48 volt golf car · 2016-07-10 · 48 volt golf car ydre lit-19626-21-10 jw9-f8199-10 yamaha...

48 VOLT GOLF CAR YDRE

LIT-19626-21-10 JW9-F8199-10YAMAHA GOLF-CAR

COMPANY1000 HWY 34 EastNewnan, GA 30265

770-254-4000

Printed in U.S.A2010-KCC

!

OWNER’S / OPERATOR’SMANUAL

READ THIS MANUAL CAREFULLY!It contains important safety information.

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INTRODUCTIONCongratulations on your purchase of aYamaha golf car. This manual containsinformation you will need for proper operation, maintenance, and care of yourgolf car. A thorough understanding ofthese simple instructions will help you toobtain maximum enjoyment from yournew Yamaha.

If you have any questions about the operation or maintenance of your golfcar, please consult a Yamaha dealer.

YAMAHA GOLF-CAR COMPANY

YDRE OWNER’S/OPERATOR’SMANUAL

© 2010 by Yamaha Golf-Car Company1st Edition

All rights reserved. Any reprintingor unauthorized use without the

written permission ofYamaha Golf-Car Company

is expressly prohibited.Printed in U.S.A.LIT-19626-21-10

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IMPORTANT MANUAL INFORMATION

TIPYamaha continually seeks advancements in product designand quality; therefore, while thismanual contains the most currentproduct information available at thetime of printing, there may be minordiscrepancies between your golf carand this manual. If you have any questions concerning thismanual, please consult yourYamaha dealer.

Read and understand this manualcompletely before operating yourgolf car. This manual should beconsidered a permanent part ofyour golf car and should remainwith the car when resold.

Particularly important information isdistinguished in this manual by the following notations:

This is the safety alert symbol. It isused to alert you to potentialpersonal injury hazards. Obey allsafety messages that follow thissymbol to avoid possible injury ordeath.

A WARNING indicates a hazardoussituation which, if not avoided,could result in death or seriousinjury.

A NOTICE indicates specialprecautions that must be taken toavoid damage to the vehicle orother property.

TIPA TIP provides key information tomake procedures easier or clearer.

NOTICE


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WARRANTY

CONTENTS

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IMPORTANT LABELS 2

SAFETY CONSIDERATIONS 4

MAINTENANCE 8

STORAGE

SPECIFICATIONS

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WIRING 11

OPERATION 7

PRE-OPERATION CHECKS 6

CONTROLS 5

OPERATOR SAFETY 3

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WARRANTY

Yamaha Golf-Car Company hereby warrants that anynew YDRA gas or YDRE electric Yamaha golf carpurchased from an authorized Yamaha golf cardealer in the United States will be free from defectsin material and workmanship for FOUR years fromdate of purchase, subject to the stated limitations.

DURING THE PERIOD OF WARRANTY anyauthorized Yamaha golf car dealer will, free ofcharge, repair or replace, at Yamaha’s option, anypart adjudged defective by Yamaha due to faultyworkmanship or material from the factory. Parts usedin warranty repairs will be warranted for the balanceof the vehicle’s warranty period. All parts replacedunder warranty become property of Yamaha Golf-CarCompany.

GENERAL EXCLUSIONS from this warranty shallinclude any failures caused by:

a. Abnormal strain, neglect, or abuse, includinglack of proper maintenance, and use contraryto 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 otherthan 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 Exclusionsbelow.

Year 2: The second year exclusions are the YDRAbattery, body parts, seats, mats, bumperassembly, bag carrier, scorecard holder, trim,and the Specific Exclusions below.

Year 3: The third year exclusions include the secondyear exclusions, plus the control cables andelectrical system (except electronic speedcontroller, battery charger, and electric motor),and the Specific Exclusions below.

Year 4: The fourth year of the warranty covers onlythe electric motor, speed controller, batterycharger, and transaxle on the YDRE and theengine, clutch system (except drive belt), andtransaxle on the YDRA.

SPECIFIC EXCLUSIONS: Specific exclusions fromthis warranty shall include the following:

• Electric car batteries, which are covered undera separate warranty.

• Any parts replaced due to normal wear orroutine maintenance, including oil and air filterelements, tire wear, spark plugs, starter andclutch drive belts.

• Any charges incurred in transporting a golf caror charger to and from an authorized Yamahagolf car dealer for service or in performing fieldservice are also excluded from this warranty.

• Gasoline powered golf car starting batteries onvehicles equipped with a golf course GPSdevice, or any other device with a highparasitic current draw, unless the vehicle isequipped with an optional factory installeddeep cycle starting battery.

THE CUSTOMER’S RESPONSIBILITY under thiswarranty shall be to:1. Operate and maintain the golf car and charger as

specified in the appropriate Owner’s/Operator’sManual;

2. Give notice to an authorized Yamaha golf cardealer of any and all apparent defects within ten(10) days after discovery, and make the vehicle orcharger available at that time for inspection andrepairs by the dealer’s authorized representative.

WARRANTY TRANSFER: Any transfer of warrantymust take place within the first three years of theoriginal in-service date of the vehicle. The vehiclemust be re-registered by an authorized Yamaha Golf-Car Dealer within 30 days of transfer. A fee may becharged for the transfer of the warranty.

YAMAHA GOLF-CAR COMPANY MAKES NOOTHER WARRANTY OF ANY KIND, EXPRESSEDOR IMPLIED. ALL IMPLIED WARRANTIES OFMERCHANTABILITY AND FITNESS FOR APARTICULAR PURPOSE WHICH EXCEED THEOBLIGATIONS AND TIME LIMITS STATED IN THISWARRANTY ARE HEREBY DISCLAIMED BYYAMAHA GOLF-CAR COMPANY AND EXCLUDEDFROM THIS WARRANTY.

SOME STATES DO NOT ALLOW LIMITATIONS ONHOW LONG IMPLIED WARRANTY LASTS, SOTHE ABOVE LIMITATION MAY NOT APPLY TOYOU. ALSO EXCLUDED FROM THIS WARRANTYIS ANY INCIDENTAL OR CONSEQUENTIALDAMAGES INCLUDING LOSS OF USE. SOMESTATES DO NOT ALLOW THE EXCLUSION ORLIMITATION OF INCIDENTAL ORCONSEQUENTIAL DAMAGES, SO THE ABOVEEXCLUSION MAY NOT APPLY TO YOU.

THIS WARRANTY GIVES YOU SPECIFIC LEGALRIGHTS, AND YOU MAY ALSO HAVE OTHERRIGHTS, WHICH VARY, FROM STATE TO STATE.

Yamaha Golf-Car Company, NEWNAN, GEORGIA 30265-1320

EFFECTIVE DATE: 6/1/10 LIT-13710-01-11

LIMITED 4-YEAR GOLF CAR LIMITED WARRANTY


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YAMAHA Golf-Car Company (herein referred to as “YGC”) herebywarrants to the Original Retail Purchaser or Lessee of a YAMAHAYDRE golf car or PTV, U-MAX or Adventurer utility vehicle, orYAMAHA transportation or specialty vehicle purchased from anAuthorized YGC Dealer, that the Trojan batteries charged with aYAMAHA supplied battery charger will be free from defects inmaterials and workmanship, and will provide “36-hole performance” fora period of four-years or “1,000 rounds” from the date of purchase,whichever event occurs first, subject to the terms and conditionscontained herein.

This limited warranty covers defects in materials and workmanshiponly for a period of four-years or “1,000 rounds”, as applicable, fromdate of purchase, whichever event occurs first. The terms of thisFOUR-YEAR LIMITED WARRANTY shall be to furnish one or morereplacement batteries within the four-year period or before 20,000amp-hours are discharged, whichever event occurs first, asdetermined by YGC using the information recorded and stored in theGenius controller.

• This warranty only applies to factory installed Trojan battery setscharged with a Yamaha supplied battery charger.

• “1,000 rounds” means 20,000 amp-hours discharged, as recordedin the Genius controller.

• The customer must perform (or have a contracted Yamaha Dealerperform) all periodic maintenance and discharge testing asspecified in the Yamaha Service Manual Maintenance Schedule.No labor or transportation expenses are included in this limitedwarranty. Maintenance records must be kept.

• Replacement batteries may be of a different brand or capacity, butare warranted to provide 36-hole performance for the remainder ofthe warranty term.

• “36-hole performance” is defined as 60-minutes discharge time astested and recorded using a Lester model #17770 dischargemachine at an ambient temperature of between 60 and 100degrees F (16 and 38 degrees C). Ambient temperaturesbetween 60 and 80 degrees F (16 and 27 degrees C) must becorrected using the formula: Adjusted Discharge Time =(Discharge Minutes) / (1-(((80-TEMP)/100) x 0.64)).

• The customer must notify the Dealer within 10 days that a vehiclehas failed to make 36 holes per day. YGC reserves the right totest and recharge any batteries in question.

ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESSFOR A PARTICULAR PURPOSE SHALL BE VOID AND EXCLUDEDSUBSEQUENT TO ONE YEAR FROM THE DATE OF PURCHASE.THE REPLACEMENT OF THE BATTERY IS THE EXCLUSIVEREMEDY UNDER THIS WRITTEN WARRANTY OR ANY IMPLIEDWARRANTY. YAMAHA MAKES NO OTHER REPRESENTATIONOR WARRANTY OF ANY KIND, AND NO REPRESENTATIVE,EMPLOYEE, DISTRIBUTOR OR DEALER OF YAMAHA HAS THEAUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION,PROMISE OR AGREEMENT WHICH IN ANY WAY VARIES THETERMS OF THIS LIMITED WARRANTY.

LIMITED WARRANTY EXCLUSIONSWithout limiting the generality of the foregoing in any way, and aspart of its limited warranty exclusion, YAMAHA does not warrantthat its battery is suitable for use in any application other than in agolf car or utility vehicle. As in the use of any battery, a prudentowner will read and study the charger owner’s manual, the vehicleowner’s manual, the operator’s instructions, and the battery warninglabels; and will exercise due care in working on or around batteries.

THE PROVISIONS OF THIS LIMITED WARRANTY SHALL NOTAPPLY IF BATTERIES ARE SUBJECTED TO ANY OF THEFOLLOWING CONDITIONS:• Abuse or neglect such as improper fluid levels, loose wiring,

rusted or corroded hardware.

• Lack of proper maintenance as outlined in the electric vehicleOwner’s/Operator’s Manual. For example, lack of regularbattery watering or adding water to the battery beforecharging.

• 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 anuncharged condition (below half-charge – 1.200 specificgravity).

• Battery charged by systems other than the original equipmenttype battery charger.

• On fleet golf cars, the use of any non-YAMAHA suppliedelectrical devices that consume more than one amp-hour perround or two amp-hours per day of battery energy. Examplesof these devices include, but are not limited to: heating orcooling systems; GPS (global position system) devices;information gathering devices; lights; radios or stereos; oryardage measuring devices.

• Inadequate facility electrical power to power all chargers.Examples include more than one charger on a single circuit ornot 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 15car fleet.

• The use of any system that does not allow the batterychargers to shut off automatically. For example, timersystems that are designed to switch battery charger AC poweron and off during peak demand hours.

THIS BATTERY IS INTENDED TO BE USED BY PERSONSWITH TRAINING AND EXPERIENCE WITH BATTERIES ANDONLY IN YAMAHA ELECTRIC VEHICLES. ANY OTHER USERENDERS THE LIMITED WARRANTIES EXPRESSED HEREINAND ALL IMPLIED WARRANTIES NULL AND VOID AND SAMEARE HEREBY EXCLUDED.

ALSO EXCLUDED FROM THIS LIMITED WARRANTY AREANY AND ALL INCIDENTAL OR CONSEQUENTIAL DAMAGESINCLUDING, BUT NOT LIMITED TO, LOSS OF USE ORREVENUE, LOSS OF TIME, INCONVENIENCE OR ANYOTHER ECONOMIC LOSS.

Some states do not allow limitation on the duration of an impliedwarranty, exclusions or limitations of incidental or consequentialdamages. Therefore, the above limitations or exclusions may notapply to you.

WARRANTY LIMITATIONSYamaha Golf-Car Company’s and Trojan Battery Company’s limitof liability shall be to replace a defective battery. Replacementshall mean furnishing a new battery or used battery with sufficientlife to complete the remainder of the warranty term, which isidentical or reasonably equivalent to the warranted product at nocost to the purchaser during the limited warranty period, exceptfor labor or transportation expenses.

Damage not resulting from a defect in materials or workmanshipor which occurs due to abuse or neglect (including failure toprovide 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 alsohave other rights, which vary from state to state.

For further information or to submit a warranty claim, contact yourlocal Yamaha Golf-Car Dealer or contact Yamaha Golf-CarCompany toll free at (877) 811-8250.

Yamaha Golf-Car Company, NEWNAN, GEORGIA 30265-1320EFFECTIVE DATE: 06/01/10 LIT-13710-EL-10

YAMAHA FOUR-YEAR LIMITED WARRANTY FOR TROJAN BRANDELECTRIC GOLF CAR AND UTILITY VEHICLE BATTERIES WHEN

CHARGED WITH A YAMAHA SUPPLIED 48-VOLT CHARGER


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IMPORTANT LABELS

Y-924f

3 54

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SAFETY AND INSTRUCTION LABELS

Read the following labels carefully before operating your golf car, andpromptly replace any labels which become damaged or removed. Death orserious personal injury can result from failing to read and comply with thesafety instruction labels.

Y-500c

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IMPORTANT LABELS

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IMPORTANT LABELS

Y-16

07f

YEAR

OF CO

NSTR

UCTIO

N: 2

0XX

YAMA

HA M

OTOR

POW

ERED

PROD

UCTS

CO., L

TD.

200-

1 SAK

AGAW

A, KA

KEGA

WA,

JAPA

NMA

X. BA

TTER

Y WEIG

HT: X

XX kg

MODE

L: YD

REX

MAX.

POW

ER: X

.X KW

WEIG

HT (N

O BAT

T): X

XX kg

JXX-

F423

6-XX

5

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GOLF CAR SERIALNUMBERThe golf car serial number 1 isidentified in the location shown.

TIPThe first three digits of the serialnumber 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 YamahaGolf-Car Company dealer.Y-1539

JWX

-000

000

1

IMPORTANT LABELS


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OPERATOR SAFETY!

Y-928

Y-68

Yamaha golf cars are designed to besimple to operate. However, be sureto observe the following to reducethe risk of serious injury or death dueto loss of control and other hazards:

BEFORE OPERATINGTHE GOLF CARl Read this Owner’s/Operator’s

manual and all safety and instructionlabels on the golf car before operating.

l Perform the pre-operation checksfound in Section 6 of this manual.

l Only authorized people shoulddrive the golf car, from the driver’sside only, and only in designatedareas.

l Do not allow more than two occupants per seat. This golf car isrestricted to two occupants unlessequipped with a rear seat.

l Do not operate the golf car whileunder the influence of alcohol ordrugs; their effect on vision andjudgment make operating a golfcar dangerous.

l Do not operate the golf car on public streets, roads or highwaysunless allowed by law or local regulating authority.

WHILE OPERATING THEGOLF CARl Keep your entire body inside the

golf car, remain seated, and holdon when the car is in motion.

l Do not start the golf car until alloccupants are seated.

l Keep your hands on the steeringwheel and your eyes on the pathahead.


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l Use extra care in congested areasor when backing up. Always backup slowly, and watch carefully.

l Avoid starting or stopping abruptly.

l Vary the speed of the golf car tomatch the terrain of the course.

l Avoid turning the steering wheeltoo sharply at higher speeds toavoid tipping or rolling the golf car.

l Always drive slowly straight up orstraight down slopes – never at anangle to avoid tipping or rolling thegolf car.

l Do not run the engine indoors.Exhaust gas is poisonous andcould result in carbon monoxidepoisoning.

l Do not make any modification oraddition which affects capacity orsafe operation, or make anychanges not in accordance withthe owner’s/operator’s manual.

Y-921

Y-922

Y-923

OPERATOR SAFETY!


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SAFETY CONSIDERATIONS!

Like all machines, golf cars cancause injury if improperly used ormaintained. This section containsbroad safety practices required forsafe golf car operation. Before golfcars are operated, golf course personnel should establish any additional safety practices that maybe required for safe operation.

Experience has shown that golf cars are safe when operated inaccordance with the safety warningsaffixed to every golf car. This safeoperation is enhanced when golfcars are used according to the safetyrules and practices established tomeet the terrain and conditions ofthe course they are used on.

The information contained here isintended for golf course personnelresponsible for golf car safety. If youare responsible for the operationand maintenance of this golf car, weencourage you to implement thisgolf car safety program.

DRIVER QUALIFICATIONSAllow only authorized people tooperate golf cars. It is recommendedthat only people who possess avalid motor vehicle driver’s licensebe allowed to operate golf cars.

Place operation and safety instructions recommended by thegolf car manufacturer, along with the golf course safety rules, in aconspicuous place near the golf carrental area or golf car pick-up area.It is also recommended that the following warning be posted in aconspicuous location:

Do not operate golf cars whenunder the influence of alcohol ordrugs. Death or serious personalinjury can result from failing tocomply with the safetyinstructions in this manual.

GOLF COURSE SAFETYSURVEYPerform safety surveys regularly toidentify hazardous areas where golfcars should not be operated.

GOLF COURSE HAZARDPREVENTIONThe following golf course hazardsmust be made safe:

l Steep Grades. Where steepgrades exist, restrict golf cars todesignated golf car pathwayswhere possible. In addition, identify steep grades with a suitable warning like:

Descend steep grades slowly withfoot on brake. Death or seriouspersonal injury can result fromfailing to comply with the safetyinstructions in this manual.

l Sharp Turns, Blind Corners,Bridge Approaches. Chain orrope off these potentially hazardous areas or identify themwith a suitable warning describingthe nature of the hazard and theproper precautions to be taken toavoid the hazard.


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l Wet Areas. Wet grass may causea golf car to lose traction and mayaffect stability. Golf car operatorsshould reduce speed in wet areasor during periods of inclementweather.

l Loose Terrain. Loose terrain maycause a golf car to lose tractionand may affect stability. Repairloose terrain, chain or rope offthese areas, or identify loose terrain with a suitable warning.

l Golf Car and Pedestrian Interference. Reroute golf car traffic or pedestrian traffic in congested areas wherever possibleto prevent accidents. If it is impractical to reroute traffic, erectwarning signs to warn pedestriansof golf car traffic, and to warn golfcar operators to drive slowly, usecaution, and watch for pedestrians.

MAINTENANCE REQUIRED FOR GOLFCAR SAFETYPractice the following to help ensurethe safety of golf car operators:

l Preventative Maintenance. Perform all scheduledmaintenance in accordance withmanufacturer’s recommendationsto provide the golfing patron with asafe, properly operating golf car.

l Personnel. Allow only qualified,trained, and authorized personnelto inspect, adjust, and maintaingolf cars.

l Parts and Materials. Use onlyreplacement parts and materialsrecommended by the manufacturer.

l Ventilation. Properly ventilate allmaintenance and storage areas inaccordance with applicable firecodes and ordinances to avoid firehazards. Ventilation is required toremove flammable vapors andfumes from gasoline powered carstorage areas. Ventilation is alsorequired to remove hydrogen gasfrom the car storage areas duringthe battery charging process.

For electric powered golf cars, theamount of hydrogen gas emittedduring charging depends on anumber of factors, such as thecondition of the batteries, the outputrate of the battery charger, and theamount of time the batteries are oncharge. Because of the highlyvolatile nature of hydrogen gas andits propensity to rise and accumulateat the ceiling in pockets, a minimumof 5 air changes per hour isrecommended. Consult applicablefire and safety codes for the specificventilation levels requirement, aswell as requirements for the use ofexplosion proof electrical apparatus.


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SAFETY PRECAUTIONSDURING MAINTENANCEWhen performing maintenance, followall safety instructions contained in themanufacturer’s operation and servicemanuals, as well as the followingsafety procedures:

l Properly immobilize golf car beforebeginning any maintenance to avoidany unexpected vehicle movement.

l Properly block chassis before working underneath golf car toavoid any unexpected vehiclemovement.

l When working on the fuel system orthe battery, do not smoke, or allowany sparks or open flames near thevehicle, to avoid any fires orexplosions.

l Before working on an electric golfcar, disable the car’s electricalsystem in accordance with themanufacturer’s instructions to avoidelectrical shock or damage to theelectrical system.

l Use only properly insulated toolswhen working on electricallypowered golf cars or aroundbatteries to avoid electrical shock ordamage to the electrical system.

l Maintain all safety devices includingbrakes, steering mechanisms,warning devices, and governors, ina safe operating condition. Do notmodify these safety devices assupplied by the manufacturer.

l After each maintenance or repair,the car must be driven by aqualified, trained, and authorizedperson – in an area free ofpedestrian traffic – to ensure properoperation and adjustment.

l Record all maintenance performedin a maintenance record log bydate, name of person performingmaintenance, and type ofmaintenance. Periodically inspectmaintenance log to ensureaccurate and complete entries.

l Provide operator comment cardsto assist in identifying non-periodicmaintenance needs for specificgolf cars.

l Maintain in a legible condition allnameplates, warnings, andinstructions provided by the manufacturer.

l If new nameplates, warnings, orinstructions are needed, contactyour Yamaha Golf-Car Companydealer.

STORAGE AND BATTERY CHARGINGTake the following precautions toensure maintenance worker safety:

l Only use battery charging facilitiesand procedures that are in accordance with applicable ordinances and regulations toavoid explosions, electrical shockor damage to the electricalsystem.

l Periodically inspect charging facilities and procedures to be certain that applicable safetycodes, regulations, and procedures are being followed toavoid any fires or explosions.



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CONTROLS

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FEATURES1 Brake pedal2 Parking brake pedal3 Accelerator pedal4 Steering wheel5 Main switch6 Receptacle7 Batteries8 Seat9 Front bodya Front tireb Front bumperc Rear bodyd Rear tiree Rear bumperf Tow switchg Drive select switch

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CONTROLS

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OFFON

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REV FWD

OFFON

Y-913

REV FWD

MAIN SWITCHThe main switch controls the following items:

“OFF”All electrical control circuits areswitched off (controller remainsenergized). The golf car cannot beoperated. The key can be removedonly in this position.

“ON”Electrical circuits are switched on.The golf car can be driven.


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CONTROLS

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DRIVE SELECT SWITCHThe drive select switch is used toshift the golf car into forward orreverse. After coming to a completestop, move the lever to the desired position.

Switch Position Car Movement

FWD FORWARD

REV REVERSE

TIPThe reverse alarm will sound whenthe drive select switch is turned to“REV.”

ACCELERATOR PEDALThe accelerator pedal controls thegolf car’s speed.

Action Car Speed

Depress pedal Increase

Release pedal Decrease

å Accelerator pedal

BRAKE PEDALPress down on the brake pedal tostop the golf car.

∫ Brake pedal

Y-920

BEEP

Y-20A

A

OFFON

Y-904

REV FWD

Y-21a

B


CONTROLS

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Y-22a

C

PARKING BRAKEPEDALPress down on the parking brakepedal whenever parking the golf car.

ç Parking brake pedal

TIPRelease the parking brake bydepressing the accelerator pedal.

The parking brake will automaticallyrelease when the accelerator pedalis depressed. If the main switch isin the “ON” position, depressingthe accelerator may suddenly causethe golf car to move. Death orserious personal injury can resultfrom failing to comply with thesafety labels in this manual.


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TOW SWITCHBefore operating the car, make sure the tow switch is in the “RUN”position.

å Tow switch

Ensure that the “Drive SelectSwitch” is in the “FWD” positionand then move the “TOW Switch”to “TOW” before towing.

After moving switch from “RUN”to “TOW,” wait 15 secondsminimum before switching again.Failure to do so may lead to drivesystem damage while towing.

NOTICE

Y-1995

TOW

RUN

A


PRE-OPERATION CHECKS

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Y-905

Pre-operation checks should bemade each time you use your golfcar. Get in the habit of performingthe following checks in the sameway so that they become secondnature.

To keep car from moving whileperforming pre-operation checks:

l Remove main switch key. l Apply parking brake.

Death or serious personal injurycan result from failing to complywith the safety instructions in thismanual.

PRE-OPERATIONCHECKLISTBefore each use check the following:

4 Batteries4 Tire condition4 Steering system4 Reverse alarm4 Pedal operation4 Body and chassis

SEATOpen the seat for checking and servicing.


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BATTERIESCheck that the batteries are heldsecurely in place to prevent themfrom being damaged from vibrationor jarring. Also check that no batterycaps are missing to prevent batteryacid from spilling from the batteries.Check the battery terminals for corrosion.

Battery electrolyte is poisonousand dangerous, causing severeburns, etc. It contains sulfuricacid. Avoid contact with skin, eyesor clothing. Ventilate whencharging or using in enclosedspace. Always shield eyes whenworking near batteries. KEEP OUTOF REACH OF CHILDREN.

TIRE CONDITION

Tire Air PressureCheck the tire air pressure beforeoperating the golf car.

Tire pressure:

138 kPa, 1.4 kgf/cm2 (20 psi)

Tire Wear LimitCheck the tire surface for damage,cracks or embedded objects. Whentire tread wears down to 1 mm(0.04 in.), replace the tire.

å Wear limit

Y-30

A

Y-31



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Y-20A

A

Y-932

OFFON

Y-911b

REV FWD

STEERING SYSTEMCheck the steering system forexcessive free play by:

l moving the steering wheel up and down, and back and forth.

l turning the steering wheel slightly to the right and left.

If you feel excessive free play, orhear rattling sounds which may indicate loose steering components,consult a Yamaha dealer.

REVERSE ALARMCheck the reverse alarm by movingthe drive select switch to “REV” forreverse. The alarm should sound.

PEDAL OPERATIONCheck the following pedal controlsfor proper operation. If a pedal doesnot work properly, consult a Yamahadealer.

Accelerator Pedal1. WARNING! Make sure the

main switch is in the “OFF”position.

2. Make sure the accelerator pedaloperates smoothly.


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Brake PedalMake sure the brake pedal feels firmwhen pressed and returns to its original position when released.

∫ Brake pedal

Parking Brake PedalMake sure the parking brake pedallocks in place with a positive click,and releases when the acceleratorpedal is pressed.

ç Parking brake pedal

TIPRelease the parking brake bydepressing the accelerator pedal.

BODY AND CHASSISBefore each use, visually inspect the golf car body and chassis fordamage and/or missing parts.

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C

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OPERATION

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OFFON

Y-911b

REV FWD

REV FWD

OFFON

Y-933

Y-20A

A

STARTING1. With the parking brake applied,

turn the drive select switch to“FWD” for forward, or “REV” forreverse.

Do not shift from “FWD” forwardto “REV” reverse while the golfcar is moving. Transmissiondamage can result.

2. Turn the main switch to “ON.”

Do not depress the acceleratorpedal when turning on the mainswitch or the golf car may startmoving unexpectedly. Death orserious personal injury can resultfrom failing to comply with thesafety instructions in this manual.

3. Check that your path is clear inthe direction you plan to go, andslowly depress the acceleratorpedal. The golf car will start tomove.


TIPThe parking brake automaticallyreleases when the accelerator pedalis depressed.

NOTICE


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OPERATION

7-2JW9

STOPPINGTo stop the golf car, gradually pressdown on the brake pedal.

å Brake pedal

Do not hold the golf car on anincline with the accelerator – usethe brake. Transmission damagecan result.

When the car has come to a stop,apply the parking brake pedal andturn the main switch to “OFF.”

∫ Parking brake pedal

NOTICE

Y-65cA

B


MAINTENANCE

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8-1 JW9

PERIODIC MAINTENANCE CHARTSRegular maintenance is required for the best performance and safe operation ofyour golf car.

Be sure to turn off the main switch and apply the parking brake when youperform maintenance, unless otherwise specified. If the owner is not familiarwith servicing the machine, death or serious personal injury can result. When indoubt the work should be done by a Yamaha dealer or other qualified mechanic.

DailyPre-

Opera-tion

20 hours100 miles160 kms(EveryMonth)

125 hrs600 mls

1000 kms(Every 6months)

250 hrs1200 mls2000 kms

(EveryYear)

500 hrs2500 mls4000 kms(Every 2years)


PageRemarks

40 rounds 250 rounds 500 rounds 1000 rounds 2000 rounds

ChargePRE-OP

EVERYMONTH

EVERY 6MONTHS

4-3/8-5

6-2/8-3

6-4/8-10

*

*

*

*

—

6-3

6-3

6-2

6-4

8-3/8-4

* Items without a page number reference should be serviced by a Yamaha dealer or other qualified mechanic. This manual doesnot contain these procedures. They are contained in the Service Manual.

CS - CHECK CA - CHECK AND ADJUST R - REPLACE S - SERVICE CL - CLEAN AND LUBRICATE L - LUBRICATE

Clean battery tops, check fortightness of hold-down screws andterminals

Check brake pedal freeplay andadjust if necessary

Check steering operation

Check tire pressure, tread depth,tire surface for damage

Check body and chassis for damage

Check tightness of all bolts, nuts,screws and rivets

Check for loose or brokenconnections

Check all wire insulation for cracksand/or worn spots

Check shock absorbers for oil leaksand damaged springs

Clean/Lube pedal control area

Check reverse alarm operation

Check electrolyte level

S

S

CS

CS

CS

S

S

CA

CA

CL

CS

S

S

CA

CA

CS

S

S

CA

CA

CS

S

S

CA

CA

CS

S

S

CA

CA

CS

CS CS CS CS CS CS

CS CS CS CS CS CS

CS CS CS CS CS CS

CS CS CS CS CS

CS CS CS CS CS

CS CS CS CS

CS CS CS CS


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MAINTENANCE

8-2JW9

DailyPre-

Opera-tion

20 hours100 miles160 kms(EveryMonth)

125 hrs600 mls

1000 kms(Every 6months)

250 hrs1200 mls2000 kms

(EveryYear)



PageRemarks

40 rounds 250 rounds 500 rounds 1000 rounds 2000 rounds

EVERYYEAR

EVERY 4YEARS

*

*

*

*

—

8-9

*

* Items without a page number reference should be serviced by a Yamaha dealer or other qualified mechanic. This manual doesnot contain these procedures. They are contained in the Service Manual.

CS - CHECK CA - CHECK AND ADJUST R - REPLACE S - SERVICE CL - CLEAN AND LUBRICATE L - LUBRICATE

Check wheel nut tightness, frontwheel bearing play

Check transaxle oil level andinspect for leakage

Perform a discharge test

Apply Terminal protectant

Check pedal stop operation and adjust if necessary

Inspect internal wet brake andreplace pads if necessary

Replace transaxle oil

S

S

CA

S

S

CA

S

S

CA

CA

*

*

Check rear axle bearing playfor roughness or freeplay

CS

CA

CS

CA

CS

CS CS CS

CS CS CS

CA

R

Check steering knucklebushing freeplay / Adjustwheel alignment


MAINTENANCE

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8-3 JW9

Battery Care

Battery electrolyte is poisonousand dangerous, causing severeburns, etc. It contains sulfuric acid.Avoid contact with skin, eyes, orclothing.Antidote:EXTERNAL: Flush with water. INTERNAL: Drink large quantities ofwater or milk. Follow with milk ofmagnesia, beaten egg, or vegetableoil. Call 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 inenclosed space. Always shield eyeswhen working near batteries.KEEP OUT OF REACH OFCHILDREN.

Six 8-volt deep cycle batteriesprovide power for your electric golfcar and must be properly maintainedand recharged for maximumperformance and service life.

To maintain your batteries:

1. Clean the tops of the batterieswith a solution of baking sodaand water, as necessary, toremove corrosion.

Do not allow cleaning solution toenter battery cells. Serious batterydamage can result.

2. Check the fluid level before andafter charging.

NOTICE


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MAINTENANCE

8-4JW9

l Before charging: only add distilledwater if fluid is below the top of theplates, and then add just enough tocover plates.

l After charging: open the vent capsand look inside the fill wells. Adddistilled water until the electrolytelevel is 3 mm (1/8") below thebottom of the fill well. A piece ofrubber can be used safely as adipstick to help determine this level.Clean, replace and tighten all ventcaps.

Normal tap water containsminerals which are harmful to abattery; therefore, refill only withdistilled water.

3. Using a hydrometer, check thespecific gravity of the battery fluidin each cell against the readingson the chart below. Consult aYamaha dealer if any low readingsare found, or if readings vary morethan one point between cells.

Temperature Satisfactory Uncorrected

°C °F Hydrometer Reading

48.9 120 1.244

43.3 110 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

NOTICE

Y-936a

1/8”(3 mm)

Electrolyte 1/8” BelowBottom of Fill Well

Max. Level - discharged battery

Max. Level - charged battery

Fill Well

Electrolyte

Y-937c


MAINTENANCE

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8-5

OFFON

Y-912

REV FWD

Battery Charging

Read and understand the owner’smanual provided with your golfcar’s battery charger beforecharging batteries. Death orserious personal injury can resultfrom failing to comply with thesafety instructions in this manual.

Explosive hydrogen gas is produced while batteries arebeing charged. Only charge batteries in well ventilated areas(a minimum of five air changesper hour is recommended). Deathor serious personal injury canresult from failing to comply withthe safety instructions in thismanual.

To charge the batteries in your golf car, follow the instructionscontained in your battery charger’sowner’s manual. The following is asummary of the charging steps. 1. Turn main switch key to “OFF”

position.

Always put the tow switch in the“TOW” position before chargingbattery or damage to the electricalsystem may result.

2. Lift up the seat and move the towswitch to the TOW position.

NOTICE

JW9


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MAINTENANCE

8-6JW9

Use only battery chargers that arerated for use with 48-volt YamahaGolf Cars. Serious battery damagecan result. Thoroughly read andunderstand the user manualsupplied with your 48-volt charger.

3. With the charger properlyconnected and grounded (seecharger’s owner’s manual), insertthe DC output into the golf carreceptacle.

Do not disconnect the DC outputcord from the battery receptaclewhen the charger is on or an arccould occur that may cause anexplosion. Death or seriouspersonal injury can result fromfailing to comply with the safetyinstructions in this manual.

å Power ON Light (Red)∫ Error Light 1 (Red)ç Error Light 2 (Red)∂ Charging Light (Yellow)fl Charged Light (Green)

4. When the charger is plugged intothe AC power, the Power ONLight illuminates continuously.

5. If Error 1 or Error 2 light isblinking, there is a problem withthe batteries or the charger.Contact your Yamaha Dealer.

6. During normal charging, theCharging Light blinks orcontinually illuminates.

7. The charger turns offautomatically when the batteriesreach full charge.

NOTICE

POWER ON

ERROR1

ERROR2

CHARGING90%

CHARGED

Y-1559

A

B

C

D

E

Y-669c


MAINTENANCE

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8-7 JW9

8. After the charger has turned off,disconnect the DC output plugfrom the golf car receptacle bygrasping the plug body andpulling the plug straight out ofthe receptacle.

Battery Installation

When working with batteries, donot put wrenches or other metalobjects across the batteryterminals. An arc can occurcausing an explosion or fire at thebattery. Death or serious personalinjury can result from failing tocomply with the safetyinstructions in this manual.

1. Install the battery holddownplates and torque to 7-9 Nm,0.7-0.9 m•kg (62-80 in•lb) asshown.

å Forward∫ Batteryç Battery holddown plate

2. Connect the wire leads andtorque to 9-10 Nm, 0.9-1.0 m•kg(80-89 in•lb) as shown.

When installing batteries:l Carefully place battery cables

and hold-downs making surethat cables do not lay acrossvent caps.

l Always remove the negative (–)cable to the motor controllerfirst, and install it last. A sparkcan occur causing an explosionor fire at the battery. Death orserious personal injury canresult from failing to complywith the safety instructions inthis manual.

Y-751D

B CA

Y-672h


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MAINTENANCE

8-8JW9

Do not overtighten the batteryholddown nuts. Excessive forcewill damage the battery casing.

Fuse Replacement

Be sure to use the specified fuse.Using a wrong fuse can causeelectrical system damage andcreate a fire hazard. Death orserious personal injury can resultfrom failing to comply with thesafety instructions in this manual.

When replacing a fuse be surethe main switch is turned off toprevent accidental short-circuiting and electrical systemdamage.

1. Locate the in-line fuse holder onthe main wire harness adjacentto the tow switch.

2. Pull fuse holder cover off.

3. Pull fuse out, inspect and replaceif necessary.

å Fuse holder∫ Fuse

NOTICE

NOTICEFuse Type:

3 Amp, Blade Style

Y-523aAB


MAINTENANCE

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8-9 JW9

4

Y-1214

1

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Y-1994

Transaxle OilTo check transaxle oil level:

1. Place the golf car on a flat, levelsurface.

2. Remove seven plastic rivets 1and two bolts 2, and remove thebag holder insert 3.

3. Place an oil pan under thetransaxle case.

4. Clean area around servicing plug 4.

5. Using an 8 mm hex wrench,remove transaxle oil servicingplug located on the rear of thetransaxle case.

6. Transaxle oil should be at the topof the oil servicing hole or justbeginning to run out of hole.

Do not allow foreign material toenter transaxle. Serious transaxledamage can result.

7. If needed, add Yamalube FrictionModified Shaft Drive Gear Oiluntil it is at the top of the plughole or just beginning to run outof servicing hole.

TIPThe YDRE Golf Car is equipped withan internal wet brake. Use of oil otherthan Yamalube Friction ModifiedShaft Drive Gear Oil will cause brakenoise.

8. Install the transaxle servicingplug and tighten to 14-19 Nm,1.4-1.9 m•kg (120-168 in•lb).

9. Install the bag holder insert3 and secure with two bolts 2and seven plastic rivets 1.

NOTICE


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MAINTENANCE

8-10JW9

TIPFor transaxle oil replacement,consult a Yamaha dealer or otherqualified mechanic.

Before performing wheel or brakemaintenance, verify that the mainswitch is in the “OFF” position.Serious transaxle damage canresult.

Wheel ReplacementTo remove and install a wheel onyour 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 jackand remove the wheel nuts andthe wheel.

3. Reverse the removal steps wheninstalling the wheel.

Wheel nut tightening torque:80 Nm, 8.0 m.kg (58 ft.lb)

Brake Adjustment The brakes on your golf car are self-adjusting.Before you operate the car, pressdown on the brake pedal severaltimes to make sure the brakes arefunctioning properly.

Consult your Yamaha dealerbefore using your golf car if yoususpect brake problems. Death orserious personal injury can resultfrom failing to comply with thesafety instructions in this manual.

NOTICE

Y-57


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8-11 JW9

MAINTENANCE

Y-61c

Y-909A

A B

Y-62b

7

1817

1615

1413

1211

109

8

a

Brake Pedal Free PlayAdjustment

Before adjusting brake pedal freeplay, pump the brake pedal severaltimes to self-adjust the brakes.

To adjust the brake pedal free play:

1. Remove the floor mat and service lid from the floor of thegolf car.

2. Check the brake pedal free playby pressing against the pedalwith two fingers (using lightforce) and measuring the distance the pedal travels beforeresistance is felt.

Brake pedal free play Å:45-50 mm (1.77-1.96 in.)

3. If the free play distance needsadjusting, loosen the lock nut åand turn the adjusting nut ∫ in or out until the free play specification is met. Then tightenthe lock nut in place.

Do not over-tighten the brakecables. Over-tightening willincrease brake wear and affectoverall performance of car.Premature brake wear can result.

NOTICE

NOTICE


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STORAGE

9-1JW9

2. Have the batteries rechargedevery 60-90 days to keep themfully charged. The batteries mustbe kept fully charged to avoid damage.

Do not allow cleaning solution toenter battery cells. Seriousbattery damage can result.

3. Clean the top of the batterieswith a solution of baking sodaand water, as necessary, toremove corrosion.

NOTICE

Perform the following preparationswhen storing your golf car forextended periods of time:

TIPTurn main switch key to “OFF”position, remove key, and store keyin a safe place.

CHASSIS PREPARATION1. Verify the tire pressure is set to

138 kPa, 1.4 kgf/cm2 (20 psi).

2. Clean exterior of the golf car andapply a rust inhibitor.

3. Cover the golf car with a breathable cover and store it in adry, well-ventilated area.

BATTERY PREPARATION1. Remove the batteries from the

golf car and store them in a cool,dry place that stays between 0°C (32°F) and 30°C (90°F).


SPECIFICATIONS

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10-1 JW9

GENERAL SPECIFICATIONS

Items YDREDimensions:

Overall length 2395 mm (93.4 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 lb)

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

PAINT CODESName Ditzler NumberGlacier 918519

Emerald 48748Garnet 701739

Tanzanite 917834Onyx Metallic 918520

Anthracite Metallic 918522Sandstone Metallic 918523


BATTERIESItems YDRE

Battery: Trojan - Golf Car Type T-875 (6x8-volt)RC: minimum 115 min

CHASSISItems YDRE

Steering system:Type Rack and PinionSteering angle (L.H.) 1.85 turnSteering angle (R.H.) 1.85 turn

Brakes:Brake system MechanicalType of brake Maintenance-Free internal transaxle disc brakeBrake pedal freeplay linkageadjustment 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 PRRear 18 x 8.50–8.00/4 PRRim size: 7.00–I–8.00Tire pressure: 138 kPa, 1.4 kgf/cm2 (20 psi)

TRANSMISSIONItems YDRE

Differential/reduction gear:Differential type Bevel gearLubricant/capacity Yamalube Friction Modified Shaft Drive Gear

Oil / 1350 mL (1.45 quarts total). Alternativelubricant is mixture of 1280 mL (1.35 quarts)

80W90 Gear Oil and 70 mL (0.10 quarts)API G15 Limited Slip Additive.

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SPECIFICATIONS

JW9 10-2


11-1 JW9

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WIRING YDRE WIRING DIAGRAM

Y-94

0g

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lack

L...

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Y/B

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w/B

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R/Y

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R/W

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L

BL

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RW

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SE

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B

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W

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GATE DRIVER CIRCUIT

PWM OUTPUT

RB

PB

PB

PB

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RW

Br

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Br

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BA

TT

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x8v)

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13

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Gy

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1211

84

109

2426

25

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VF

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RY Y W

DIR

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TIO

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TACH

A1F1

(A2)

(A1)

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(F2)

(F1)

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LB

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CONT

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AS

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FUSE (3 AMP)

CO

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PLI

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JW

2-H

2590

-10

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Br RW

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TIO

NA

L

B W


48 VOLT GOLF CAR YDRE

LIT-19626-21-10 JW9-F8199-10YAMAHA GOLF-CAR

COMPANY1000 HWY 34 EastNewnan, GA 30265

770-254-4000

Printed in U.S.A2010-KCC

!

OWNER’S / OPERATOR’SMANUAL

READ THIS MANUAL CAREFULLY!It contains important safety information.

JW9-F8199-10_cover_LIT_19626_11_07 cover.qxd 4/27/10 12:28 PM Page 1

48 volt golf car · 2016-07-10 · 48 volt golf car ydre lit-19626-21-10 jw9-f8199-10 yamaha...

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