Yamaha THE DRIVE ELECTRIC-YDR-E User Manual

OWNER’S / OPERATOR’S MANUAL

YDRE

48 VOLT GOLF CAR

LI T -19626-21-07

JW2-F8199-10

INTRODUCTION

Congratulations on your purchase of a Yamaha golf car. This manual contains information you will need for proper operation, maintenance, and care of your golf car. A thorough understanding of these simple instructions will help you to obtain maximum enjoyment from your new Yamaha.

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

YAMAHA GOLF-CAR COMPANY

YDRE OWNER’S/OPERATOR’S

MANUAL

1st Edition

or unauthorized use without the

written permission of

Yamaha Golf-Car Company

is expressly prohibited.

Printed in U.S.A.

LIT-19626-21-07

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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!

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.

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

G 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.

G This manual should be considered

a permanent part of your golf car and should remain with the car when resold.

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

This message provides additional key information.

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CONTENTS

WARRANTY

IMPORTANT LABELS 2

OPERATOR SAFETY 3

SAFETY CONSIDERATIONS 4

CONTROLS 5

PRE-OPERATION CHECKS 6

OPERATION 7

MAINTENANCE 8

STORAGE

SPECIFICATIONS

WIRING 11

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iii

WARRANTY

Yamaha Golf-Car Company hereby warrants that any new YDRA gas or YDRE electric Yamaha golf car purchased from an authorized Yamaha golf car dealer

in the United States will be free from defects in material and workmanship for 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 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 property of Yamaha Golf-Car Company.

GENERAL EXCLUSIONS from this warranty shall

include any failures caused by:

a. Abnormal strain, neglect, or abuse, including

lack of proper maintenance, and use contrary to the Owner’s/Operator’s Manual instructions.

b. Accident or collision damage. c. Installation of parts or accessories that are not

original equipment.

d. Fading, rust, or deterioration due to exposure

or ordinary wear and tear.

e. Modifications or alterations that affect the car’s

condition, operation, performance, or durability, or which makes the car serve a purpose other

than use as a two-person, golf course vehicle. f. Damage due to improper transportation. g. Acts of God, i.e. lightning, hail damage,

flooding, fire, etc.

SPECIFIC EXCLUSIONS: The first year of warranty shall cover the entire car except for the specific exclusions below. Parts excluded from the second year of warranty include the YDRA battery, 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 and the electrical system (except electronic speed controller, battery charger, 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 and air filter elements, tire wear, spark plugs, starter and clutch drive belts. Any charges incurred in transporting a golf car or charger to and from an authorized Yamaha golf car dealer for service or in performing field service is also excluded from this warranty.

YAMAHA LIMITED 3-YEAR

GOLF CAR WARRANTY

THE CUSTOMER’S RESPONSIBILITY under this

warranty shall be to:

1. Operate and maintain the golf car and charger as specified in the appropriate Owner’s/Operator’s Manual;

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

WARRANTY TRANSFER: To transfer any remaining warranty from the original purchaser to any subsequent purchaser, it is imperative that the machine be inspected and registered for warranty by an authorized Yamaha golf car dealer. In order for this warranty to remain in effect, this inspection and registration must take place within ten (10) days after transfer. An inspection and registration fee will be charged for this service.

YAMAHA GOLF-CAR COMPANY MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA GOLF-CAR COMPANY AND EXCLUDED FROM THIS WARRANTY.

SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS, WHICH VARY, FROM STATE TO STATE.

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

EFFECTIVE DATE: 10/01/06 LIT-13710-03-06B

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WARRANTY

YAMAHA FOUR-YEAR LIMITED WARRANTY FOR TROJAN BRAND

ELECTRIC GOLF CAR AND UTILITY VEHICLE BATTERIES WHEN

CHARGED WITH A YAMAHA 48-VOLT CHARGER

Yamaha Golf-Car Company (herein referred to as “YGC”) hereby warrants to the Original Retail Purchaser or Lessee of a Yamaha YDRE golf car or PTV, G23E or G27E utility vehicles purchased from an Authorized Yamaha Dealer, that the Trojan batteries charged with a Yamaha battery charger will be free from defects in materials and workmanship, and will provide “36-hole performance” for a period of four-years or “1,000 rounds” from the date of purchase, whichever event occurs first, subject to the terms and conditions contained herein.

This limited warranty covers defects in materials and workmanship only for a period of four-years or “1,000 rounds”, as applicable, from date of purchase, whichever event occurs first. The terms of this four-year or “1,000 round” limited warranty shall be as follows:

For YDRE golf car or PTV, G23E or G27E utility vehicles free replacement within four years or 20,000 amp-hours discharged or 500 hours elapsed time usage, whichever event occurs first, as determined by YGC using the information recorded and stored in the Genius controller.

This warranty only applies to Trojan battery sets charged with a Yamaha brand battery charger supplied by YGC.

The customer must perform (or have a contracted Yamaha Dealer perform) all periodic maintenance and discharge testing as specified in the Yamaha Service Manual Maintenance Schedule. No labor or transportation expenses are included in this limited warranty.

“Thirty-six hole performance” is defined as 60-minutes discharge time as tested and recorded using a Lester model #17770 discharge machine at an ambient temperature of between 60 and 100 degrees F (16 and 38 degrees C).

mbient temperatures between 60 and 80 degrees F (16 and 27 degrees C) must be corrected using the formula: Adjusted Discharge Time = (Discharge Minutes)/(1-(((80-TEMP)/100) x 0.64)).

The customer must notify the Dealer within 10 days that a vehicle has failed to make 36 holes per day. Yamaha reserves the right to test and recharge any batteries in question.

ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL BE VOID AND EXCLUDED SUBSEQUENT TO ONE YEAR FROM THE DATE OF PURCHASE. THE REPLACEMENT OF THE BATTERY IS THE EXCLUSIVE REMEDY UNDER THIS WRITTEN WARRANTY OR ANY IMPLIED WARRANTY. YAMAHA MAKES NO OTHER REPRESENTATION OR WARRANTY OF ANY KIND, AND NO REPRESENTATIVE, EMPLOYEE, DISTRIBUTOR OR DEALER OF YAMAHA HAS THE AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION, PROMISE OR AGREEMENT WHICH IN ANY WAY VARIES THE TERMS OF THIS LIMITED WARRANTY.

LIMITED WARRANTY EXCLUSIONS

Without limiting the generality of the foregoing in any way, and as part of its limited warranty exclusion, YAMAHA does not warrant that its battery is suitable for use in any application other than in a golf car or utility vehicle. As in the use of any battery, a prudent owner will read and study the charger owner’s manual, the vehicle owner’s manual, the operator’s instructions, and the battery warning labels; and will exercise due care in working on or around batteries.

THE PROVISIONS OF THIS LIMITED WARRANTY SHALL NOT APPLY TO FAILURE DUE TO:

Abuse or neglect such as improper fluid levels, loose wiring, rusted or corroded hardware; Lack of proper maintenance as outlined in the electric vehicle Owner’s/Operator’s Manual; Damage caused by improper installation of the battery; Neglect, breakage, freezing, fire, explosion, wreckage, the addition of any chemical, or the operation of the battery in an uncharged condition (below half-charge – 1.200 specific gravity); and a battery charged by systems other than the original equipment type battery charger. The golf car facility must have ample electrical power to charge the cars, and the chargers must be allowed to shut off automatically.

THIS BATTERY IS INTENDED TO BE USED BY PERSONS WITH TRAINING AND EXPERIENCE WITH BATTERIES AND ONLY IN YAMAHA ELECTRIC VEHICLES. ANY OTHER USE RENDERS THE LIMITED WARRANTIES EXPRESSED HEREIN AND ALL IMPLIED WARRANTIES NULL AND VOID AND SAME ARE HEREBY EXCLUDED.

ALSO EXCLUDED FROM THIS LIMITED WARRANTY ARE ANY AND ALL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING, BUT NOT LIMITED TO, LOSS OF USE OR REVENUE, LOSS OF TIME, INCONVENIENCE OR ANY OTHER ECONOMIC LOSS.

Some states do not allow limitation on the duration of an implied warranty, exclusions or limitations of incidental or consequential damages. Therefore, the above limitations or exclusions may not apply to you.

WARRANTY LIMITATIONS

Yamaha Golf-Car Company and Trojan Battery Company’s liability shall be to replace a defective battery. Replacement shall mean furnishing a new battery or used battery with sufficient life to complete the remainder of the warranty term, which is identical or reasonably equivalent to the warranted product at no cost to the purchaser during the limited warranty period, except for labor or transportation expenses.

Damage not resulting from a defect in materials or workmanship or which occurs due to abuse or neglect (including failure to provide reasonable and necessary maintenance), accident, alteration or acts of God is excluded from this limited warranty.

This warranty gives you specific legal rights, and you may also have other rights, which vary from state to state.

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

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Yamaha Golf-Car Company, NEWNAN, GEORGIA 30265-1320 EFFECTIVE DATE: 10/01/06 LIT-13710-EL-16B

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IMPORTANT LABELS

Y-924

SAFETY AND INSTRUCTION LABELS

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

Y-844a

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Y-500a

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IMPORTANT LABELS

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IMPORTANT LABELS

GOLF CAR SERIAL NUMBER

The golf car serial number 1 is identified in the location shown.

The first three digits of the serial

0 00

-00 X

Y-910b

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 Golf-Car Company dealer.

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OPERATOR SAFETY

Y-68

Yamaha golf cars are designed to be simple to operate. However, be sure to observe the following:

BEFORE OPERATING THE GOLF CAR

G Read this Owner’s/Operator’s

manual and all safety and instruction labels on the golf car before operating.

G Perform the pre-operation checks

found in Section 6 of this manual.

G Only authorized people should

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

G Do not allow more than two

occupants per seat. This golf car is restricted to two occupants unless equipped with a rear seat.

G 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.

G Do not operate the golf car on

public streets, roads or highways unless allowed by law or local regulating authority.

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Y-9 28

WHILE OPERATING THE GOLF CAR

G Keep your entire body inside the

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

G Do not start the golf car until all

occupants are seated.

G Keep your hands on the steering

wheel and your eyes on the path ahead.

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OPERATOR SAFETY

G Use extra care in congested areas

or when backing up. Always back up slowly, and watch carefully.

G Avoid starting or stopping abruptly.

G Vary the speed of the golf car to

match the terrain of the course.

G Avoid turning the steering wheel

too sharply at higher speeds.

G Always drive slowly straight up or

straight down slopes – never at an angle.

Y- 9 2 1

G Do not run the engine indoors.

Exhaust gas is poisonous.

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Y-922

G 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- 9 2 3

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SAFETY CONSIDERATIONS

Like all machines, golf cars can cause injury if improperly used or maintained. This section contains broad safety practices required for safe golf car operation. Before golf cars are operated, golf course personnel should establish any additional safety practices that may be required for safe operation.

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:

G 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:

Steep Grade, Descend Slowly With Foot On Brake

G 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.

G Wet Areas. Wet grass may cause

a golf car to lose traction and may affect stability. Reduce speed in wet areas or during periods of inclement weather.

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SAFETY CONSIDERATIONS

G Loose Terrain. Loose terrain may

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

G Golf Car and Pedestrian

Interference. Reroute golf car traffic or pedestrian traffic in congested areas wherever possible to prevent accidents. If it is impractical to reroute traffic, erect warning signs to warn pedestrians of golf car traffic, and to warn golf car operators to drive slowly, use caution, and watch for pedestrians.

MAINTENANCE REQUIRED FOR GOLF CAR SAFETY

Practice the following to help ensure the safety of golf car operators:

G Preventative Maintenance.

Perform all scheduled maintenance in accordance with

manufacturer’s recommendations to provide the golfing patron with a safe, properly operating golf car.

G Parts and Materials. Use only

replacement parts and materials recommended by the manufacturer.

G Ventilation. Properly ventilate all

maintenance and storage areas in accordance with applicable fire codes and ordinances to avoid fire hazards. Ventilation is required to remove flammable vapors and fumes from gasoline powered car storage areas. Ventilation is also required to remove hydrogen gas from the car storage areas during the battery charging process.

For electric powered golf cars, the amount of hydrogen gas emitted during charging depends on a number of factors, such as the condition of the batteries, the output rate of the battery charger, and the amount of time the batteries are on charge. Because of the highly volatile nature of hydrogen gas and its propensity to rise and accumulate at the ceiling in pockets, a minimum of 5 air changes per hour is recommended. Consult applicable fire and safety codes for the specific ventilation levels requirement, as well as requirements for the use of explosion proof electrical apparatus.

G Personnel. Allow only qualified,

trained, and authorized personnel to inspect, adjust, and maintain golf cars.

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