Yamaha DR2E PTV 2019 Owner'S/Operator'S Manual Download | Manualshive

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MAINTENANCE

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8-21

B

A

Y-2281

J0E

Y-61c

Y-62b

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a

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.

Brake pedal free play

Å

:

50-55 mm (1.97-2.17 in.)

To adjust the brake pedal free play:

1. Remove the floor mat and

service lid from the floor of the
PTV.

2. If the free play distance needs

adjusting, loosen the lock nut

å

and turn the adjusting nut

∫

in

or out until the free play
specification is met. Then tighten
the lock nut in place.

Do not over-tighten the brake
cables. Over-tightening will
increase brake wear and affect
overall performance of PTV.
Premature brake wear can result.
Death or serious personal injury
can result from failing to comply
with the warning labels in this
manual.

©

2019 Yamaha Golf-Car Company

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Summary of Contents for DR2E PTV 2019

Page 1: ... S OPERATOR S MANUAL Read this manual carefully before operating this vehicle J0E F8199 11 LIT 19626 A0 08 DR2E PTV PERSONAL TRANSPORT VEHICLE 2019 MODEL YEAR 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

Page 2: ... 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

Page 3: ...maximum enjoyment from your new Yamaha If you have any questions about the operation or maintenance of your 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 Printed in U S A ...

Page 4: ...ermanent part of your PTV and should remain with the PTV when resold Particularly important information is distinguished in this manual by the following notations This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoide...

Page 5: ...Y CONTENTS 1 IMPORTANT LABELS 2 SAFETY CONSIDERATIONS 4 MAINTENANCE 8 STORAGE SPECIFICATIONS 9 WIRING 11 OPERATION 7 PRE OPERATION CHECKS 6 CONTROLS 5 OPERATOR SAFETY 3 10 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

Page 6: ...ary wear and tear x Modifications or alterations that affect the car s condition operation performance or durability x Damage due to improper transportation x Acts of God e g lightning hail damage flooding fire etc This Limited Warranty does not cover any parts replaced due to normal wear or routine maintenance including oil and air filter elements brake shoes tire wear spark plugs starter and clu...

Page 7: ...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 IF BATTERIES ARE SUBJECTED TO ANY OF THE FOLLOWING CONDITIONS s Abuse or neglect such as improper...

Page 8: ...pathways Do not use on such pathways without specific permission from golf course management Read the warning label on the beverage holder panel before operating Be sure occupants are seated Select FORWARD OR REVERSE then turn main switch to ON Press the accelerator pedal to start moving The motor will start and the parking brake will release automatically To stop release the accelerator pedal and...

Page 9: ...1 2 3 4 5 6 7 8 9 10 11 IMPORTANT LABELS 2 2 J0E 4 2 3 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

Page 10: ...er ou avant l entreposage Non observation pourrait Dommages de système d entrainement en remourquant Causer une decharge totale de la batterie et endommager la batterie pendant l entreposage a long terme Apres avoir change l interrupteur de position RUN a position TOW attendre un minimum de 15 seconds avant de le remettre K8298 DATE OF CONSTRUCTION MY YAMAHA MOTOR POWERED PRODUCTS CO LTD 200 1 SAK...

Page 11: ...ion shown TIP 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 IMPORTANT LABELS 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

Page 12: ...side only and only in designated areas Do not allow more than two occupants per seat This PTV is restricted to two occupants unless equipped with a rear seat Do not operate the PTV while under the influence of alcohol or drugs their effect on vision and judgment make operating a PTV dangerous Do not operate the PTV on public streets roads or highways unless allowed by law or local regulating autho...

Page 13: ...he steering wheel too sharply at higher speeds to avoid tipping or rolling the vehicle Always drive slowly straight up or straight down slopes never at an angle to avoid tipping or rolling the vehicle 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 2831 OPERATOR SAFETY 2 0 1 9 Y a m a h a G...

Page 14: ...ling to comply with the warning instructions in this manual HAZARD PREVENTION Drivers should be mindful of road hazards and avoid dangerous situations that may include the following Steep Grades Where steep grades exist restrict PTV to designated roadway or path and descend slowly with foot on the brake Descend steep grades slowly with foot on brake Death or serious personal injury can result from...

Page 15: ...ed trained and authorized personnel to inspect adjust and maintain PTVs 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 durin...

Page 16: ...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 mainte nance Periodically inspect mainte nance log to...

Page 17: ...rive select switch 3 Steering wheel 4 Battery gauge 5 Brake pedal 6 Parking brake pedal 7 Horn switch 8 Accelerator pedal 9 USB ports a Reflector b Batteries c Headlights d Front body e Seat f DC charger receptacle g Front tire h Front bumper i Rear body j Taillights k Rear bumper l Rear tire m Tow switch Y 2837 22 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

Page 18: ...tion ON Electrical circuits are switched on The vehicle can be driven ON WITH LIGHTS The functions for this position are the same as for the ON position however this position will activate the headlights and taillights BATTERY GAUGE The battery gauge displays how much charge is left in the batteries When the batteries are at full charge all the LEDs will be lit Y 2839 ON OFF BATTERY Y 2840 BATTERY...

Page 19: ... less 1 LED will blink on and off meaning the batteries should be charged immediately DRIVE SELECT SWITCH The drive select switch is used to shift the PTV 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 TIP The reverse alarm will sound when the drive select switch is depressed to the REV position Y...

Page 20: ...edal Increase Release pedal Decrease å Accelerator pedal BRAKE PEDAL Press down on the brake pedal to stop the PTV Brake pedal PARKING BRAKE PEDAL Press down on the parking brake pedal whenever parking the PTV ç Parking brake pedal TIP Release the parking brake by depressing the accelerator pedal The parking brake will automatically release when the accelerator pedal is depressed If the main switc...

Page 21: ...ching again Failure to do so may lead to drive system damage while towing HEADLIGHT TAILLIGHT ON POSITION Turn the main switch all the way to the right to the second ON position This will activate the headlights and taillights HORN SWITCH The horn is located adjacent to the brake pedal and is activated by depressing with your foot Horn Switch TIP It is advisable to sound the horn when approaching ...

Page 22: ... 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 Apply parking brake PRE OPERATION CHECKS Refer to the Periodic Maintenance charts on pages 8 1 and 8 2 SEAT Open the seat for checking and servicing 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

Page 23: ...ery electrolyte is poisonous and dangerous causing severe burns etc It contains sulfuric acid Avoid contact with skin eyes or clothing Ventilate when charging or using in enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN TIRE CONDITION Tire Air Pressure Check the tire air pressure before operating the PTV Tire pressure 152 kPa 1 5 kgf cm2 22 psi Tire Wear ...

Page 24: ...rattling sounds which may indicate loose steering components consult a Yamaha dealer REVERSE ALARM Check the reverse alarm by moving the drive select switch to REV for reverse The alarm should sound 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 th...

Page 25: ...ick and releases when the accelerator pedal is pressed ç Parking brake pedal TIP Release the parking brake by depressing the accelerator pedal Headlights Taillights Ensure the headlights and taillights are operational Never operate the PTV at night or during inclement weather without properly working headlights taillights Horn Switch Make sure the horn operates correctly å Horn Switch Y 22a Y 2761...

Page 26: ...o REV reverse while the PTV is moving Transmission damage can result 2 Turn the main switch to ON Do not depress the accelerator pedal when turning on the main switch or the PTV 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 PTV will start to move å Accelerator pedal TIP The parking brake automatically releases...

Page 27: ...e pedal å Brake pedal Do not hold the PTV on an incline with the accelerator use the brake Transmission damage can result When the PTV has come to a stop apply the parking brake pedal and turn the main switch to OFF Parking brake pedal NOTICE Y 65b A B 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

Page 28: ... OP EVERY MONTH EVERY 6 MONTHS 4 3 8 5 8 6 6 2 8 3 6 4 8 11 6 3 6 3 6 2 7 1 8 3 8 4 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 CS CHECK CA CHECK AND ADJUST R REPLACE S SERVICE CL CLEAN AND LUBRICATE L LUBRICATE Clean battery tops check for tightness of...

Page 29: ...al does not contain these procedures They are contained in the Service Manual CS CHECK CA CHECK AND ADJUST R REPLACE S SERVICE CL CLEAN AND LUBRICATE L LUBRICATE Check wheel nut tightness front wheel bearing play Check transaxle oil level and inspect for leakage Perform a discharge test Apply Terminal protectant Inspect brake shoes and adjust or replace if necessary Replace transaxle oil S S S S S...

Page 30: ...ve gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an 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 PTV 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...

Page 31: ...harmful to a battery therefore refill only with distilled water 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 Satisfactory Uncorrected C F Hydrometer Reading 48 9 120 1 244 43 3 110 1 248 37 8 100 1 252 3...

Page 32: ...serious personal injury can result from failing to comply with the warning labels in this manual To charge the batteries in your PTV 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 PTV s batteries without thoroughly reading and understanding the owner s manual provided with your charger 1 Tu...

Page 33: ...ual insert the DC output into the DC charger receptacle Do not disconnect the DC output cord from the DC charger receptacle when the charger is on or an arc could occur that may cause an explosion NOTICE Y 669c 4 The charger will turn off automatically when the batteries reach full charge 5 After the charger has turned off disconnect the DC output plug from the DC charger receptacle by grasping th...

Page 34: ...ward Battery ç Battery hold down plate 2 Connect the wire leads and torque to 9 10 Nm 0 9 1 0 m kg 80 89 in lb as shown When installing batteries Carefully place battery cables and hold downs making sure that cables do not lay across vent caps Always remove the negative cable to the motor controller first and install it last A spark can occur causing an explosion or fire at the battery Do not over...

Page 35: ...use be sure the main switch is turned off to prevent accidental short circuiting and electrical system damage 1 Locate the in line fuse holder on the main wire harness adjacent to the tow switch 2 Pull fuse holder cover off 3 Pull fuse out inspect and replace if necessary å Fuse holder Fuse NOTICE Fuse Type 10 Amp Blade Style B A Y 2417 8 8 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

Page 36: ...oosting Automatically boosts battery pack when individual cell voltages are not balanced and restores pack capacity BATTERY CHARGER Prepare for Emergencies Be prepared for possible injury or fire Keep the following items handy First aid kit Fire extinguisher Emergency phone numbers Read the text located on the case of the charger before operating or using the charger Features Switch Mode Design Hi...

Page 37: ... Also maximum Ampere varies depending on AC voltage Please refer to AC Input in General Specifications RISK OF FIRE Use this charger only on circuits with a 15 amp or higher branch circuit protection circuit breaker or fuse in accordance with the national electrical code ANSI NFPA 70 and all applicable local codes and ordinances When using an extension cord use only a grounded 3 wire 12 AWG cord n...

Page 38: ...d vertically it is recommended that the AC input cord be at the lower end of the charger Keep the charger free of oil dirt mud or dust to keep the cooling fins operating as efficiently as possible Mount the charger by the mounting plate using appropriate fasteners TIP The charger s AC plug must be locat ed at least 46 cm 18 above the ground and the display visible to the user Chargers can ignite f...

Page 39: ...e charger is equipped with a 3 prong AC cord set The AC cord set must be connected to an appropriate receptacle that is properly installed and grounded in accordance with the National Electrical Code and all local codes and ordinances Improper connection of the equipment grounding conductor can result in a risk of an electric shock The conductor with insulation that has an outer surface that is gr...

Page 40: ...acles are damaged or distressed in any way Using the charger with any of the above symptoms could result in a fire property damage or personal injury 8 13 Charge only 48 volt battery systems manufactured by Trojan Battery Company Damage to the charger and batteries may result if this charger is used on the wrong battery type NOTICE Do not disconnect the DC cord set plug from the DC charger recepta...

Page 41: ...AC cord set to AC power Then connect the DC cord set plug to the vehicle charging receptacle by grasping the plug handle and pushing the plug straight into the DC charger receptacle The charger will start automatically Upon connection to AC power source the lower four LEDs come on as a Power On Self Test then the AC power LED turns on Upon connection to battery pack output indicators turn on to in...

Page 42: ...nternal charger temperature Current output reduced 80 Charge Amber On 80 charged Step 2 complete Begin Step 3 Blinking With no battery connected indicates algorithm selected by number of flashes at startup 100 Charge Green On Charging complete Charger in Storage Mode Blinking Step 3 complete Begin Step 4 AC On Amber On AC power good Fault Red Blinking Charger error Refer to Troubleshooting on next...

Page 43: ...ntended 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 Do not operate the charger if it is malfunctioning Personal injury or property damage could result 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y...

Page 44: ...or 15 seconds Charge Timeout caused by battery pack not reaching required voltage Charger output was reduced due to high temperatures Check connections Operate charger at a lower ambient temperature Check Battery Battery could not be trickle charged up to minimum voltage Check for shorted or damaged cells Over Temperature Charger shut down due to high internal temperature Ensure sufficient cooling...

Page 45: ... cord if damaged Charger does not start charging when DC cord set is plugged into charger receptacle and the Amber AC On LED is illuminated Incorrect wiring or disconnection from DC cord charger receptacle and batteries Battery voltage less than 20 Volts Ensure polarity for wiring is correct from DC cord charger receptacle and batteries Check battery pack voltage Charger runs longer than 20 hours ...

Page 46: ...emove the plug Do not allow foreign material to enter transaxle Serious transaxle damage can result 5 The oil level should be right at the bottom of the oil level plug hole 4 or just starting to flow out of the hole 6 If needed add Yamalube SAE 90 gear oil until it starts to flow from the oil level plug hole 7 Allow excess gear oil to flow out of the hole until it stops 8 Install the oil level plu...

Page 47: ...ack and remove the wheel nuts and the wheel 3 Reverse the removal steps when installing the wheel Wheel nut tightening torque 80 Nm 8 0 m kg 58 ft lb Brake Adjustment The brakes on your PTV are self adjusting 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 p...

Page 48: ...rake pedal free play 1 Remove the floor mat and service lid from the floor of the PTV 2 If the free play distance needs adjusting loosen the lock nut å and turn the adjusting nut in or out until the free play specification is met Then tighten the lock nut in place Do not over tighten the brake cables Over tightening will increase brake wear and affect overall performance of PTV Premature brake wea...

Page 49: ... to the parking brake pedal until the brake nail catches the first latch position on the sector 2 Loosen the locknut and turn the bolt counterclockwise until it contacts the sector 3 Turn the bolt clockwise 3 8 120 degrees then tighten locknut 1 Parking brake pedal 2 Bolt 3 Locknut 4 Brake nail 5 Sector NOTICE Y 2823 1 2 3 4 5 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

Page 50: ...ove the light control unit 3 Remove the four screws 3 to remove the headlight assembly from the holder 4 Remove the headlight assembly from the holder 5 Install new headlight assembly into holder and secure with the four screws 6 Install the light control unit and fasten with three screws 7 Connect the wire connector to the headlight assembly Y 2769 Y 2767 1 Y 2768 2 3 2 0 1 9 Y a m a h a G o l f ...

Page 51: ...1 2 Turning the screw clockwise will lower the beam and turning the screw counter clockwise will raise the beam Replacing a Taillight Bulb 1 If a taillight bulb burns out replace the bulb assembly 1 by removing the rubber grommet 2 from the bezel assembly 3 2 Remove the wire connector replace the bulb and reinstall by fitting the rubber grommet 2 over the bulb assembly 1 and bezel 3 NOTICE Y 2771 ...

Page 52: ...afe place CHASSIS PREPARATION 1 Verify the tire pressure is set to 152 kPa 1 5 kgf cm2 max 22 psi 2 Clean exterior of the PTV and apply a rust inhibitor 3 Cover the PTV with a breathable cover and store it in a dry well ventilated area NOTICE 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 Serious b...

Page 53: ...n Weight Dry weight with suntop 272 kg 600 lb without battery Performance Factory speed setting 19 km h 12 mph Maximum speed 24 km h 15 mph Optional maximum speed 31 km h 19 mph Minimum turning radius 2 9 m 114 in Seating capacity 2 occupants per seat TRANSMISSION Items DR2E19 PTV Differential reduction gear Secondary reduction system helical gear Secondary reduction ratio Forward Reverse 12 44 1 ...

Page 54: ...ers Type of brake Dual internal expanding shoe Leading trailing shoes self adjusting Brake pedal freeplay linkage adjustment 50 55 mm 1 97 2 17 in Brake cable end play 0 004 0 02 in 0 1 0 5 mm Parking brake Type Foot type parking brake with automatic release Wheel Tire size Front 20 5 x 8 0 10 4P Rear 20 5 x 8 0 10 4P Rim size 9 00 I 10 00 Tire pressure 152 kPa 1 5 kgf cm2 max 22 psi Lights Bulb v...

Page 55: ...VAC 11 5A 110VAC 6 1A 200VAC 5 6A 220VAC 5 4A 230VAC 5 1A 240VAC Current nom Arms 10A 120VAC 6A 200VAC 5A 230VAC AC Power Factor 0 98 at nominal input current Dimensions 28 0 x 24 5 x 14 0 cm 11 x 9 7 x 5 5 Weight 5 kg 12 lbs Environmental Enclosure IP46 Operating Temperature 30 C to 50 C 22 F to 122 F derated above 30 C below 0 C Storage Temperature 40 C to 70 C 40 F to 158 F AC Input Connector I...

Page 56: ... 10 11 10 4 J0E Mechanical Drawings 278 3 mm 196 3 mm 260 3 mm 176 3 mm 125 mm 246 3 mm 3 1 mm M4 4 mm Grounding Stud Ref 139 3 mm 111 3 mm SPECIFICATIONS BATTERY CHARGER 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

Page 57: ...11 1 J0E 1 2 3 4 5 6 7 8 9 10 11 WIRING DR2E19 PTV WIRING DIAGRAM Y 2827 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

Page 58: ...J0E 1 2 3 4 5 6 7 8 9 10 11 NOTES 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

Page 59: ... 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

Page 60: ...PRINTED IN USA 2018 12 0 3 2 CR E 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

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