Yamaha G22 E Page 38 Owner'S/Operator'S Manual Download

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OWNER’S/
OPERATORS
MANUAL

YAMAHA MOTOR

MANUFACTURING CORP.

OF AMERICA

GOLF CAR

G19E

Printed in U.S.A.

KCC

Yamaha Motor Corp., USA

Cypress, California

made in

12/01/00

LIT196260076

USA

*LIT196260076*

1PC - G19E O/M

LIT-19626-00-76

JR1-F8199-11

Summary of Contents for G22 E

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Page 2: ...u have any questions about the operation or maintenance of your golf car please consult a Yamaha dealer TECHNICAL SERVICE DEPT GOLF CAR SALES GROUP YAMAHA MOTOR MANUFACTURING CORP OF AMERICA G19E OWNER S OPERATOR S MANUAL 2000 by Yamaha Motor Manufacturing Corporation of America 1st edition All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Manufa...

Page 3: ... car and should remain with the car when resold Read and understand this manual completely before operating your golf car WARNING NOTE Particularly important information is distinguished in this manual by the fol lowing notations The Safety Alert Symbol means ATTENTION BE ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instruc tions could result in severe injury or death to the golf car oc...

Page 4: ...iii G19E 1 WARRANTY CONTENTS 1 IMPORTANT LABELS 2 MAINTENANCE SAFETY PROGRAM 4 MAINTENANCE 8 STORAGE SPECIFICATIONS 9 WIRING 11 OPERATION 7 PRE OPERATION CHECKS 6 CONTROLS 5 OPERATOR SAFETY 3 10 ...

Page 5: ...he 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 from this warranty shall include any parts replaced due to normal wear or routine maintenance such as brake shoes Any charges incurred in transporting a golf car to and from an autho rized Yamaha Golf Car Dea...

Page 6: ...MPORTANT LABELS Y 654 1 2 3 5 4 Y 500 Y 655 Y 656 1 3 4 Y 844 5 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 WARNING 2 ...

Page 7: ...MBER The golf car serial number is stamped in the location shown The first three digits of the serial num ber are for model identification the remaining digits are the unit produc tion number Keep a record of these numbers for reference when ordering parts from a Yamaha dealer NOTE ...

Page 8: ...ly 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 dan gerous Operation...

Page 9: ...rting or stopping abruptly Vary the speed of the golf car to match the terrain of the course Avoid turning the steering wheel too sharply at higher speeds Always drive slowly straight up or straight down slopes never at an angle 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 OPERATOR SAFETY ...

Page 10: ... vehicle driver s license be allowed to operate golf cars Place operation and safety instruc tions 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 rec ommended that the following warning be posted in a conspicuous location Do Not Operate Golf Cars When Under The Influence Of Al...

Page 11: ...operating golf car Personnel Allow only qualified trained and authorized personnel to inspect adjust and maintain golf cars 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 hydrog...

Page 12: ...anufacturer After each maintenance or repair the car must be driven by a quali fied trained and authorized per son 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 ensure accurate and complete ent...

Page 13: ... 15 13 14 Y 660 12 10 2 11 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 a Front cowl b Front tire c Front bumper d Rear cowl e Rear bumper f Rear tire g Receptacle Y 662 9 ...

Page 14: ... FWD OFF O N Y 663 REV FWD OFF O N Y 664 MAIN SWITCH The main switch controls the follow ing items OFF Ignition circuit is switched off The key can be removed only in this position ON Electrical circuits are switched on The golf car can be driven ...

Page 15: ...tion Car Movement FWD FORWARD REV REVERSE The back up buzzer will beep when the drive select switch is depressed to the REV position ACCELERATOR PEDAL The accelerator pedal controls the golf car s speed Action Car Speed Depress pedal Increase Release pedal Decrease å Accelerator pedal BRAKE PEDAL Press down on the brake pedal to stop the golf car å Brake pedal NOTE CONTROLS Y 19 Y 20 A REV FWD OFF...

Page 16: ...or pedal TOW SWITCH Before operating the car make sure the tow switch is in the RUN position å Tow switch Anytime the tow switch is moved from the RUN position to the TOW posi tion and immediately moved back to RUN there is a delay of approxi mately 30 seconds before the car will run Make sure the tow switch is in the TOW position if towing this vehicle NOTE NOTE CONTROLS Y 22 A A TOW RUN Y 666 ...

Page 17: ...hat they become second nature Be sure the main switch key is removed before performing the pre operation checks to prevent accidental starting and apply the parking brake to keep the car from moving PRE OPERATION CHECKLIST Before each use check the following Batteries Tire condition Steering system Back up buzzer Pedal operation Body and chassis SEAT Open the seat for checking and ser vicing WARNI...

Page 18: ...on or jarring Also check that no battery caps are missing to prevent battery acid from spilling from the bat tery 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 Tire Wear Limit Check the tire surface for damage cracks or embedded objects When tire tread wears down to 0 04 ...

Page 19: ...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 PEDAL OPERATION 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 fee...

Page 20: ...ing brake pedal Release the parking brake by depressing the accelerator pedal Accelerator Pedal Before checking operation of the accelerator pedal be sure the main switch is in the OFF posi tion Make sure the accelerator pedal operates smoothly å Accelerator pedal BODY AND CHASSIS Before each use visually inspect the golf car body and chassis for damage and or missing parts WARNING NOTE Y 22 A Y 2...

Page 21: ...EV reverse while the golf car is moving 2 Turn the main switch to ON Do not depress the accelerator pedal when turning on the main switch or the golf car may sudden ly 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 å Accelerator pedal The parking brake automatically releases when the accelerator ...

Page 22: ...olf car gradually press down on the brake pedal å Brake pedal When the car has come to a stop apply the parking brake pedal and turn the main switch to OFF Parking brake pedal Do not hold the golf car on an incline with the accelerator use the brake CAUTION Y 65 B A ...

Page 23: ... the best performance and safe operation of your golf car 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 WARNING ...

Page 24: ...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 for loose or broken connections Check all wire insulation for cracks and or worn spots Check wheel nut tightness front wheel bearing play Check gear box oil level and leakage Check shock ab...

Page 25: ...attention Batteries produce explosive gases Keep sparks flame ciga rettes etc away Ventilate when charging or using in enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHIL DREN 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...

Page 26: ...tery cap Plates ç Maximum fluid level Minimum fluid level Normal tap water contains miner als which are 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 Te...

Page 27: ...mmended 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 1 Turn main switch key to OFF position 2 With the charger properly con nected and g...

Page 28: ...e 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 When working with batteries do not put wrenches or other metal objects across the battery termi nals An arc can occur causing explosion of the battery 1 Install the battery holddown plates as shown å Forwa...

Page 29: ...ent 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 Fuse Replacement Be sure to use the specified fuse Using a wrong fuse can cause electrical system damage and cre ate a fire hazard When replacing a fuse be sure the main switch is turned off to pre vent accidental sh...

Page 30: ... from the car 3 Remove the oil level plug A 4 Add gear oil little by little until oil flows from the level plug hole B Recommended oil SAE 90 gear oil Gearcase capacity 0 32 US qt 0 3 L 0 06 Imp gal 5 Allow excess gear oil to flow out until it stops 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...

Page 31: ...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 self adjusting Before you operate the car press down on the brake pedal several times to make sure the brakes are functioning properly Consult yourYamaha dealer before using your golf car if you suspect brake problems Brake fa...

Page 32: ...nst the pedal with two fingers using light force and measuring the distance the pedal travels before resistance is felt Brake pedal free play 25 30 mm 0 98 1 18 in 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 ...

Page 33: ...1 Increase the tire pressure to 20 psi 137 kPa 1 4 kgf cm2 2 Clean exterior of the golf car and apply a rust inhibitor 3 Cover the golf car with a breath able cover and store it in a dry well ventilated area NOTE 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 ...

Page 34: ...in 870 mm Rear 38 6 in 980 mm Min ground clearance 3 8 in 97 mm Weight Dry weight without battery 560 lb 254 kg Performance Maximum speed 12 15 mph 19 24 km h Minimum turning radius 113 0 in 2 8 m Seating capacity 2 persons Hill climbing ability 24 44 grade on pavement TRANSMISSION Items G19E Differential reduction gear Differential type Bevel gear Lubricant capacity SAE 90 gear oil 0 32 US qt 0 3...

Page 35: ... rear wheel with self adjusters Type of brake Dual internal expanding shoe Leading trailing shoes self adjusting Brake pedal freeplay linkage adjustment 25 30 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 Release timing Bolt heads round parallel to arm 0 04 in 1 mm Wheel Tire size Front 18 x 8 50 8 00 4 PR Rear 18 x 8 50 8 00 4 P...

Page 36: ...D ASSY MOSFET BOARD ASSY N P A1 A2 F2 F1 3 4 REC REV FWD Y R Y W R W R W R Y R Y R R Y R Y W R Y Y W R Y Y Br 3 2 1 Y 671 T A C H R W R Y 5 4 3 2 1 8 9 7 6 10 11 12 Main switch Tow storage switch Accelerator stop switch Buzzer Directional switch DC motor Controller Throttle sensor Relay Receptacle Fuse 3A Batteries 6 x 8V 1 2 3 4 5 6 7 8 9 10 11 12 COLOR CODE B Black L Blue G Green Y Yellow R Red ...

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