 30917 4658 USA We hope you will consider this owner s manual a permanent part of your Club Car vehicle If you sell the vehicle please include the manual so that the next owner will have the important operating safety and maintenance information it contains MAINTENANCE ITEMS Battery Terminal Protector Spray Engine Air Filter 404 cc CC PN 1014305 CC PN 102558201 Chassis Lube Spark Plug O H C 404 cc EP NLGI Grade 2 commercially available CC PN 105017801 Dry Moly Lube CC PN 1012151 Page 2 CAFE EXPRESS Vehicle Owner s Manual TABLE OF CONTENTS safety Decal ld erititication 2 icy ct 3222 A ae HE ken a A E 4 Practice MOYA E east ae dre ae eee ees 7 Proposition 65 Sta
71. y be used in the performance of any warranty maintenance or repairs and must be provided without charge to the owner Such use will not reduce the warranty obligations of CLUB CAR Page 46 CAFE EXPRESS Vehicle Owner s Manual Warranties 10 Add on or modified parts that are not exempted by the Air Resources Board may not be used The use of any non exempted add on or modified parts by the ultimate purchaser will be grounds for disallowing a warranty claims CLUB CAR will not be liable to warrant failures of warranted parts caused by the use of a non exempted add on or modified part CLUB CAR its authorized dealers or a service agency approved by CLUB CAR ITEMS COVERED BY THIS WARRANTY The repair or replacement of any warranted part otherwise eligible for warranty coverage may be excluded from such warranty coverage if CLUB CAR demonstrates that the engine or equipment has been abused neglected or improperly maintained and that such abuse neglect or improper maintenance was the direct cause of the need for repair or replacement of the part That notwithstanding any adjustment of a component that has a factory installed and properly operating adjustment limiting device is still eligible for warranty coverage The following emission warranty parts list are covered SYSTEMS COVERED PARTS DESCRIPTION Fuel Metering Carburetor assembly fuel injection pump fuel injection nozzle fuel regulator Exhaust Catalytic Converter Exhaust Manif

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