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

Page 1
OWNER'S MANUAL
/
OPERATOR
GOLF CAR G22E
,
S
LIT-19626-00-79
Page 2
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
i
Page 3
IMPORTANT MANUAL
WARNING
NOTE:
NOTE:
CAUTION
WARNING
!
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!
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.
Yamaha continually seeks ad-
vancements 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.
This message describes special precautions that must be taken to avoid damage to the golf car.
This message provides additional key information.
ii
Read and understand this manual completely before operating your golf car.
G22E
Page 4
CONTENTS
WARRANTY
IMPORTANT LABELS 2
OPERATOR SAFETY 3
MAINTENANCE SAFETY PROGRAM 4
CONTROLS 5
PRE-OPERATION CHECKS 6
OPERATION 7
MAINTENANCE 8
1
1
STORAGE
SPECIFICATIONS
WIRING 11
G22E
iii
9
10
Page 5
WARRANTY
1
YAMAHA MOTOR MANUFACTURING
CORPORATION OF AMERICA
2
Yamaha Motor Manufacturing of America hereby war­rants that any new Yamaha Golf Car (gas and electric models) purchased from an authorized Yamaha dealer in the United States will be free from defects in material
3
and workmanship for THREE 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
4
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 of the machine’s war­ranty period. All parts replaced under warranty become
5
property of Yamaha Motor Manufacturing Corporation of America.
GENERAL EXCLUSIONS from this warranty shall include any failures caused by:
6
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
7
8
9
10
11
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 respective manufacturers. Parts excluded from the sec­ond 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 war­ranty include the second year exclusions, the electrical 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.
LIMITED 3-YEAR
GOLF CAR WARRANTY
1-1
G22E
Page 6
IMPORTANT LABELS
Y-844
WARNING
1
2
1
3
4
SAFETY AND
INSTRUCTION
1
LABELS
2
Please read the following labels carefully before operating your golf car, and
Y-654a
5
promptly replace any labels which become damaged or removed.
3
2
3
4
5
6
7
Y-500
Y-655
8
4
G22E
5
Y-656
Y-843
2-1
9
10
11
Page 7
IMPORTANT LABELS
NOTE:
1
2
3
JU2
Y-102b
4
NUMBER
The golf car serial number is stamped in the location shown.
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 dealer.
5
6
7
8
GOLF CAR SERIAL
9
10
11
2-2
G22E
Page 8
OPERATOR SAFETY
Y-67
!
Y-8
Y-68
Yamaha golf cars are designed to be simple to operate. However, be sure to observe the following:
BEFORE OPERATING THE GOLF CAR
Read this Owner’s/Operator’s man-
ual 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 pub-
lic streets, roads or highways. Such use is prohibited by law, and dan­gerous. Operation on public roads can result in collision with other vehicles.
1
2
3
4
5
6
7
8
9
10
G22E
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.
3-1
11
Page 9
!
OPERATOR SAFETY
1
2
3
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.
4
Avoid turning the steering wheel too
sharply at higher speeds.
5
Always drive slowly straight up or
straight down slopes – never at an angle.
6
Y-10
7
8
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.
9
10
11
3-2
Y-69
G22E
Page 10
!
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.
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
1
2
3
4
5
6
7
8
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:
G22E
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.
4-1
9
10
11
Page 11
GOLF COURSE SAFETY PROGRAM
!
Loose Terrain. Loose terrain may
1
2
3
4
5
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.
Golf Car and Pedestrian Interfer-
ence. 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
6
REQUIRED FOR GOLF CAR SAFETY
Practice the following to help ensure
7
the safety of golf car occupants:
Preventative Maintenance. Per-
8
9
form all scheduled maintenance in accordance with manufacturer’s recommendations to provide the golfing patron with a safe, properly operating golf car.
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.
Personnel. Allow only qualified,
10
11
trained, and authorized personnel to inspect, adjust, and maintain golf cars.
Parts and Materials. Use only
replacement parts and materials recommended by the manufacturer.
4-2
G22E
Page 12
!
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 includ-
ing 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
Ta ke 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 facili-
ties and procedures to be certain that applicable safety codes, regu­lations, and procedures are being followed.
1
2
3
4
5
6
7
8
9
10
11
G22E
4-3
Page 13
CONTROLS
1
6
5
2
4
P
3
1
7
8
Y-6 59a
FEATURES
1 Steering wheel 2 Seat 3 Batteries 4 Brake pedal 5 Parking brake pedal 6 Accelerator pedal 7 Main switch 8 Drive selector switch 9 Tow switch
4
a Front cowl b Front tire c Front bumper
5
d Rear cowl e Rear bumper f Rear tire
16
3
Y-658
g Receptacle
6
7
8
2
10
11
13
9
10
11
5-1
14
12
Y-660
9
CAUTION / AVERTISSEMENT
Y-6 62a
15
Y-661
G22E
Page 14
CONTROLS
REV FWD
REV FWD
MAIN SWITCH
The main switch controls the follow­ing items:
OFF Ignition circuit is switched off. The key can be removed only in this
OFF
ON
position.
1
2
3
4
Y-663
ON Electrical circuits are switched on. The golf car can be driven.
OFF
ON
5
6
7
8
Y-664
G22E
9
10
11
5-2
Page 15
NOTE:
CONTROLS
1
OFF
2
REV FWD
ON
3
Y-665
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 switch to the desired position.
Switch Position Car Movement
FWD FORWARD
REV REVERSE
4
5
The back-up buzzer will beep when the drive select switch is depressed to the “REV” position.
6
Y-19
7
ACCELERATOR PEDAL
A
8
The accelerator pedal controls the golf car’s speed.
9
10
11
5-3
Action Car Speed
Depress pedal Increase
Y-20A
Release pedal Decrease
å Accelerator pedal
BRAKE PEDAL
Press down on the brake pedal to stop the golf car.
Brake pedal
B
Y-21a
G22E
Page 16
NOTE:
WARNING
NOTE:
CONTROLS
A1
F2
C
CAUTION / AVERTISSEMENT
PARKING BRAKE PEDAL
Press down on the parking brake pedal whenever parking the golf car.
ç Parking brake pedal
Y-22a
Release the parking brake by depressing the accelerator pedal.
1
2
3
4
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.
5
6
7
TOW SWITCH
Before operating the car, make sure
TOW
RUN
A
the tow switch is in the “RUN” posi­tion.
å Tow switch
8
9
G22E
Anytime the tow switch is moved from
Y-666a
the “RUN” position to the “TOW” posi­tion and immediately moved back to “RUN”, there is a delay of approxi­mately 30 seconds before the car will run.
Make sure the tow switch is in the “TOW” position if towing this vehicle.
10
11
5-4
Page 17
PRE-OPERATION CHECKS
WARNING
1
2
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.
3
Be sure the main switch key is
removed before performing the
4
pre-operation checks to prevent accidental starting, and apply the parking brake to keep the car from moving.
5
PRE-OPERATION
6
7
8
CHECKLIST
Before each use check the following:
BatteriesTire conditionSteering systemBack-up buzzerPedal operationBody and chassis
9
10
11
6-1
SEAT
Open the seat for checking and ser­vicing.
Y-512
G22E
Page 18
PRE-OPERATION CHECKS
BATTERY
Charge batteries before each use. See charging steps in chapter 8,
Maintenance.
Check that the batteries are held securely in place to prevent the batteries from being damaged from vibration or jarring. Also check that no battery caps are missing to prevent battery acid from spilling from the battery. Check the battery terminals for corrosion.
TIRE CONDITION
Tire Air Pressure
Check the tire air pressure before operating the golf car.
Tire pressure:
20 psi (137 kPa, 1.4 kgf/cm2)
1
2
3
4
5
6
7
8
G22E
Y-30
9
Tire Wear Limit
A
Y-31
Check the tire surface for damage, cracks or embedded objects. When tire tread wears down to 0.04 in. (1 mm), replace the tire.
å Wear limit
10
11
6-2
Page 19
PRE-OPERATION CHECKS
1
2
3
4
Y-667
5
6
REV FWD
OFF
ON
STEERING SYSTEM
Check the steering system for exces­sive freeplay by:
moving the steering wheel up and
down, and back and forth.
turning the steering wheel slightly
to the right and left.
If you feel excessive freeplay, or hear rattling sounds which may indicate loose steering components, consult a Yamaha dealer.
BACK-UP BUZZER
Check the back up buzzer by moving the drive select switch to “REV” for reverse. The buzzer should sound.
7
8
Y-668
PEDAL OPERATION
9
10
11
6-3
Check the following pedal controls for proper operation. If a pedal does not work properly, consult a Yamaha dealer.
Brake Pedal
Make sure the brake pedal feels firm when pressed and returns to its orig­inal position when released.
Brake pedal
B
Y-21a
G22E
Page 20
PRE-OPERATION CHECKS
WARNING
NOTE:
Parking Brake Pedal
Make sure the parking brake pedal locks in place with a positive click, and releases when the accelerator pedal is pressed.
C
Y-22a
ç Parking brake pedal
Release the parking brake by depressing the accelerator pedal.
1
2
3
4
Accelerator Pedal
5
Before checking operation of the accelerator pedal, be sure the main switch is in the “OFF” posi­tion.
Make sure the accelerator pedal
A
operates smoothly.
å Accelerator pedal
6
7
8
G22E
Y-20A
BODY AND CHASSIS
Before each use, visually inspect the golf car body and chassis for damage and/or missing parts.
6-4
9
10
11
Page 21
OPERATION
NOTE:
WARNING
CAUTION
1
OFF
2
REV FWD
ON
3
Y-665
STARTING
1. With the parking brake applied, turn the drive select switch to “FWD” for forward, or “REV” for reverse.
Do not shift from “FWD” forward to “REV” reverse while the golf car is moving.
4
2. Turn the main switch to “ON.”
5
OFF
REV FWD
ON
6
7
8
Y-664
A
9
Do not depress the accelerator pedal when turning on the main switch or the golf car may sudden­ly start moving.
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.
10
11
7-1
å Accelerator pedal
Y-20A
The parking brake automatically releases when the accelerator pedal is depressed.
G22E
Page 22
OPERATION
CAUTION
STOPPING
To stop the golf car, gradually press down on the brake pedal.
Brake pedal
When the car has come to a stop,
C
apply the parking brake pedal and turn the main switch to “OFF.”
ç Parking brake pedal
1
2
3
4
B
Y-65a
Do not hold the golf car on an incline with the accelerator – use the brake.
5
6
7
8
G22E
9
10
11
7-2
Page 23
MAINTENANCE
1
Regular maintenance is required for the best performance and safe operation of your golf car.
2
3
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 machine servicing, this work should be done by a Yamaha dealer or other qualified mechanic.
PERIODIC MAINTENANCE CHARTS
4
5
6
7
8
9
10
11
8-1
G22E
Page 24
MAINTENANCE
FOR G22E
C - CHECK CA - CHECK AND ADJUST R - REPLACE S - SERVICE CL - CLEAN AND LUBRICATE L - LUBRICATE
PRE-OP
EVERY MONTH
EVERY 6 MONTHS
EVERY YEAR
EVERY 4 YEARS
Charge
Clean battery tops, check for tightness of hold-down screws and terminals
Check brake pedal freeplay and adjust 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, and screws
Check reverse buzzer operation
Check electrolyte level
Check for loose or broken connections
Clean/Lube pedal control area
Check all wire insulation for cracks and/or worn spots
Check shock absorbers for oil leaks and damaged springs
Perform a discharge test
Apply Terminal protectant
Check shoe lining thickness and rear axle bearing play
Check steering knuckle bushing freeplay / Adjust wheel alignment
Check wheel nut tightness, front wheel bearing play
Check gear box oil level and leakage
Check operation and adjust pedal stop if necessary
Replace gear box oil
Check for grease leakage; adjust gear box if necassry
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.
Pre-
20 rounds 125 rounds 250 rounds 500 rounds 1000 rounds
Opera­tion
S
S
C
C
C
C
C
C
20 hours
100 miles
160 kms
(Every Month)
S
S
CA
C
CA
C
C
C
C
C
CL
600 mls
1000 kms
(Every 6 months)
125 hrs
S
S
CA
C
CA
C
C
C
C
C
C
C
250 hrs
1200 mls
2000 kms
(Every
Year)
S
S
CA
C
CA
C
C
C
C
C
C
C
S
S
C
CA
C
C
CA
500 hrs
2500 mls
4000 kms
(Every 2
years)
S
S
CA
C
CA
C
C
C
C
C
C
C
S
S
C
CA
C
C
CA
1000 hrs 5000 mls
8000 kms
(Every 4
years)
S
S
CA
C
CA
C
C
C
C
C
C
C
S
S
C
CA
C
C
CA
R
CA
PageRemarks
8-5
8-3/
6-2
8-9/ 8-10
6-3
6-2
6-4
*
6-3
8-3/8-4
*
*
*
*
*
*
8-9/
8-8
*
*
8-8
1
2
3
4
5
6
7
8
9
*
10
11
G22E
8-2
Page 25
MAINTENANCE
CAUTION
WARNING
1
2
3
4
5
6
7
8
9
10
11
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. 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 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.
8-3
Do not allow cleaning solution to enter battery cells.
2. Check the fluid level before and
after charging.
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Page 26
MAINTENANCE
CAUTION
Before charging: only add distilled
water if fluid is below the top of the plates, and then add just enough to cover plates.
After charging: check that the fluid
level is approximately 1/4 to 1/2 inch above the plates and 1/4 to 3/8 inch below the level indicator. If the fluid level is low, carefully add distilled water. Adding distilled water after charging helps prevent boil over.
D
A
C
B
Y-829
å Battery capPlates ç Maximum fluid levelMinimum fluid level
Normal tap water contains miner­als which are harmful to a battery; therefore, refill only with distilled water.
1
2
3
4
5
6
7
3. Using a hydrometer, check the
specific gravity of the battery fluid
Y-47
in each cell against the readings on the chart below. Consult a Yamaha dealer if any low readings are found, or if readings vary more than one point between cells.
Temperature
˚F ˚C
120 48.9 1.244
110 43.3 1.248
100 37.8 1.252
90 32.2 1.256
80 26.7 1.260
70 21.1 1.264
60 15.6 1.268
50 10.0 1.272
40 4.4 1.276
30 -1.1 1.280
Satisfactory Uncorrected
Hydrometer Reading
8
9
10
11
G22E
8-4
Page 27
MAINTENANCE
CAUTION
WARNING
WARNING
REV FWD
OFF
ON
Y-663
1
2
Battery Charging
Read and understand the owner’s manual provided with your golf car’s battery charger before charg­ing batteries.
3
4
5
6
7
8
Explosive hydrogen gas is pro­duced while batteries are being charged. Only charge batteries in well ventilated areas (a minimum of 5 air changes per hour is rec­ommended).
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 charging steps. Do not attempt to
recharge your golf car’s batteries without thoroughly reading and understanding the owner’s manual provided with your charger.
9
10
11
8-5
1. Turn main switch key to “OFF” position.
2. With the charger properly con­nected and grounded (see charg­er’s owner’s manual), insert the DC output plug into the golf car receptacle.
Y-669
Use only battery chargers that are rated for use with 48 volt Yamaha Golf Cars. Thoroughly read and understand the user manual supplied with your 48 volt charger.
G22E
Page 28
MAINTENANCE
WARNING
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.
3. The charger will turn off automat­ically when the batteries reach full charge.
4. 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
1
2
3
4
5
6
C
B
G22E
When working with batteries, do not put wrenches or other metal objects across the battery termi­nals. An arc can occur causing explosion of the battery.
A
1. Install the battery holddown plates as shown.
å ForwardBattery ç Battery fitting plate
7
8
9
10
11
Y-7 51a
8-6
Page 29
MAINTENANCE
CAUTION
WARNING
CAUTION
WARNING
B
A
-
+
-
+
-
+
-
+
-
+
-
+
D
C C
FORWARD
Y-653
B
A
1
2. Connect the wire leads as shown.
å ForwardTo receptacle
2
ç To motor control unitBetween batteries
To relay
3
4
5
6
7
When installing batteries:
Carefully place battery cables
and holddowns making sure that cables do not lay across vent caps.
Always remove the negative (–)
cable to the motor controller first, and install it last.
Do not overtighten the battery holddown nuts. Excessive force will damage the battery casing.
8
9
10
11
Fuse Type:
8-7
3 Amp, Blade Style
Fuse Replacement
Be sure to use the specified fuse. Using a wrong fuse can cause electrical system damage and cre­ate a fire hazard.
When replacing a fuse be sure the main switch is turned off to pre­vent accidental short-circuiting.
å Fuse caseFuse
G22E
Page 30
MAINTENANCE
NOTE:
CAUTION
Y-48
Gear Box Oil
To check gear box oil level:
1. Place the golf car on a level sur-
face.
2. Remove the access panel by
removing the rivets in the two lower corners of the panel and pulling the panel from the car.
3. Remove the oil level plug å.
1
2
3
4
4. Add gear oil little by little until oil
flows from the level plug hole ∫.
5
Recommended oil:
SAE 90 gear oil
A
B
Y-520A
Gearcase capacity:
0.32 US qt (300 mL, 300 cc)
6
7
5. Allow excess gear oil to flow out
until it stops.
8
G22E
Do not allow foreign material to enter the gear box.
6. Reinstall the oil level plug.
For gear oil replacement, consult a Yamaha dealer or other qualified mechanic.
8-8
9
10
11
Page 31
MAINTENANCE
WARNING
CAUTION
1
Before performing wheel or brake maintenance, verify that the main
2
3
switch is in the “OFF” position.
Wheel Replacement
To remove and install a wheel on your golf car:
4
5
6
7
8
9
10
11
Y-57
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:
58 ft.lb (80 Nm, 8.0 m.kg)
Brake Adjustment
The brakes on your golf car are self­adjusting.
Before you operate the car, press down on the brake pedal several times to make sure the brakes are functioning properly.
Consult your Yamaha dealer before using your golf car if you suspect brake problems. Brake failure could result in a serious accident.
8-9
G22E
Page 32
MAINTENANCE
WARNING
CAUTION
Brake Pedal Free Play
1
Adjustment
2
Before adjusting brake pedal free play, pump the brake pedal several times to self-adjust the brakes.
3
To adjust the brake pedal free play:
1. Remove the service lid from the floor of the golf car.
4
5
Y-61a
6
2. Check the brake pedal free play by pressing against the pedal with two fingers (using light force)
a
18
17
16
15
14
13
12
11
10
9
8
7
and measuring the distance the pedal travels before resistance is felt.
7
8
Brake pedal free play Å:
20-25 mm (0.79-0.98 in.)
Y-62b
9
G22E
Y-63
3. If the free play distance needs adjusting, loosen the lock nut and turn the adjusting nut in or out until the free play specification is met. Then tighten the lock nut in place.
Do not overtighten the brake cables. The self adjusters may not operate properly, reducing braking performance.
8-10
10
11
Page 33
STORAGE
NOTE:
CAUTION
Perform the following preparations
1
when storing your golf car for extend­ed periods of time:
2
Turn main switch key to “OFF” posi­tion, remove key, and store key in a safe place. Move the tow switch into the “TOW” position.
3
CHASSIS
4
PREPARATION
1. Verify the tire pressure is set to
5
20 psi (137 kPa, 1.4 kgf/cm2).
2. Clean exterior of the golf car and apply a rust inhibitor.
6
3. Cover the golf car with a breath­able cover and store it in a dry, well-ventilated area.
7
8
BATTERY PREPARATION
1. Recharge the batteries and check the fluid levels at least once a month.
Do not allow cleaning solution to enter battery cells.
2. Clean the tops of the batteries
with a solution of baking soda and water, as necessary, to remove corrosion.
9
10
11
9-1
G22E
Page 34
SPECIFICATIONS
GENERAL SPECIFICATIONS
Items G22E
Dimensions:
Overall length 93.9 in. (2385 mm) Overall width 47.2 in. (1200 mm) Overall height (steering height) 46.9 in. (1190 mm) Height of floor 11.8 in. (300 mm) Wheelbase 64.3 in. (1632 mm) Tread: Front 34.3 in. (870 mm) Rear 38.6 in. (980 mm)
Min. ground clearance 3.8 in. (97 mm)
Weight:
Dry weight (without battery) 549 lb (249 kg)
Performance:
Factory speed setting 12 mph (19 km/h)
Maximum speed 15 mph (24 km/h)
Minimum turning radius 114.2 in. (2.9 m)
Seating capacity 2 persons
Hill climbing ability 20°
on pavement
1
2
3
4
5
6
7
8
TRANSMISSION
Items G22E
Differential/reduction gear: Differential type Bevel gear Lubricant/capacity SAE 90 gear oil/
0.32 US qt (300 mL, 300 cc)
BATTERIES
Items G22E
Battery: BCI group GC-2H
RC: minimum 105 min
G22E
9
10
11
10-1
Page 35
SPECIFICATIONS
CHASSIS
1
Items G22E
Steering system:
2
3
4
5
6
7
8
9
Type Rack and Pinion Steering angle (L.H.) 1.55 turn Steering angle (R.H.) 1.55 turn
Brakes:
Brake system Mechanical drum brake on each rear wheel
Type of brake Dual internal expanding shoe.
Brake pedal freeplay linkage adjustment 20-25 mm
(Brake cable end play) 0.004-0.02 in. (0.1-0.5 mm)
Parking brake:
Type Foot type; parking brake with automatic
Release timing (With pedal segment in second notch) (Bolt heads round parallel to arm) 0.000 ~ 0.001 in. (0.0 ~ 0.3 mm)
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–I–8.00 Tire pressure: 20 psi (137 kPa, 1.4 kgf/cm2)
with self-adjusters.
Leading/trailing shoes (self-adjusting)
release.
10
11
10-2
G22E
Page 36
G22E WIRING DIAGRAM
Main switch
Tow/storage switch
Accelerator stop switch
Buzzer
Directional switch
DC motor
Controller
Throttle sensor
Relay
Receptacle
Fuse (3A)
123456789
R
R
B/
W
B
W
W
TRANSCEIVER
Y
1
REV FWD
R/Y
32
W R/Y
W R/Y Y
Y
W
5
B
B
P
Br
R/W
P
Br
R/W
BUZZER
OFF ON
Br
R/W
4
3
2
OFF ON
R
R/Y R
R/Y
B/W
B
Y
R/Y
W
B
P
Br
R/W
WR/Y Y
RW
R/W
R/W
RY
101112
B/W
B
R/Y
R/Y
R
R
W
R/Y
W
B
R/Y
Batteries (6 x 8V)
R/W
COLOR CODE
B.....................Black
L.......................Blue
G...................Green
F2
F1
T
A
C
H
B
R
G
GRR
G
BB
B
R
G
19
18
10
236 45
1
1
987
11
R/B
R/Y
R
11
Y...................Yellow
R.......................Red
P.......................Pink
Br...................Brown
W....................White
A2
A1
6
21
20
15
23
14
16
R/B
R/B
Y
R/W
R
3/4 REC
(P) (A1) (A2)
L
BLL
B
L
5K
WIRING
B/R..........Black/Red
Y/B......Yellow/Black
R/Y........Red/Yellow
R/W........Red/White
B/W......Black/White
(F2)
(F1)
ASSY
BOARD
MOSFET
(N)
ASSY
BOARD
CONTROL
B
O
OO
B
O
8
R
R
B
9
12
Y-671
7
1
2
3
4
5
6
7
8
9
10
11
G22E
1
OFF ON
R/W
R
10
11-1
Page 37
NOTES
G22E
Page 38
Printed in U.S.A
2004-KCC
YAMAHA MOTOR
MANUFACTURING CORP.
OF AMERICA 1000 HWY 34 East Newnan, GA 30265
770-254-4000
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