Yamaha G-MAX 48V 48 VOLT ELECTRIC-G22-E Manual

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OWNER'S / OPERATOR,S MANUAL

GOLF CAR G22E

LIT-19626-00-79

JU2-F8199-12

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 MOTOR MANUFACTURING

CORP OF AMERICA

G22E

OWNER’S/OPERATOR’S

MANUAL

© 2004 by Yamaha Motor Manufacturing Corporation of America

1st edition

All rights reserved. Any reprinting or unauthorized use without the written permission of

Yamaha Motor Manufacturing

Corporation of America is expressly prohibited.

Printed in U.S.A.

P/N LIT-19626-00-79

G22E

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IMPORTANT MANUAL

INFORMATION

Particularly important information is distinguished in this manual by the following notations:

!

The Safety Alert Symbol means ATTENTION! BE ALERT! YOUR SAFETY IS INVOLVED!

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the golf car occupants, a bystander, or a person inspecting or repairing the golf car.

NOTE:

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.

This manual should be considered a permanent part of your golf car and should remain with the car when resold.

CAUTION

This message describes special precautions that must be taken to avoid damage to the golf car.

NOTE:

This message provides additional key information.

WARNING

Read and understand this manual completely before operating your golf car.

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G22E

CONTENTS

WARRANTY

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IMPORTANT LABELS

2

 

 

 

 

OPERATOR SAFETY

3

 

 

 

 

MAINTENANCE SAFETY PROGRAM

4

 

 

 

 

CONTROLS

5

 

 

 

 

PRE-OPERATION CHECKS

6

 

 

 

 

OPERATION

7

 

 

 

 

MAINTENANCE

8

 

 

 

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STORAGE

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SPECIFICATIONS

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WIRING

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WARRANTY

 

 

 

 

 

 

 

 

YAMAHA MOTOR MANUFACTURING

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CORPORATION OF AMERICA

 

 

 

 

LIMITED 3-YEAR

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GOLF CAR WARRANTY

 

 

Yamaha Motor Manufacturing of America hereby war-

 

 

rants that any new Yamaha Golf Car (gas and electric

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models) purchased from an authorized Yamaha dealer

 

in the United States will be free from defects in material

 

 

 

 

and workmanship for THREE years from date of pur-

 

 

chase, subject to the stated limitations.

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DURING THE PERIOD OF WARRANTY any autho-

 

rized 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

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will be warranted for the balance of the machine’s war-

 

ranty period. All parts replaced under warranty become

 

property of Yamaha Motor Manufacturing Corporation of

America.

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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 alteration that affects 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, ie: lightning, hail damage, flooding, fire, etc.

 

SPECIFIC EXCLUSIONS: The first year of warranty

 

shall cover the entire car except for batteries, battery

 

chargers, tires and rims, which are warranted by their

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respective manufacturers. Parts excluded from the sec-

ond year of warranty include the body parts, seats,

 

mats, bumper assembly, bag carrier, scorecard holder,

 

and the trim. Parts excluded from the third year of war-

 

ranty include the second year exclusions, the electrical

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system (except electronic speed controller and electric

motor) and control cables. Other specific exclusions

from this warranty shall include any parts replaced due to normal wear or routine maintenance, including oil, air filter elements, brake shoes, spark plugs, starter and clutch drive belts. Any charges incurred in transporting a golf car to and from an authorized Yamaha Golf Car Dealer for service or in performing field service are also excluded from this warranty.

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G22E

Yamaha G-MAX 48V 48 VOLT ELECTRIC-G22-E Manual

IMPORTANT LABELS

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3 4

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Y-654a

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SAFETY AND INSTRUCTION LABELS

WARNING

Please read the following labels carefully before operating your golf car, and promptly replace any labels which become damaged or removed.

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Y-500

Y-655

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Y-656

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Y-843

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Y-844

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IMPORTANT LABELS

 

 

GOLF CAR SERIAL

 

 

 

NUMBER

 

 

The golf car serial number is stamped

U

 

in the location shown.

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J

 

 

Y-102b

 

NOTE:

 

 

The first three digits of the serial num-

 

 

 

ber are for model identification; the

 

 

remaining digits are the unit produc-

 

 

tion number. Keep a record of these

 

 

numbers for reference when ordering

 

 

parts from a Yamaha dealer.

 

 

 

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! OPERATOR SAFETY

Yamaha golf cars are designed to be

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simple to operate. However, be sure

to observe the following:

 

BEFORE OPERATING

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THE GOLF CAR

 

Y-8

Y-68

Y-67

Read this Owner’s/Operator’s manual and all safety and instruction labels on the golf car before operating.

Perform the pre-operation checks found in Section 6 of this manual.

Only authorized people should drive the golf car, from the driver’s side only, and only in designated areas.

Do not allow more than two people to ride in the golf car. This golf car is restricted to two occupants.

Do not operate the golf car while under the influence of alcohol or drugs; their affect on vision and judgment make operating a golf car dangerous.

Do not operate the golf car on public streets, roads or highways. Such use is prohibited by law, and dangerous. Operation on public roads can result in collision with other vehicles.

WHILE OPERATING THE GOLF CAR

Keep your entire body inside the golf car, remain seated, and hold on when the car is in motion.

Do not start the golf car until all occupants are seated.

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! OPERATOR SAFETY

Keep your hands on the steering wheel and your eyes on the path ahead.

Use extra care in congested areas or when backing up. Always back up slowly, and watch carefully.

Avoid starting or stopping abruptly.

Vary the speed of the golf car to match the terrain of the course.

Avoid turning the steering wheel too sharply at higher speeds.

Always drive slowly straight up or straight down slopes – never at an angle.

Y-10

Do not make any modification or addition which affects capacity or safe operation, or make any changes not in accordance with the owner’s/operator’s manual.

Y-69

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! GOLF COURSE SAFETY PROGRAM

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.

Experience 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:

Do Not Operate Golf Cars When

Under The Influence Of Alcohol Or

Drugs

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 course hazards must be made safe:

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:

Warning: Steep Grade, Descend

Slowly With Foot On Brake

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.

Wet Areas. Wet grass may cause a golf car to lose traction and may affect stability. Chain or rope off wet areas or identify wet areas with a suitable warning.

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! GOLF COURSE SAFETY PROGRAM

Loose Terrain. Loose terrain may

1cause a golf car to lose traction and may affect stability. Repair loose terrain, chain or rope off these areas, or identify loose terrain with

2a suitable warning.

Golf Car and Pedestrian Interfer-

3ence. Reroute golf car traffic or pedestrian traffic in congested areas wherever possible to prevent

 

accidents. If it is impractical to

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reroute traffic, erect warning signs

 

to warn pedestrians of golf car traf-

 

fic, and to warn golf car operators to

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drive slowly, use caution, and watch

for pedestrians.

MAINTENANCE

6REQUIRED FOR GOLF CAR SAFETY

7Practice the following to help ensure

the safety of golf car occupants:

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Preventative Maintenance. Per-

form all scheduled maintenance in

 

accordance with

manufacturer’s

 

recommendations

to provide the

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golfing patron with a safe, properly

operating golf car.

 

 

 

Personnel. Allow

only

qualified,

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trained, and authorized

personnel

 

to inspect, adjust, and maintain golf

 

cars.

 

 

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Parts and Materials. Use only

 

replacement parts

and

materials

 

recommended by the manufacturer.

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 hydrogen gas from electric powered car storage areas during the 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.

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! GOLF COURSE SAFETY PROGRAM

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:

Properly immobilize golf car before beginning any maintenance.

Properly block chassis before working underneath golf car.

Avoid fire hazards, and have appropriate fire protection equipment available.

Before working on an electric golf car, disable the car’s electrical system in accordance with the manufacturer’s instructions.

Use only properly insulated tools when working on electrically powered golf cars or around batteries.

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.

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.

Record all maintenance performed in a maintenance record log by date, name of person performing maintenance, and type of maintenance. Periodically inspect maintenance log to ensure accurate and complete entries.

Provide operator comment cards to assist in identifying non-periodic maintenance needs for specific golf cars.

Maintain in a legible condition all nameplates, warnings, and instructions provided by the manufacturer.

If new nameplates, warnings, or instructions are needed, contact your Yamaha dealer.

STORAGE AND BATTERY CHARGING

Take the following precautions to ensure maintenance worker safety:

Only use battery changing and charging facilities and procedures that are in accordance with applicable ordinances and regulations.

Periodically inspect charging facilities and procedures to be certain that applicable safety codes, regulations, and procedures are being followed.

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