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Yamaha DRIVE2 AC 2019 Owner's/Operator's Manual
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Yamaha DRIVE2 AC 2019 Owner's/Operator's Manual

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2019
MODEL YEAR
OWNER'S / OPERATOR'S MANUAL
PERSONAL TRANSPORT VEHICLE
Read this manual carefully before operating this vehicle.
DR2E PTV
LIT-19626-A0-08
J0E-F8199-11

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  • Page 1 2019 MODEL YEAR OWNER’S / OPERATOR’S MANUAL PERSONAL TRANSPORT VEHICLE Read this manual carefully before operating this vehicle. DR2E PTV LIT-19626-A0-08 J0E-F8199-11...
  • Page 3 PTV, please consult a Yamaha dealer. Yamaha Golf-Car Company DR2E PTV Owner's/Operator's Manual © 2019 by Yamaha Golf-Car Company 1st edition All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Golf-Car Company is expressly prohibited.
  • Page 4 If you have any safety messages that follow this questions concerning this manual, symbol to avoid possible injury or please consult your Yamaha dealer. death. A WARNING indicates a hazardous Read and understand this manual situation which, if not avoided,...

  • Page 5: Table Of Contents

    CONTENTS WARRANTY IMPORTANT LABELS OPERATOR SAFETY SAFETY CONSIDERATIONS CONTROLS PRE-OPERATION CHECKS OPERATION MAINTENANCE STORAGE SPECIFICATIONS WIRING...

  • Page 6: Warranty

    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 are also excluded from this warranty.
  • Page 7 THE PROVISIONS OF THIS LIMITED WARRANTY SHALL Yamaha Golf-Car Company (herein referred to as “YGC”) hereby warrants to the Original Retail Purchaser or Lessee of a YAMAHA The NOT APPLY IF BATTERIES ARE SUBJECTED TO ANY OF THE FOLLOWING CONDITIONS:...

  • Page 8: Important Labels

    • This vehicle was not manufactured for use on public streets and does not comply with federal motor vehicle safety standards applicable to passenger cars. • This vehicle is capable of speeds over 15 mph (24 kph) and therefore does not conform to standards for golf cars (ANSI Z130.1). YAMAHA J0D-K7762-00...
  • Page 9 IMPORTANT LABELS...
  • Page 10 “TOW”, attendre un minimum de 15 seconds avant de le remettre. ***-K8298-** DATE OF CONSTRUCTION: *** **** MY**** YAMAHA MOTOR POWERED PRODUCTS CO., LTD 200-1 SAKAGAWA, KAKEGAWA, JAPAN MAX. BATTERY WEIGHT: *** kg MODEL: ****** NOMINAL SYSTEM VOLTAGE: **V MAX.
  • Page 11 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 Golf- Car Company dealer. Y-2829...

  • Page 12: Operator Safety

    OPERATOR SAFETY Yamaha PTVs are designed to be simple to operate. However, be sure to observe the following to reduce the risk of serious injury or death due to loss of control and other hazards: BEFORE OPERATING THE PTV Read this Owner’s/Operator’s...
  • Page 13 OPERATOR SAFETY 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 PTV to match the terrain. Avoid turning the steering wheel too sharply at higher speeds to avoid tipping or rolling the vehicle.

  • Page 14: Safety Considerations

    SAFETY CONSIDERATIONS Like all machines, PTVs can cause HAZARD PREVENTION injury if improperly used or maintained. Drivers should be mindful of road hazards, and avoid dangerous Experience has shown that PTVs situations that may include the are safe when operated in following: accordance with the safety warnings affixed to every PTV.
  • Page 15 SAFETY CONSIDERATIONS Loose Terrain – Avoid areas of Ventilation. Properly ventilate all loose terrain which may cause a maintenance and storage areas in PTV to lose traction and affect accordance with applicable fire stability. Take notice of conditions codes and ordinances to avoid fire and reduce speed when driving on hazards.
  • Page 16 If new nameplates, warnings or When working on the battery, do instructions are needed, contact not smoke, or allow any sparks or your Yamaha dealer. open flames near the vehicle, to avoid any fires or explosions. STORAGE AND Before working on an electric PTV, disable the car’s electrical...

  • Page 17: Controls

    CONTROLS FEATURES 1 Main/light b Batteries c Headlights switch 2 Drive select d Front body e Seat switch 3 Steering wheel f DC charger 4 Battery gauge receptacle 5 Brake pedal g Front tire 6 Parking brake h Front bumper i Rear body pedal 7 Horn switch...
  • Page 18 CONTROLS MAIN SWITCH The main switch controls the following items: “OFF” BATTERY All electrical circuits are switched off (motor controller unit remains energized). The golf car cannot be Y-2838 operated. The key can be removed only in this position. “ON” Electrical circuits are switched on.
  • Page 19 CONTROLS As the battery energy decreases, the LEDs will move to the left toward the “E.” When the LED light below BATTERY the “E” is the only one lit, the batteries must be charged. Y-2842 Use the table to determine the remaining battery capacity.
  • Page 20 CONTROLS USB PORTS A USB port is located inside the dash on the driver side and passenger side. These can be used to power or charge USB devices or accessories. The USB is only powered when the key is in the ON position. 1 USB port ACCELERATOR PEDAL The accelerator pedal controls the...
  • Page 21 CONTROLS TOW SWITCH Before operating the car, make sure the tow switch is in the “RUN” position. å Tow switch NOTICE Ensure that the “Drive Select Switch” is in the “FWD” position and then move the “TOW Switch” Y-1995 to “TOW” before towing. After moving switch from “RUN”...

  • Page 22: Pre-Operation Checks

    PRE-OPERATION CHECKS Pre-operation checks should be made each time you use your PTV. Get in the habit of performing the following checks in the same way so that they become second nature. To keep car from moving while performing pre-operation checks: Remove main switch key.
  • Page 23 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.
  • Page 24 The alarm should sound. Y-2846 PEDAL OPERATION Check the following pedal controls for proper operation. If a pedal does not work properly, consult a Yamaha dealer. Accelerator Pedal With the main switch in the “OFF” position, make sure the accelerator pedal operates smoothly.
  • Page 25 PRE-OPERATION CHECKS Brake Pedal Make sure the brake pedal feels firm when pressed and returns to its original position when released. ∫ Brake pedal Y-21a Parking Brake Pedal Make sure the parking brake pedal locks in place with a positive click, and releases when the accelerator pedal is pressed.

  • Page 26: Operation

    OPERATION BODY AND CHASSIS Before each use, visually inspect the PTV body and chassis for damaged and/or missing parts. STARTING 1. With the parking brake applied, turn the drive select switch to BATTERY “FWD” for forward, or “REV” for reverse. Y-2847 NOTICE Do not shift from “FWD”...
  • Page 27 OPERATION STOPPING To stop the PTV, gradually press down on the brake pedal. å Brake pedal NOTICE Do not hold the PTV on an incline with the accelerator – use the brake. Transmission damage can result. Y-65b When the PTV has come to a stop, apply the parking brake pedal and turn the main switch to “OFF.”...

  • Page 28: Maintenance

    Check shock absorbers for oil leaks and damaged springs 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.
  • Page 29 Inspect brake shoes and adjust or replace if necessary 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.
  • Page 30 MAINTENANCE Battery Care Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil.
  • Page 31 3. Using a hydrometer, check the specific gravity of the battery fluid 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...
  • Page 32 MAINTENANCE Battery Charging Read and understand the owner’s manual provided with your PTV’s battery charger before charging batteries. Death or serious personal injury can result from failing to comply with the warning labels in this manual. Explosive hydrogen gas is produced while batteries are being charged.
  • Page 33 MAINTENANCE NOTICE Use only battery chargers that are rated for use with 48-volt Yamaha PTVs. Serious battery damage can result. Thoroughly read and understand the user manual supplied with your 48-volt charger. 3. With the charger properly connected and grounded (see charger’s owner’s manual),...
  • Page 34 MAINTENANCE Battery Installation 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. 1. Install the battery hold-down plates and torque to 7-9 Nm, 0.7-0.9 m•kg (62-80 in•lb) as shown.
  • Page 35 MAINTENANCE Fuse Replacement Be sure to use the specified fuse. Using a wrong fuse can cause electrical system damage and create a fire hazard. NOTICE When replacing a fuse, be sure the main switch is turned off to prevent accidental short-circuiting and electrical system damage.
  • Page 36 MAINTENANCE Multi-Charge Steps: Ensures a BATTERY CHARGER consistent and repeatable charge. Prepare for Emergencies Step 1: Pre-test: Tests several Be prepared for possible injury or fire. conditions before charging begins. Keep the following items handy: If a problem is detected, charging is terminated.
  • Page 37 MAINTENANCE Installation The AC line connected to the charger The output of chargers with must be capable of supplying 12 greater than 48 volts may pose an Amperes to the charger. AVOID energy and/or shock hazard under connecting a charger and another normal use.
  • Page 38 MAINTENANCE Mounting This charger is not designed for on-board use. Improper mounting or installation could result in a risk of fire or damage to the golf car. Mount the charger on a shelf or on the wall with adequate ventilation. Ideally it will be mounted horizontally with airflow from below.
  • Page 39 MAINTENANCE Grounding Charging The battery charger must be grounded to reduce the risk of electric shock. The charger is equipped with To reduce the risk of an electric a 3-prong AC cord set. The AC cord shock, connect only to a properly set must be connected to an grounded, single-phase (3-wire) appropriate receptacle that is properly...
  • Page 40 MAINTENANCE NOTICE Do not disconnect the DC cord set Charge only 48-volt battery plug from the DC charger systems manufactured by Trojan receptacle when the charger is on. Battery Company. Damage to the If the charger must be stopped, charger and batteries may result if first disconnect the AC power this charger is used on the wrong supply cord from its AC outlet, and...
  • Page 41 MAINTENANCE OPERATING INSTRUCTIONS 1. PLUG AC CORD INTO A GROUNDED RECEPTACLE 2. PLUG DC CORD INTO DC CHARGER RECEPTACLE 3. CHARGE CYCLE WILL BEGIN AFTER A FEW SECONDS AND AMMETER WILL TURN ON 4. CHARGER SHUTS OFF AUTO- MATICALLY WHEN BATTERIES ARE CHARGED Connect charger’s AC cord set to AC power.
  • Page 42 MAINTENANCE Under normal charge circumstances, the LEDs operate as follows: Ammeter Displays approximate scale (Amber) of current output during Step 2. Blinking: High internal charger temperature. Current output reduced. 80% Charge 80% charged, Step 2 complete. Begin (Amber) Step 3. Blinking: With no battery connected,...
  • Page 43 MAINTENANCE Troubleshooting 1. LED Error Codes (For Battery Condition) Incorrect reassembly may result in a risk of electric shock or fire. The following procedures are intended only to determine if a malfunction may exist in the charger. To reduce the risk of electric shock, always disconnect the charger’s AC cord set plug from AC power and its DC cord set plug from batteries before attempting any maintenance or cleaning.
  • Page 44 MAINTENANCE If a fault occurs, count the number of red flashes between pauses and refer to the table below: Red Flashes Cause Solution Battery High Voltage Check battery size and condition and reset charger (interrupt DC connection for 15 seconds). Battery Low Voltage Check battery size and condition and reset charger...
  • Page 45 MAINTENANCE 2. Hardware System Faults Problem Description Cause Remedy Charger does not start. No AC power to Ensure correct voltage No LEDs illuminate or charger. at AC outlet. Check AC blink when AC cord is cord connections. connected. Replace AC cord if damaged.
  • Page 46 MAINTENANCE Transaxle Oil To check transaxle oil level: 1. Place the PTV on a flat, level surface. 2. Remove two bolts 1, and remove the bag holder insert 2. 3. Place an oil pan under the transaxle case. 4. Clean the area around the oil Y-2739 level plug 3 and then remove the plug.
  • Page 47 Before you operate the PTV, press down on the brake pedal several times to make sure the brakes are functioning properly. Consult your Yamaha dealer before using your PTV if you suspect brake problems. Brake failure could result in a serious accident.
  • Page 48 MAINTENANCE Brake Pedal Free Play Adjustment Check the brake pedal free play by pressing against the pedal with two fingers (using light force) and measuring the distance the pedal travels before resistance is felt. Y-62b Brake pedal free play Å: 50-55 mm (1.97-2.17 in.) To adjust the brake pedal free play: 1.
  • Page 49 MAINTENANCE Parking Brake Release Adjustment NOTICE Before performing parking brake release adjustment, adjust brake pedal free play. 1. Apply pressure to the parking brake pedal until the brake nail catches the first latch position on the sector. Y-2823 2. Loosen the locknut and turn the bolt counterclockwise until it contacts the sector.
  • Page 50 MAINTENANCE Replacing a Headlight Bulb If the headlight burns out, replace it as follows: 1. Disconnect the wire connector 1 from the headlight assembly. 2. Remove the three screws 2 and remove the light control unit. Y-2767 3. Remove the four screws 3 to remove the headlight assembly from the holder.
  • Page 51 MAINTENANCE Adjusting a Headlight NOTICE It is recommended to have the headlight adjustment performed by a Yamaha dealer. The screw can be accessed from under the fender. 1. Using a Phillips head screwdriver, turn the adjusting screw 1. 2. Turning the screw clockwise will...

  • Page 52: Storage

    1. Recharge the batteries and check the fluid levels at least NOTICE once a month. Yamaha Golf-Car Company does not approve the use of high- NOTICE pressure washers to clean the products they manufacture. Doing Do not allow cleaning solution to so may damage the finish on the enter battery cells.

  • Page 53: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS Items DR2E19 PTV Dimensions: Overall length 2395 mm (94.3 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...
  • Page 54 SPECIFICATIONS BATTERIES Items DR2E19 PTV Battery: Trojan - Golf Car Type T-875 (6x8volt) RC: minimum 117 min CHASSIS Items DR2E19 PTV Steering system: Type Rack and Pinion Steering angle (L.H.) 1.85 turn Steering angle (R.H.) 1.85 turn Brakes: Brake system Mechanical drum brake on each rear wheel with self-adjusters Type of brake...
  • Page 55 SPECIFICATIONS BATTERY CHARGER General Specifications DC Output – see Operating Instructions Voltage - nom (V) Voltage - max (V) 67.2 Current - max (A) Battery Type Specific to selected algorithm Reverse Polarity Electronic protection – auto-reset Short Circuit Electronic current limit AC Input Voltage - max (Vrms) 85-265...
  • Page 56 SPECIFICATIONS BATTERY CHARGER Mechanical Drawings 278 ±3 mm 196 ±3 mm 260 ±3 mm 3 ±1 mm M4(4 mm) Grounding Stud(Ref.) 10-4...

  • Page 57: Wiring

    WIRING DR2E19 PTV WIRING DIAGRAM 11-1...
  • Page 58 NOTES...
  • Page 60 PRINTED IN USA 2018.12-0.3×2 CR...

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