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Yamaha DR2E17 - User Manual

Yamaha DR2E17
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Printed in U.S.A
2008-KCC
48 VOLT GOLF CAR
DR2E17
LIT-19626-66-17
J0C-F8199-60
Printed in U.S.A
2017-KCC
DR2E17 48 VOLT GOLF CAR
All rights reserved. Any reprinting or unauthorized use without the
written permission of Yamaha Motor Company, Japan is expressly prohibited.
Se reservan todos los derechos. Queda expresamente prohibida cualquier reimpresión
o uso no autorizado sin el consentimiento escrito de Yamaha Motor Company de Japón.
Tous droits réservés. Toute réimpression ou utilisation non autorisée sans
la permission écrite de Yamaha Motor Company, Japon, est expressément interdite.
Alle Rechte vorbehalten. Nachdruck oder unautorisierte Nutzung ohne schriftliche
Zustimmung der Yamaha Motor Company, Japan, ist ausdrücklich verboten.
Yamaha Motor Corporation USA
800-879-0078
!
OWNER’S / OPERATOR’S MANUAL
MANUAL DE OPERACION DE YAMAHA
MANUEL D’EXPLOITATION ET D’UTILISATION
BEHUTZER- / BET RIEBSAN LEITUNG
READ THIS MANUAL CAREFULLY!
It contains important safety information.
¡LEA ATENTAMENTE ESTE MANUAL!
Contiene información importante sobre
seguridad.
LIRE CE MANUEL ATTENTIVEMENT!
Il contient des informations de sécurité
importantes.
LESEN SIE DIESE ANLEITUNG AUFMERKSAM!
Sie enthält wichtige Angaben zur Sicherheit.
J0C-F8199-60
J0C-F8199-60_cover.qxp_LIT_19626_11_07 cover.qxd 6/24/16 2:59 PM Page 1
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Summary

Introduction

Important Manual Information

Safety Alert Symbol

Explains the safety alert symbol used for potential personal injury hazards.

Warning Instructions

Details hazardous situations that could result in death or serious injury.

Notice Instructions

Provides special precautions to avoid vehicle or property damage.

Tips for Easier Procedures

Offers key information to make procedures easier or clearer.

Important Labels

Safety and Instruction Labels

Details various safety and instruction labels found on the golf car.

Operating Warnings and Instructions

Provides crucial warnings and operating instructions for safe use of the golf car.

Additional Safety Labels

Operator Safety Warnings

Safety warnings to reduce the risk of accidents, injury, or death.

Main Switch and Vehicle Identification

Illustrates the main switch and provides vehicle identification details.

Battery and Tow Switch Labels

Battery Safety Warnings

Details warnings related to battery handling, charging, and electrical hazards.

Tow Switch Operation Notice

Provides notice on the correct operation of the tow switch for towing or storage.

Golf Car Serial Number

Serial Number Location and Identification

Explains the location and structure of the golf car serial number for model identification.

Operator Safety

Before Operating the Golf Car

Covers essential safety checks and precautions before driving the golf car.

While Operating the Golf Car

Details safe operating practices to follow while the golf car is in motion.

Operator Safety - Continued

Safe Operation Practices

Provides guidance on safe driving, speed control, and avoiding modifications.

Safety Considerations

Driver Qualifications

Specifies requirements for authorized drivers and placement of safety instructions.

Golf Course Safety Survey

Recommends regular safety surveys to identify hazardous areas.

Golf Course Hazard Prevention - Steep Grades

Addresses hazards on steep grades and provides warnings.

Golf Course Hazard Prevention - Turns and Approaches

Covers hazards like sharp turns and blind corners, with precautions.

Safety Considerations - Continued

Wet and Loose Terrain Safety

Advises on operating in wet or loose terrain to maintain traction and stability.

Golf Car and Pedestrian Interference

Discusses managing traffic and pedestrian interactions to prevent accidents.

Maintenance Required for Golf Car Safety

Outlines essential preventative maintenance and personnel requirements for safety.

Safety Precautions and Storage

Safety Precautions During Maintenance

Details critical safety procedures to follow when performing maintenance.

Storage and Battery Charging Safety

Provides safety guidelines for storing the vehicle and charging the batteries.

Controls Overview

Golf Car Features Identification

Identifies and lists the main features and components of the golf car.

Main Switch Operation

Main Switch OFF Position

Explains the OFF position of the main switch, disabling the ignition circuit.

Main Switch ON Position

Details the ON position of the main switch, enabling electrical circuits for driving.

Drive Controls

Drive Select Switch Function

Describes how to use the drive select switch for forward and reverse movement.

Accelerator Pedal Operation

Explains how the accelerator pedal controls the golf car's speed.

Brake Pedal Function

Details how to use the brake pedal to stop the golf car.

Parking Brake Control

Parking Brake Pedal Operation

Explains how to engage and disengage the parking brake pedal.

Parking Brake Automatic Release Warning

Warns about the automatic release of the parking brake when the accelerator is depressed.

Tow Switch Operation

Tow Switch RUN Position

Instructs to ensure the tow switch is in the 'RUN' position before operating the car.

Towing Procedure and Notice

Provides notice and procedure for setting the tow switch to 'TOW' before towing.

Pre-Operation Checks

Pre-Operation Check Safety Warning

Warns about the risk of unexpected movement during pre-operation checks.

Periodic Maintenance Reference

Refers to periodic maintenance charts on pages 7-1 and 7-2 for detailed checks.

Seat Inspection

Details how to open the seat for checking and servicing.

Pre-Operation Checks - Batteries and Tires

Battery Condition Checks

Covers checks for battery security, caps, and terminal corrosion.

Battery Electrolyte Safety Warning

Warns about the hazards of battery electrolyte and necessary precautions.

Tire Air Pressure Check

Instructs to check the tire air pressure before operating the golf car.

Tire Wear Limit Inspection

Details checking the tire surface for damage and the wear limit for replacement.

Pre-Operation Checks - Systems

Steering System Check

Explains how to check the steering system for excessive free play.

Reverse Alarm Check

Describes how to check if the reverse alarm is functioning correctly.

Accelerator Pedal Operation Check

Details checking the accelerator pedal for smooth operation when the main switch is off.

Pre-Operation Checks - Pedals and Chassis

Brake Pedal Check

Ensures the brake pedal feels firm and returns to its original position.

Parking Brake Pedal Check

Verifies the parking brake pedal locks and releases correctly.

Body and Chassis Inspection

Visually inspects the golf car body and chassis for damage or missing parts.

Operation - Starting

Starting the Golf Car

Step-by-step instructions for starting the golf car safely.

Drive Select Shift Notice

Warns against shifting drive select while the car is moving.

Main Switch Turn-On Warning

Warns about potential unexpected movement when turning on the main switch.

Operation - Stopping

Stopping the Golf Car

Instructions on gradually pressing the brake pedal to stop the golf car.

Incline Stopping Notice

Advises using the brake, not the accelerator, to hold the car on an incline.

Maintenance - Periodic Charts

Periodic Maintenance Schedule

Presents a schedule of maintenance tasks based on usage intervals.

Maintenance Safety Warning

Warns to turn off the main switch and apply parking brake during maintenance.

High-Pressure Washer Usage Notice

Disapproves high-pressure washers for cleaning due to potential damage.

Maintenance - Periodic Charts Continued

Annual and Four-Year Maintenance

Details maintenance tasks for annual and every four years intervals.

Maintenance - Battery Care

Battery Electrolyte Safety Warning

Details hazards of battery electrolyte and provides antidotes and safety measures.

Battery Cleaning and Fluid Level Checks

Instructs on cleaning battery tops and checking fluid levels.

Cleaning Solution Notice

Warns not to allow cleaning solution into battery cells to prevent damage.

Battery Charging and Specific Gravity

Battery Fluid Level Adjustment

Guides on adding distilled water before and after charging batteries.

Tap Water Notice

Warns that tap water contains harmful minerals and to use only distilled water.

Specific Gravity Check Procedure

Explains how to check battery fluid specific gravity using a hydrometer.

Maintenance - Battery Charging Steps

Battery Charger Emergency Preparation

Recommends preparing for emergencies and reading charger instructions.

Battery Charging Process Summary

Summarizes the steps for charging the golf car batteries.

Tow Switch Position for Charging Notice

Advises placing the tow switch in 'TOW' position before charging to prevent damage.

Battery Charging and Installation Safety

DC Output Cord Disconnection Warning

Warns against disconnecting the DC output cord while the charger is on.

Battery Installation Safety

Details safety precautions for battery installation, avoiding arcs and explosions.

Battery Installation Details and Fuse Replacement

Battery Installation Cable and Holddown Precautions

Provides precautions for placing battery cables and holddowns, and cable connection order.

Battery Holddown Nut Tightness Notice

Warns against overtightening battery holddown nuts to prevent casing damage.

Fuse Replacement Safety Warning

Warns about using the specified fuse to prevent electrical damage and fire hazards.

Fuse Replacement Main Switch Notice

Advises turning off the main switch before replacing a fuse to prevent short-circuits.

Fuse Replacement Procedure

Locating Fuse Holders

Describes how to locate in-line fuse holders on the main wire harness.

Fuse Pulling and Inspection

Details pulling fuse holder covers and inspecting/replacing fuses.

Battery Charger Features and Operation

Battery Charger Emergency Preparation

Recommends keeping essential items handy for possible battery charger emergencies.

Battery Charger Features

Highlights features like switch-mode design, LED display, and charge protection.

Battery Charger Charge Algorithm

Explains the I-E-I charge profile and multi-charge steps.

Battery Charger Installation and AC Input

Battery Charger AC Line Requirements

Specifies AC line requirements for the charger to avoid overloading circuits.

Circuit Protection Warning

Warns to use 15-amp or higher protection for circuits with the charger.

Extension Cord Usage Warning

Advises using a grounded 3-wire, 12-AWG cord no longer than 15m for extension.

Charger Output Voltage Warning

Warns that chargers with >48 volts output may pose an energy or shock hazard.

Battery Charger Mounting and Safety

Battery Charger Mounting Guidelines

Provides guidelines for mounting the charger with adequate ventilation.

Charger Cooling Fin Maintenance

Recommends keeping charger fins free of oil, dirt, and dust for efficiency.

Charger Plug Location Tip

Suggests locating the charger's AC plug at least 46cm above ground for visibility.

Flammable Material Warning

Warns that chargers can ignite flammable materials and vapors.

Battery Charger Grounding and Charging Safety

Battery Charger Grounding Requirements

Details grounding requirements for the charger to reduce electric shock risk.

Improper Grounding Conductor Warning

Warns about the risk of electric shock from improper connection of the grounding conductor.

Charging Outlet and Safety

Instructs to connect only to a properly grounded outlet and avoid uninsulated parts.

Hot Surface Warning

Warns that surfaces may be hot and to avoid touching them.

Correct Battery Type Notice

Advises charging only 48-volt systems to prevent charger and battery damage.

Battery Charger Inspection and Operation

DC Output Cord Inspection

Details visual and manual inspection of the DC cord, plug, and receptacle.

Charger Use Conditions Warning

Warns against using the charger with damaged or poorly connected parts.

Removing Plugs Warning

Instructs to pull plugs from the body, not the cords, when removing them.

Charger Operating Instructions

Provides daily reference operating instructions for the battery charger.

Stopping Charger Operation Warning

Instructs how to stop charger operation by first disconnecting AC power.

Battery Charger LED Indicators

Ammeter LED Operation

Explains the amber LED indication for current output and charger temperature.

80% Charge LED Operation

Details the amber LED indication for 80% charge completion and algorithm selection.

100% Charge LED Operation

Explains the green LED indication for charging complete and storage mode.

AC On LED Operation

Describes the amber LED indication for AC power status and overheating.

Fault LED Operation

Explains the red LED indication for charger errors and troubleshooting.

Troubleshooting - LED Error Codes

Incorrect Reassembly Warning

Warns that incorrect reassembly can lead to electric shock or fire.

Disconnecting Before Maintenance Warning

Instructs to disconnect power and battery before maintenance or cleaning.

Malfunctioning Charger Warning

Warns against operating a malfunctioning charger to prevent injury or damage.

Troubleshooting - Red Flash Codes

Battery High;Low Voltage Faults

Details solutions for battery high voltage and low voltage faults.

Charge Timeout and Output Reduction Faults

Provides solutions for charge timeout and reduced output due to high temperatures.

Battery Trickle Charge Faults

Explains how to check for shorted or damaged cells affecting trickle charging.

Over-Temperature and Internal Faults

Details solutions for over-temperature shutdowns and internal charger faults.

Service Technician Inspection Warning

Advises having a qualified service technician inspect if problems persist.

Troubleshooting - Hardware System Faults

Charger Start-Up Faults

Addresses issues where the charger does not start or LEDs do not illuminate.

Charging Initiation Faults

Covers problems with starting charging, including wiring and battery voltage.

Extended Charging Time Fault

Discusses chargers running longer than 20 hours, possibly due to boosting.

Service Technician Inspection Warning

Reiterates the need for a qualified technician if problems persist.

Maintenance - Transaxle Oil Check

Transaxle Oil Level Check Procedure

Details the steps for checking the transaxle oil level.

Foreign Material Entry Notice

Warns against allowing foreign material into the transaxle to prevent damage.

Adding Transaxle Oil

Guides on adding Yamalube SAE 90 gear oil if the level is low.

Wheel and Brake Maintenance

Wheel Replacement Procedure

Provides instructions for removing and installing a wheel on the golf car.

Wheel Nut Tightening Torque

Specifies the correct torque for tightening wheel nuts.

Brake Adjustment and Function Check

Explains that brakes are self-adjusting and how to check their function.

Brake Problem Consultation Warning

Advises consulting a dealer for suspected brake problems.

Brake Pedal Free Play Adjustment

Brake Pedal Free Play Measurement

Details how to measure the brake pedal free play.

Brake Pedal Free Play Adjustment Procedure

Guides on adjusting the brake pedal free play using lock and adjusting nuts.

Brake Cable Tightening Warning

Warns against over-tightening brake cables to prevent wear and performance issues.

Parking Brake Release Adjustment

Parking Brake Adjustment Notice

Advises adjusting brake pedal free play before parking brake release adjustment.

Parking Brake Release Adjustment Steps

Provides steps for adjusting the parking brake release mechanism.

Storage Preparation

High-Pressure Washer Usage Notice

Reiterates disapproval of high-pressure washers for cleaning.

Storage Switch and Key Handling

Provides tips on setting switches and storing the key safely for storage.

Chassis Preparation for Storage

Details chassis preparation steps including tire pressure and rust inhibitor.

Battery Preparation for Storage

Outlines battery preparation steps for extended storage periods.

General Specifications

Golf Car Dimensions

Lists the overall dimensions, wheelbase, tread, and ground clearance.

Golf Car Weight

Specifies the dry weight of the golf car without the battery.

Vibration Levels

Provides vibration levels for the footboard and steering wheel.

Noise Levels

Lists the acceleration and constant speed noise levels.

Golf Car Performance Specifications

Details factory speed settings, maximum speed, turning radius, and seating capacity.

Specifications - Batteries, Chassis, Transmission

Battery Specifications

Details the type of battery used and its minimum run time (RC).

Chassis Specifications

Covers steering system, brakes, parking brake, wheels, and tire pressure.

Transmission Specifications

Details the differential/reduction gear, ratios, and lubricant requirements.

Battery Charger General Specifications

Battery Charger DC Output Specifications

Lists DC output voltage, current, battery type, and protection features.

Battery Charger AC Input Specifications

Details AC input voltage, frequency, current, and power factor.

Battery Charger Mechanical Specifications

Covers dimensions, weight, environmental ratings, and operating temperatures.

Battery Charger Mechanical Drawings

Battery Charger Top and Side Views

Illustrates the top and side mechanical dimensions of the battery charger.

DR2 E17 Wiring Diagram

Main Power and Control Wiring

Shows the main power supply, fuses, switches, and control board connections.

Motor and Sensor Wiring

Illustrates wiring for the DC motor, throttle position sensor, and tachometer.

Yamaha DR2E17 Specifications

General IconGeneral
CategoryGolf Cars
ManufacturerYamaha
ModelDR2E17
Seating Capacity2
Battery Voltage48V
Battery TypeLead-Acid
Charger TypeOnboard
Front SuspensionIndependent
Warranty4 years

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