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2013 YDRE Electric Car Owners Manual
Contents
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2. SAFETY CONSIDERATIONS SAFETY PRECAUTIONS DURING MAINTENANCE When performing maintenance follow all safety instructions contained in the manufacturer s operation and service manuals as well as the following safety procedures e Properly immobilize golf car before beginning any maintenance to avoid any unexpected vehicle movement e Properly block chassis before working underneath golf car to avoid any unexpected vehicle movement e When working on the fuel system or the battery do not smoke or allow any sparks or open flames near the vehicle to avoid any fires or explosions e Before working on an electric golf car disable the car s electrical System in accordance with the manufacturer s instructions to avoid electrical shock or damage to the electrical system e Use only properly insulated tools when working on electrically powered golf cars or around batteries to avoid electrical shock or damage to the electrical system e Maintain all safety devices including brakes steering mechanisms warning devices and governors in a safe operating condition Do not modify these safety devices as supplied by the manufacturer e After each maintenance or repair the car must be driven by a qualified trained and authorized person in an area free of pedestrian traffic to ensure proper operation and adjustment 4 8 e Record all maintenance performed in a maintenance record log by date name o
3. Authorized Dealer that the Trojan batteries charged with a YAMAHA supplied battery charger will be free from defects in materials and workmanship and will provide 36 hole performance for a period of four years or 1 000 rounds from the date of purchase whichever event occurs first subject to the terms and conditions contained herein This limited warranty covers defects in materials and workmanship only for a period of four years or 1 000 rounds as applicable from date of purchase whichever event occurs first The terms of this FOUR YEAR LIMITED WARRANTY shall be to furnish one or more replacement batteries within the four year period or before 20 000 amp hours are discharged whichever event occurs first as determined by YGC using the information recorded and stored in the Genius controller This warranty only applies to factory installed Trojan battery sets charged with a Yamaha supplied battery charger 71 000 rounds means 20 000 amp hours discharged as recorded in the Genius controller The customer must perform or have a contracted Yamaha Dealer perform all periodic maintenance and discharge testing as specified in the Yamaha Service Manual Maintenance Schedule No labor or transportation expenses are included in this limited warranty Maintenance records must be kept Replacement batteries may be of a different brand or capacity but are warranted to provide 36 hole performance for the remai
4. Charging Light blinks or continually illuminates 7 The charger turns off automatically when the batteries reach full charge 8 6 MAINTENANCE BATTERY INSTALLATION AND WIRE LEAD CONNECTION TO RELAY TO MOTOR CONTROL UNIT ASSY uU RECEPTACLE FORWARD Y 672h 8 After the charger has turned off disconnect the DC output plug from the golf car receptacle by grasping the plug body and pulling the plug straight out of the receptacle Battery Installation WARNING When working with batteries do not put wrenches or other metal objects across the battery terminals An arc can occur causing an explosion or fire at the battery Death or serious personal injury can result from failing to comply with the safety and warning instructions affixed to the golf car or utility vehicle 1 Install the battery holddown plates and torque to 7 9 Nm 0 7 0 9 m kg 62 80 in Ib as shown Forward Battery O Battery holddown plate 2 Connect the wire leads and torque to 9 10 Nm 0 9 1 0 m kg 80 89 in Ib as shown WARNING When installing batteries e Carefully place battery cables and hold downs making sure that cables do not lay across vent caps e Always remove the negative cable to the motor controller first and install it last A spark can occur causing an explosion or fire at the battery Death or serious personal injury can result
5. circuit rating of less than 15 amps or not enough circuits for the number of cars In fleet applications less than one battery charger per vehicle For example using only 10 battery chargers to charge a 15 car fleet The use of any system that does not allow the battery chargers to shut off automatically For example timer systems that are designed to switch battery charger AC power on and off during peak demand hours THIS BATTERY IS INTENDED TO BE USED BY PERSONS WITH TRAINING AND EXPERIENCE WITH BATTERIES AND ONLY IN YAMAHA ELECTRIC VEHICLES ANY OTHER USE RENDERS THE LIMITED WARRANTIES EXPRESSED HEREIN AND ALL IMPLIED WARRANTIES NULL AND VOID AND SAME ARE HEREBY EXCLUDED ALSO EXCLUDED FROM THIS LIMITED WARRANTY ARE ANY AND ALL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF USE OR REVENUE LOSS OF TIME INCONVENIENCE OR ANY OTHER ECONOMIC LOSS Some states do not allow limitation on the duration of an implied warranty exclusions or limitations of incidental or consequential damages Therefore the above limitations or exclusions may not apply to you WARRANTY LIMITATIONS Yamaha Golf Car Company s and Trojan Battery Company s limit of liability shall be to replace a defective battery Replacement shall mean furnishing a new battery or used battery with sufficient life to complete the remainder of the warranty term which is identical or reasonably equivalent to the warranted product at no cost
6. OJ pel u O s M NO H30 uazzng MSA Bao 5 E MS 13097 qasn LON H3AlOSNVHL AH AuaLiva z MS 3994018 E amal ASH Auatival 1 IMOL 34909 40109 NE WNOIDGHI AWO sum 229 9 J9nv9 5 01 6 NO HOLOaNNOD 390VS WNOILdO w9 1 11 COYAMAHA Printed in U S A YAMAHA GOLF CAR 2012 KCC 1000 HWY 34 East Newnan GA 30265 770 254 4000
7. PAINT CODES x Nm Glacier 918519 Emerald 48748 Garnet 701739 Tanzanite 917834 Onyx Metallic 918520 Anthracite Metallic 918522 Sandstone Metallic 918523 10 1 x SPECIFICATIONS BATTERIES Trojan Golf Car T 875 6x8 volt RC minimum 117 min CHASSIS Steering system Type Rack and Pinion Steering angle L H 1 85 turn Steering angle R H 1 85 turn Brakes Brake system Mechanical Type of brake Maintenance Free internal transaxle disc brake Brake pedal freeplay linkage adjustment 45 50 mm 1 77 1 96 in Brake cable end play 0 1 0 5 mm 0 004 0 02 in Parking brake Type Foot type parking brake with automatic release Release timing With pedal segment in second notch Bolt heads round parallel to arm 0 0 0 3 mm 0 000 0 001 in Wheel Tire size Front 18 x 8 50 8 00 4 PR Rear 18 x 8 50 8 00 4 PR Rim size 7 00 1 8 00 138 kPa 1 4 kgf cm 20 psi TRANSMISSION Differential reduction gear Differential type Bevel gear Lubricant capacity Yamalube Friction Modified Shaft Drive Gear Oil 1350 mL 1 45 quarts total Alternative lubricant is mixture of 1280 mL 1 35 quarts 80W90 Gear Oil and 70 mL 0 10 quarts API G15 Limited Slip Additive 10 2 YDRE WIRING DIAGRAM DOt6 A 3AI3O3U H39HVHO
8. accelerator Pedal and press the brake pedal lever travel at speeds too fast for the terrain visibility conditions or your experience Drive with extra caution in congested creas when operating in reverse and when driving on vel rough or loose surfaces Come to a complete stop before reversing direction Press the parking broke pedal until it locks and turn the main switch to OFF before leaving the vehicle Read the Owner s Operator s Manual for more information ATTENTION m This vehicle was not manufactured for use on public streets and does not comply with federal motor vehicle safely standards applicable to passenger cars YAMAHA 00 7762 00 Y 500c parking broke 2 1 JW9 Lu m lt l lt 01 8628 6 e Spuooes s ep MOL uonisod sady e euue juepued el 1e 10 eun e juenbunouueJ ue ep e VHVWVA ureBe Bulyoums spuooes GL MOL OF NOH YMS e 49 ueuw pue e u uA uu
9. from failing to comply with the safety and warning instructions affixed to the golf car or utility vehicle MAINTENANCE Fuse Type 3 Amp Blade Style JW9 NOTICE Do not overtighten the battery holddown nuts Excessive force will damage the battery casing Fuse Replacement 4 WARNING Be sure to use the specified fuse Using a wrong fuse can cause electrical system damage and create a fire hazard Death or serious personal injury can result from failing to comply with the safety and warning instructions affixed to the golf car or utility vehicle NOTICE When replacing a fuse be sure the main switch is turned off to prevent accidental short circuiting and electrical system damage 1 Locate the in line fuse holder on the main wire harness adjacent to the tow switch 2 Pull fuse holder cover off 3 Pull fuse out inspect and replace if necessary Fuse holder Fuse MAINTENANCE Y 1994 Transaxle Oil To check transaxle oil level 1 Place the golf car on a flat level surface 2 Remove seven plastic rivets 1 and two bolts 5 and remove the bag holder insert 3 3 Place an oil pan under the transaxle case 4 Clean area around servicing plug 4 5 Using an 8 mm hex wrench remove transaxle oil servicing plug located on the rear of the transaxle case 6 Transaxle oil should be at
10. ls s e enod HOLIMS MOL 0 peaj Aew os op einjre 4 01 Humo JenbjouJ81 ep MOL uonisod e in ldnuu lui uotiisod MOL 9U 01 U9IIMS AON NOILVOISILON 39LLON e o Liz 15 PAP 4 440 Jouooje Jo eui Jepun oq sn ueuM pue AAO 0 YOUMS WNL Buried jas s dols umop pue 5 eAug VHVINVA ui MOS SAUA uonouu ui pjoy pue paeas pejees sjuednooo Inun 1463s oq yeas uey oq epis seoJje u Ajuo pue pezuoujne u uA Ajuo eyeuedo uoneJedo uo pe1e2o jeqe eu SNOILONYLSNI 3S3H L MOTTO OL SYHNTIVA 110599 NYO TVNOSH3d YO Hivaad ONINHVM WV 2 2 IMPORTANT LABELS 1209 L A XX 9EZHA XXL XXX LiVg ON LHDT3M MA XX d3M0d XVW 1300W HDI3M AMALIE XVW ZW VOVS L 002 SDnaoud q3u3MOd YOLOW VHVWVA XX0Z NOLDfIS1
11. pedal several times to make sure the brakes are functioning properly 4 WARNING Consult your Yamaha dealer before using your golf car if you suspect brake problems Death or serious personal injury can result from failing to comply with the safety and warning instructions affixed to the golf car or utility vehicle m 8 10 MAINTENANCE Y 62b 8 11 Brake Pedal Free Play Adjustment NOTICE Before adjusting brake pedal free play pump the brake pedal several times to self adjust the brakes To adjust the brake pedal free play 1 Remove the floor mat and service lid from the floor of the golf car 2 Check the brake pedal free play by pressing against the pedal with two fingers using light force and measuring the distance the pedal travels before resistance is felt Brake pedal free play 8 45 50 mm 1 77 1 96 in 3 If the free play distance needs adjusting loosen the lock nut A under rubber bushing and turn the adjusting nut B in or out until free play specification is met Then tighten the lock nut in place NOTICE Do not over tighten the brake cables Over tightening will increase brake wear and affect overall performance of car Premature brake wear can result JW9 STORAGE Perform the following preparations 2 Have the batteries recharged when storing your golf car for every 60 90 days to keep them extend
12. AFETY Practice the following to help ensure the safety of golf car operators e Preventative Maintenance Perform all scheduled maintenance in accordance with manufacturer s recommendations to provide the golfing patron with a safe properly operating golf car e Personnel Allow only qualified trained and authorized personnel to inspect adjust and maintain golf cars JW9 e Parts and Materials Use only replacement parts and materials recommended by the manufacturer e Ventilation Properly ventilate all maintenance and storage areas in accordance with applicable fire codes and ordinances to avoid fire hazards Ventilation is required to remove flammable vapors and fumes from gasoline powered car storage areas Ventilation is also required to remove hydrogen gas from the car storage areas during the battery charging process For electric powered golf cars the amount of hydrogen gas emitted during charging depends on a number of factors such as the condition of the batteries the output rate of the battery charger and the amount of time the batteries are on charge Because of the highly volatile nature of hydrogen gas and its propensity to rise and accumulate at the ceiling in pockets a minimum of 5 air changes per hour is recommended Consult applicable fire and safety codes for the specific ventilation levels requirement as well as requirements for the use of explosion proof electrical apparatus 4 2
13. EAN AND LUBRICATE L LUBRICATE 40 rounds 250 rounds 500 rounds 1000 rounds 2000 rounds Daily 20 hours 125 hrs 250 hrs 500 hrs 1000 hrs Remarks Pre 100 miles 600 mls 1200 mls 2500 mis 5000 mls Page Opera 160 kms 1000 kms 2000 kms 4000 kms 8000 kms tion Every Every 6 Every Every 2 Every 4 Month months Year years years EVERY Perform a discharge test 5 YEAR Apply Terminal protectant s s s Check rear axle bearing play cs cs cs for roughness or freeplay Check steering knuckle bushing freeplay Adjust CA CA CA wheel alignment Check wheel nut tightness front cs cs cs wheel bearing play Check transaxle oil level and cs cs cs 8 9 inspect for leakage Check pedal stop operation and adjust if necessary li EVERY 2 YEARS Replace transaxle oil R EVERY 4 Inspect internal wet brake and YEARS replace pads if necessary Items without page number reference should be serviced by a Yamaha dealer or other qualified mechanic This manual does not contain these procedures They are contained in the Service Manual JW9 8 2 MAINTENANCE Battery Care Battery electrolyte is poisonous and dangerous causing severe burns etc It contains sulfuric acid Avoid contact with skin eyes or clothing Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil C
14. SNO 30 JW9 2 3 IMPORTANT LABELS GOLF CAR SERIAL NUMBER The golf car serial number 1 is identified in the location shown TIP The first three digits of the serial number are for model identification the remaining digits are the unit production number Keep a record of these numbers for reference when ordering parts from a Yamaha Y 1539B Golf Car Company dealer 1 2 8 8 z J Wg 2 4 OPERATOR SAFETY Yamaha golf cars are designed to be simple to operate However be sure to observe the following to reduce the risk of serious injury or death due to loss of control and other hazards BEFORE OPERATING THE GOLF CAR e Read this Owner s Operator s manual and all safety and instruction labels on the golf car before operating e Perform the pre operation checks found in Section 6 of this manual e Only authorized people should drive the golf car from the driver s side only and only in designated areas e Do not allow more than two occupants per seat This golf car is restricted to two occupants unless equipped with a rear seat e Do not operate the golf car while under the influence of alcohol or drugs their effect on vision and judgment make operating a golf car dangerous e Do not operate the golf car on public streets roads or highways unless allowed by law or local regulating author
15. YAMAHA OWNER S OPERATOR S MANUAL READ THIS MANUAL CAREFULLY It contains important safety information YDRE 48 VOLT GOLF CAR LIT 19626 21 13 JW9 F8199 21 JW9 INTRODUCTION Congratulations on your purchase of a Yamaha golf car This manual contains information you will need for proper operation maintenance and care of your golf car A thorough understanding of these simple instructions will help you to obtain maximum enjoyment from your new Yamaha If you have any questions about the operation or maintenance of your golf car please consult a Yamaha dealer YAMAHA GOLF CAR COMPANY YDRE OWNER S OPERATOR S MANUAL 2012 by Yamaha Golf Car Company 3rd Edition rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Golf Car Company is expressly prohibited Printed in U S A LIT 19626 21 13 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations AN This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death 4 WARNING A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury NOTICE A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property TIP ATIP pr
16. YDRE and the engine clutch system except drive belt and transaxle on the YDRA Year 2 Year 3 Year 4 SPECIFIC EXCLUSIONS Specific exclusions from this warranty shall include the following Electric car batteries which are covered under a separate warranty Any parts replaced due to normal wear or routine maintenance including oil and air filter elements tire wear spark plugs starter and clutch drive belts 1 1 Anycharges incurred in transporting golf car or charger to and from an authorized Yamaha golf car dealer for service or in performing field service are also excluded from this warranty Gasoline powered golf car starting batteries on vehicles equipped with a golf course GPS device or any other device with a parasitic current draw unless the vehicle is equipped from the factory with an optional deep cycle starting battery THE CUSTOMER S RESPONSIBILITY under this warranty shall be to 1 Operate and maintain the golf car and charger as specified in the appropriate Owner s Operator s Manual 2 Give notice to an authorized Yamaha golf car dealer of any and all apparent defects within ten 10 days after discovery and make the vehicle or charger available at that time for inspection and repairs by the dealer s authorized representative WARRANTY TRANSFER Any transfer of warranty must take place within the first three years of the original in service date of the vehicle The vehicle mu
17. all physician immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Six 8 volt deep cycle batteries provide power for your electric golf car and must be properly maintained and recharged for maximum performance and service life To maintain your batteries 1 Clean the tops of the batteries with a solution of baking soda and water as necessary to remove corrosion NOTICE Do not allow cleaning solution to enter battery cells Serious battery damage can result 2 Check the fluid level before and after charging MAINTENANCE Fill Well Electrolyte 1 8 Below Bottom of Fill Well Max Level charged battery e Max Level WM WN WN JW9 e Before charging only add distilled water if fluid is below the top of the plates and then add just enough to cover plates and look inside the fill wells Add distilled water until the electrolyte level is 3 mm 1 8 below the bottom of the fill well A piece of rubber can be used safely as a dipstick to help determine this level Clean replace and tighten all vent caps NOTICE Normal tap water contains minerals which are harmful to a battery therefore refill only with distil
18. ce has shown that golf cars are safe when operated in accordance with the safety warnings affixed to every golf car This safe operation is enhanced when golf cars are used according to the safety rules and practices established to meet the terrain and conditions of the course they are used on The information contained here is intended for golf course personnel responsible for golf car safety If you are responsible for the operation and maintenance of this golf car we encourage you to implement this golf car safety program DRIVER QUALIFICATIONS Allow only authorized people to operate golf cars It is recommended that only people who possess a valid motor vehicle driver s license be allowed to operate golf cars Place operation and safety instructions recommended by the golf car manufacturer along with the golf course safety rules in a conspicuous place near the golf car rental area or golf car pick up area It is also recommended that the following warning be posted in a conspicuous location 4 1 WARNING Do not operate golf cars when under the influence of alcohol or drugs Death or serious personal injury can result from failing to comply with the safety and warning instructions affixed to the golf car or utility vehicle GOLF COURSE SAFETY SURVEY Perform safety surveys regularly to identify hazardous areas where golf cars should not be operated GOLF COURSE HAZARD PREVENTION The following golf co
19. ch controls the following items OFF All electrical control circuits are switched off controller remains energized The golf car cannot be operated The key can be removed only in this position ON Electrical circuits are switched on The golf car can be driven CONTROLS OFF Y o REV FWD 904 20 21 JW9 DRIVE SELECT SWITCH The drive select switch is used to shift the golf car into forward or reverse After coming to a complete stop move the lever to the desired position Switch Position Car Movement FWD FORWARD REV REVERSE TIP The reverse alarm will sound when the drive select switch is turned to REV ACCELERATOR PEDAL The accelerator pedal controls the golf car s speed Depress pedal Increase Release pedal Decrease Accelerator pedal BRAKE PEDAL Press down on the brake pedal to stop the golf car Brake pedal CONTROLS Y 22a 5 4 PARKING BRAKE PEDAL Press down on the parking brake pedal whenever parking the golf car Parking brake pedal TIP Release the parking brake by depressing the accelerator pedal 4 WARNING The parking brake will automatically release when the accelerator pedal is depressed If the main switch is in the ON position depressing the accelerator may suddenly cause the golf car to move Death or serious per
20. ds 1000 rounds 2000 rounds Daily 20 hours 125 hrs 250 hrs 500 hrs 1000 hrs Remarks Pre 100 miles 600 mis 1200 mis 2500 mis 5000 mls Page Opera 160 kms 1000 kms 2000 kms 4000 kms 8000 kms tion Every Every 6 Every Every 2 Every 4 Month months Year years years PRE OP E Charge s s s s s Clean battery tops check for 6 2 tightness of hold down screws and s s s s s s 8 3 terminals Check brake pedal freeplay and 6 4 adjust if necessary cs 10 Check steering operation cs cs cs cs cs cs Check tire pressure tread depth cs 6 2 tire surface for damage Check body and chassis for damage cs cs cs cs cs cs 6 4 Check tightness of all bolts nuts screws and rivets cs es es cS cs x Check reverse alarm operation cs cs cs cs cs cs 6 3 EVERY Check electrolyte level cs cs cs cs cs 8 3 8 4 MONTH Check for loose or broken cs cs cs cs cs connections Clean Lube pedal control area CL mE EVERY 6 Check all wire insulation for cracks MONTHS and or worn spots cs cs cs cs 5 Check shock absorbers for oil leak eck shock absorbers for oil leaks cs cs cs cs Items without a page number reference should be serviced by a Yamaha dealer or other qualified mechanic This manual does not contain these procedures They are contained in the Service Manual 8 1 JW9 MAINTENANCE CS CHECK ADJUST R REPLACE S SERVICE CL CL
21. dy the charger owner s manual the vehicle owner s manual the operator s instructions and the battery warning labels and will exercise due care in working on or around batteries THE PROVISIONS OF THIS LIMITED WARRANTY SHALL NOT APPLY IF BATTERIES ARE SUBJECTED TO ANY OF THE FOLLOWING CONDITIONS Abuse or neglect such as improper fluid levels loose wiring rusted or corroded hardware JW9 Lack of proper maintenance as outlined in the electric vehicle Owner s Operator s Manual For example lack of regular battery watering or adding water to the battery before charging Damage caused by improper installation of the battery Neglect breakage freezing fire explosion wreckage the addition of any chemical or the operation of the battery in an uncharged condition below half charge 1 200 specific gravity Battery charged by systems other than the original equipment type battery charger fleet golf cars the use of any non YAMAHA supplied electrical devices that consume more than one amp hour per round or two amp hours per day of battery energy Examples of these devices include but are not limited to heating or cooling systems GPS global position system devices information gathering devices lights radios or stereos or yardage measuring devices Less than one charger per car or inadequate facility electrical power to power all chargers Examples include more than one charger on a single circuit
22. ed periods of time fully charged The batteries must be kept fully charged to avoid TIP damage Turn main switch key to OFF position lift seat and switch tow NOTICE switch in the TOW position Remove key from main key switch and store key in a safe place Do not allow cleaning solution to enter battery cells Serious battery damage can result CHASSIS 3 Clean the top of the batteries PREPARATION with a solution of baking soda and water as necessary to 1 Verify the tire pressure is set to remove corrosion 138 kPa 1 4 kgf cm 20 psi 2 Clean exterior of the golf car and apply a rust inhibitor 3 Cover the golf car with a breathable cover and store it in a dry well ventilated area BATTERY PREPARATION 1 Remove the batteries from the golf car and store them in a cool dry place that stays between 0 32 F and 30 90 F JW9 9 1 SPECIFICATIONS GENERAL SPECIFICATIONS Dimensions Overall length 2395 mm 893 4 in Overall width 1200 mm 47 2 in Overall height steering height 1190 mm 46 9 in Height of floor 310 mm 12 2 in Wheelbase 1640 mm 64 6 in Tread Front 870 mm 34 3 in Rear 980 mm 38 6 in Min ground clearance 110 mm 4 3 in Weight Dry weight with suntop without battery 270 kg 595 Ib Performance Factory speed setting 19 km h 12 mph Maximum speed 24 km h 15 mph Turning radius 2 8 m 9 2 ft Seating capacity 2 persons per seat
23. es are held securely in place to prevent them from being damaged from vibration or jarring Also check that no battery caps are missing to prevent battery acid from spilling from the batteries Check the battery terminals for corrosion 4 WARNING Battery electrolyte is poisonous and dangerous causing severe burns etc It contains sulfuric acid Avoid contact with skin eyes or clothing Ventilate when charging or using in enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN TIRE CONDITION Tire Air Pressure Check the tire air pressure before operating the golf car Tire pressure 138 kPa 1 4 kgf cm 20 psi Tire Wear Limit Check the tire surface for damage cracks or embedded objects When tire tread wears down to 1 mm 0 04 in replace the tire Wear limit PRE OPERATION CHECKS Y 932g OFF REV FWD 4 Y 911b Y 20A STEERING SYSTEM Check the steering system for excessive free play by e moving the steering wheel up and down and back and forth e turning the steering wheel slightly to the right and left If you feel excessive free play or hear rattling sounds which may indicate loose steering components consult a Yamaha dealer REVERSE ALARM Check the reverse alarm by moving the drive select switch to REV for reverse The alarm should sound PEDAL OPERATION C
24. esult from failing to comply with the safety and warning instructions affixed to the golf car or utility vehicle 3 Check that your path is clear in the direction you plan to go and slowly depress the accelerator pedal The golf car will start to move Accelerator pedal TIP The parking brake automatically releases when the accelerator pedal is depressed JW9 OPERATION STOPPING To stop the golf car gradually press down on the brake pedal Brake pedal NOTICE Do not hold the golf car on an incline with the accelerator use the brake Transmission damage can result Y 65c When the car has come to a stop apply the parking brake pedal and turn the main switch to OFF Parking brake pedal JW9 7 2 MAINTENANCE PERIODIC MAINTENANCE CHARTS Regular maintenance is required for the best performance and safe operation of your golf car WARNING Be sure to turn off the main switch and apply the parking brake when you perform maintenance unless otherwise specified If the owner is not familiar with servicing the machine death or serious personal injury can result When in doubt the work should be done by a Yamaha dealer or other qualified mechanic CS CHECK CA CHECKANDADJUST R REPLACE S SERVICE CL CLEANAND LUBRICATE L LUBRICATE and damaged springs 40 rounds 250 rounds 500 roun
25. f person performing maintenance and type of maintenance Periodically inspect maintenance log to ensure accurate and complete entries e Provide operator comment cards to assist in identifying non periodic maintenance needs for specific golf cars e Maintain in a legible condition all nameplates warnings and instructions provided by the manufacturer e If new nameplates warnings or instructions are needed contact your Yamaha Golf Car Company dealer STORAGE AND BATTERY CHARGING Take the following precautions to ensure maintenance worker safety e Only use battery charging facilities and procedures that are in accordance with applicable ordinances and regulations to avoid explosions electrical shock or damage to the electrical system e Periodically inspect charging facilities and procedures to be certain that applicable safety codes regulations and procedures are being followed to avoid any fires or explosions JW9 CONTROLS FEATURES D Brake pedal 2 Parking brake pedal 8 Accelerator pedal 4 Steering wheel 5 Main switch 6 Drive select switch 7 Batteries Seat 9 Front body Front tire t Front bumper 2 Rear body i3 Rear tire Rear bumper 5 Tow switch Receptacle CONTROLS OFF Y REV FWD Y 912 Y 0 REV FWD ev Y 913 5 2 MAIN SWITCH The main swit
26. ging steps 1 Turn main switch key to OFF position NOTICE Always put the tow switch in the TOW position before charging battery or damage to the electrical system may result 2 Lift up the seat and move the tow switch to the TOW position MAINTENANCE POWER ON ERROR1 ERROR2 CHARGING mi n 9 9 9 Y 1559 JW9 NOTICE Use only battery chargers that are rated for use with 48 volt Yamaha Golf Cars Serious battery damage can result Thoroughly read and understand the user manual supplied with your 48 volt charger 3 With the charger properly connected and grounded see charger s owner s manual insert the DC output into the golf car receptacle WARNING Do not disconnect the DC output cord from the battery receptacle when the charger is on or an arc could occur that may cause an explosion Death or serious personal injury can result from failing to comply with the safety and warning instructions affixed to the golf car or utility vehicle Power ON Light Red Error Light 1 Red Error Light 2 Red D Charging Light Yellow E Charged Light Green 4 When the charger is plugged into the AC power the Power ON Light illuminates continuously 5 f Error 1 or Error 2 light is blinking there is a problem with the batteries or the charger Contact your Yamaha Dealer 6 During normal charging the
27. heck the following pedal controls for proper operation If a pedal does not work properly consult a Yamaha dealer Accelerator Pedal 1 WARNING Make sure the main switch is in the OFF position 2 Make sure the accelerator pedal operates smoothly Accelerator pedal PRE OPERATION CHECKS Y 21a Y 22a JW9 Brake Pedal Make sure the brake pedal feels firm when pressed and returns to its original position when released Brake pedal Parking Brake Pedal Make sure the parking brake pedal locks in place with a positive click and releases when the accelerator pedal is pressed Parking brake pedal TIP Release the parking brake by depressing the accelerator pedal BODY AND CHASSIS Before each use visually inspect the golf car body and chassis for damage and or missing parts 6 4 OPERATION OFF Y O REV FWD NA Y 933 OFF Y Qo REV FWD N Y 911b Y 20A 7 1 STARTING 1 With the parking brake applied turn the drive select switch to FWD for forward or REV for reverse NOTICE Do not shift from FWD forward to REV reverse while the golf car is moving Transmission damage can result 2 Turn the main switch to ON 4 WARNING Do not depress the accelerator pedal when turning on the main switch or the golf car may start moving unexpectedly Death or serious personal injury can r
28. ity WHILE OPERATING THE GOLF CAR e Keep your entire body inside the golf car remain seated and hold on when the car is in motion e Do not start the golf car until all occupants are seated e Keep your hands on the steering wheel and your eyes on the path ahead OPERATOR SAFETY e Use extra care in congested areas or when backing up Always back up slowly and watch carefully e Avoid starting or stopping abruptly e Vary the speed of the golf car to match the terrain of the course e Avoid turning the steering wheel too sharply at higher speeds to avoid tipping or rolling the golf car e Always drive slowly straight up or straight down slopes never at an angle to avoid tipping or rolling the golf car Y 921 e Do not run the engine indoors Exhaust gas is poisonous and could result in carbon monoxide poisoning Y 922 4 e Do not make any modification or d addition which affects capacity or safe operation or make any m ze changes not in accordance with SS the owner s operator s manual Y 923 JW9 3 2 SAFETY CONSIDERATIONS Like all machines golf cars can cause injury if improperly used or maintained This section contains broad safety practices required for safe golf car operation Before golf cars are operated golf course personnel should establish any additional safety practices that may be required for safe operation Experien
29. led water After charging open the vent caps 3 Using a hydrometer check the specific gravity of the battery fluid in each cell against the readings on the chart below Consult Yamaha dealer if any low readings are found or if readings vary more than one point between cells Temperature C F Satisfactory Uncorrected Hydrometer Reading 48 9 120 1 244 43 3 1 248 37 8 100 1 252 32 2 90 1 256 26 7 80 1 260 21 1 70 1 264 15 6 60 1 268 10 0 50 1 272 4 4 40 1 276 1 1 30 1 280 8 4 MAINTENANCE REV FWD OFF 9v Y 912 Battery Charging Read and understand the owner s manual provided with your golf car s battery charger before charging batteries Death or serious personal injury can result from failing to comply with the safety and warning instructions affixed to the golf car or utility vehicle WARNING Explosive hydrogen gas is produced while batteries are being charged Only charge batteries in well ventilated areas a minimum ot five air changes per hour is recommended Death or serious personal injury can result from failing to comply with the safety and warning instructions affixed to the golf car or utility vehicle To charge the batteries in your golf car follow the instructions contained in your battery charger s owner s manual The following is a summary of the char
30. nder of the warranty term 36 hole performance is defined as 60 minutes discharge time as tested and recorded using a Lester model 17770 discharge machine at an ambient temperature of between 60 and 100 degrees F 16 and 38 degrees C Ambient temperatures between 60 and 80 degrees F 16 and 27 degrees C must be corrected using the formula Adjusted Discharge Time Discharge Minutes 1 80 100 x 0 64 The customer must notify the Dealer within 10 days that a vehicle has failed to make 36 holes per day YGC reserves the right to test and recharge any batteries in question ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL BE VOID AND EXCLUDED SUBSEQUENT TO ONE YEAR FROM THE DATE OF PURCHASE THE REPLACEMENT OF THE BATTERY IS THE EXCLUSIVE REMEDY UNDER THIS WRITTEN WARRANTY OR ANY IMPLIED WARRANTY YAMAHA MAKES NO OTHER REPRESENTATION OR WARRANTY OF ANY KIND AND NO REPRESENTATIVE EMPLOYEE DISTRIBUTOR OR DEALER OF YAMAHA HAS THE AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION PROMISE OR AGREEMENT WHICH IN ANY WAY VARIES THE TERMS OF THIS LIMITED WARRANTY LIMITED WARRANTY EXCLUSIONS Without limiting the generality of the foregoing in any way and as part of its limited warranty exclusion YAMAHA does not warrant that its battery is suitable for use in any application other than in a golf car or utility vehicle As in the use of any battery a prudent owner will read and stu
31. of the vehicle s warranty period All parts replaced under warranty become property of Yamaha Golf Car Company GENERAL EXCLUSIONS from this warranty shall include any failures caused by a Abnormal strain neglect or abuse including lack of proper maintenance and use contrary to the Owner s Operator s Manual instructions b Accident or collision damage c Installation of parts or accessories that are not original equipment d Fading rust or deterioration due to exposure or ordinary wear and tear e Modifications or alterations that affect the car s condition operation performance or durability or which makes the car serve a purpose other than use as a two person golf course vehicle f Damage due to improper transportation g Acts of God i e lightning hail damage flooding fire etc WARRANTY COVERAGE Year 1 The first year of warranty shall cover the entire vehicle except for the Specific Exclusions below The second year exclusions are the YDRA battery body parts seats mats bumper assembly bag carrier scorecard holder trim and the Specific Exclusions below The third year exclusions include the second year exclusions plus the control cables and electrical system except electronic speed controller battery charger and electric motor and the Specific Exclusions below The fourth year of the warranty covers only the electric motor speed controller battery charger and transaxle on the
32. ovides key information to make procedures easier or clearer TIP Yamaha continually seeks advancements in product design and quality therefore while this manual contains the most current product information available at the time of printing there may be minor discrepancies between your golf car and this manual If you have any questions concerning this manual please consult your Yamaha dealer WARNING Read and understand this manual completely before operating your golf car This manual should be considered a permanent part of your golf car and should remain with the car when resold CONTENTS e WARRANTY IMPORTANT LABELS OPERATOR SAFETY SAFETY CONSIDERATIONS CONTROLS PRE OPERATION CHECKS OPERATION MAINTENANCE STORAGE SPECIFICATIONS c 11 WARRANTY LIMITED 4 YEAR GOLF CAR LIMITED WARRANTY Yamaha Golf Car Company hereby warrants that any new YDRA gas or YDRE electric Yamaha golf car purchased from an authorized Yamaha golf car dealer in the United States will be free from defects in material and workmanship for FOUR years from date of purchase subject to the stated limitations DURING THE PERIOD OF WARRANTY any authorized Yamaha golf car dealer will free of charge repair or replace at Yamaha s option any part adjudged defective by Yamaha due to faulty workmanship or material from the factory Parts used in warranty repairs will be warranted for the balance
33. sonal injury can result from failing to comply with the safety and warning instructions affixed to the golf car or utility vehicle JW9 CONTROLS TOW SWITCH Before operating the car make sure the tow switch is in the RUN position Tow switch NOTICE Ensure that the Drive Select Switch is in the FWD position and then move the TOW Switch to TOW before towing After moving switch from RUN to TOW wait 15 seconds minimum before switching again Failure to do so may lead to drive system damage while towing JW9 5 5 PRE OPERATION CHECKS Pre operation checks should be made each time you use your golf car Get in the habit of performing the following checks in the same way so that they become second nature WARNING To keep car from moving while performing pre operation checks e Remove main switch key e Apply parking brake Death or serious personal injury can result from failing to comply with the safety and warning instructions affixed to the golf car or utility vehicle PRE OPERATION CHECKLIST Before each use check the following Batteries Tire condition Steering system V Reverse alarm operation Body and chassis SEAT Open the seat for checking and servicing PRE OPERATION CHECKS FS JW9 BATTERIES Check that the batteri
34. st be re registered by an authorized Yamaha Golf Car Dealer within 30 days of transfer A fee may be charged for the transfer of the warranty YAMAHA GOLF CAR COMPANY MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA GOLF CAR COMPANY AND EXCLUDED FROM THIS WARRANTY SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU ALSO EXCLUDED FROM THIS WARRANTY IS ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE EXCLUSION 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 Yamaha Golf Car Company NEWNAN GEORGIA 30265 1320 EFFECTIVE DATE 6 1 11 LIT 13710 01 12 JW9 WARRANTY YAMAHA FOUR YEAR LIMITED WARRANTY FOR TROJAN BRAND ELECTRIC GOLF CAR AND UTILITY VEHICLE BATTERIES WHEN CHARGED WITH A YAMAHA SUPPLIED 48 VOLT CHARGER YAMAHA Golf Car Company herein referred to as YGC hereby warrants to the Original Retail Purchaser or Lessee of a YAMAHA YDRE golf car or PTV U MAX or Adventurer utility vehicle or YAMAHA transportation or specialty vehicle purchased from an
35. the top of the oil servicing hole or just beginning to run out of hole NOTICE Do not allow foreign material to enter transaxle Serious transaxle damage can result 7 If needed add Yamalube Friction Modified Shaft Drive Gear Oil until it is at the top of the plug hole or just beginning to run out of servicing hole TIP The YDRE Golf Car is equipped with an internal wet brake Use of oil other than Yamalube Friction Modified Shaft Drive Gear Oil will cause brake noise 8 Install the transaxle servicing plug and tighten to 14 19 Nm 1 4 1 9 m kg 120 168 in lb 9 Install the bag holder insert 3 and secure with two bolts 2 and seven plastic rivets 1 MAINTENANCE TIP For transaxle oil replacement consult a Yamaha dealer or other qualified mechanic NOTICE Before performing wheel or brake maintenance verify that the main switch is in the OFF position Serious transaxle damage can result Wheel Replacement To remove and install a wheel on your golf car 1 With the wheels blocked to prevent the golf car from moving loosen the wheel nuts 2 Elevate the golf car with a jack and remove the wheel nuts and the wheel 3 Reverse the removal steps when installing the wheel Wheel nut tightening torque 80 Nm 8 0 m kg 58 10 Brake Adjustment The brakes on your golf car are self adjusting Before you operate the car press down on the brake
36. to the purchaser during the limited warranty period except for labor or transportation expenses Damage not resulting from a defect in materials or workmanship or which occurs due to abuse or neglect including failure to provide reasonable and necessary maintenance accident alteration or acts of God is excluded from this limited warranty This warranty gives you specific legal rights and you may also have other rights which vary from state to state For further information or to submit a warranty claim contact your local Yamaha Golf Car Dealer or contact Yamaha Golf Car Company toll free at 877 811 8250 Yamaha Golf Car Company NEWNAN GEORGIA 30265 1320 EFFECTIVE DATE 06 01 11 LIT 13710 EL 11 1 2 IMPORTANT LABELS S SAFETY AND INSTRUCTION LABELS E Read the following labels carefully before operating your golf car and promptly replace any labels which become damaged or removed Death or serious personal injury can result from failing to comply with the safety and warning instructions affixed to the golf car or utility vehicle OPERATING INSTRUCTIONS Read the warning label on the beverage holder panel before operating Be sure occupants are seated m Select FORWARD or REVERSE Parkin then turn main switch to ON Broke Pedal m Press the accelerator pedal to start moving The motor wili Brake Pedol start t will release automatically Accelerati To stop release the
37. urse hazards must be made safe e Steep Grades Where steep grades exist restrict golf cars to designated golf car pathways where possible In addition identify steep grades with a suitable warning like 4 WARNING Descend steep grades slowly with foot on brake Death or serious personal injury can result from failing to comply with the safety and warning instructions affixed to the golf car or utility vehicle e Sharp Turns Blind Corners Bridge Approaches Chain or rope off these potentially hazardous areas or identify them with a suitable warning describing the nature of the hazard and the proper precautions to be taken to avoid the hazard N SAFETY CONSIDERATIONS e Wet Areas Wet grass may cause a golf car to lose traction and may affect stability Golf car operators should reduce speed in wet areas or during periods of inclement weather e Loose Terrain Loose terrain may cause a golf car to lose traction and may affect stability Repair loose terrain chain or rope off these areas or identify loose terrain with a suitable warning e Golf Car and Pedestrian Interference Reroute golf car traffic or pedestrian traffic in congested areas wherever possible to prevent accidents If it is impractical to reroute traffic erect warning signs to warn pedestrians of golf car traffic and to warn golf car operators to drive slowly use caution and watch for pedestrians MAINTENANCE REQUIRED FOR GOLF CAR S
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